Monolithic PCB Inductor Core for Drop-Resistant Mounting
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Solution Overview
Problem
Existing inductive coiled components for printed circuit boards are costly and prone to damage from drops due to the need for separate magnetic cores and bases, requiring expensive manufacturing processes and additional cushioning, which complicates their assembly and increases costs.
Innovation Solution
A monolithic core is created by injection moulding, combining the magnetic core and base into a single, flexible, and thermally conductive component with integrated connecting interfaces, using a polymer body with high magnetic charge content to provide magnetic inductance and electrical insulation, reducing the number of components and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate base or bobbin is used to hold the magnetic core, then the component can be mounted on PCBs and provides electrical insulation, but the manufacturing cost increases and the component becomes more prone to damage from drops
Solution Approach 1:
The patent combines the base/bobbin and magnetic core into a single integrated component. The mounting structure and magnetic core are merged into one piece, eliminating the need for separate components and reducing assembly steps. This integration directly addresses the contradiction by reducing device complexity while improving reliability through a unified structure that eliminates interfaces between separate parts.
Solution Approach 2:
The integrated component serves multiple functions simultaneously: it provides mechanical support for mounting on PCBs, electrical insulation between the magnetic core and PCB, and magnetic core functionality. This multi-functionality resolves the contradiction by consolidating what were previously separate components into one universal element, reducing overall complexity while maintaining all necessary functions.
2Reliability
If two-component structural adhesives are used to prevent core detachment, then the component can withstand impact, but the manufacturing process becomes expensive and time-consuming
Solution Approach 1:
The patent eliminates the need for adhesives by merging the core and mounting structure into a single integrated component. The structural integrity is achieved through the unified design rather than through bonding separate parts, thereby simplifying the manufacturing process while maintaining impact resistance.
Solution Approach 2:
The patent extracts the adhesive bonding step from the manufacturing process by designing a structure that does not require adhesives. The mounting structure is designed to mechanically integrate with the PCB and core without requiring additional bonding materials or curing processes.
3Reliability
If epoxy-based adhesives and injection moulding are used to secure the core, then the component can withstand drops, but the manufacturing cost and time increase significantly
Solution Approach 1:
The patent combines the core and base into a single injection-moulded component, eliminating the need for separate adhesive application and curing steps. The integrated design allows for single-step manufacturing, significantly reducing production cycle time while maintaining drop test performance through the unified structural integrity.
4Ease of manufacture
If a monolithic core is created by injection moulding, then manufacturing is simplified and costs are reduced, but the component must maintain electrical insulation and magnetic properties
Solution Approach 1:
The patent uses composite materials in the injection moulding process, combining polymers with magnetic particles or coatings that provide both magnetic properties and electrical insulation. This allows the monolithic core to be manufactured simplistically while maintaining the necessary electrical insulation properties through the composite material structure.
Solution Approach 2:
The patent applies different material properties to different regions of the monolithic core. The exterior surface or specific regions are treated with insulating coatings or use insulating materials to provide electrical insulation, while the interior maintains magnetic properties. This local differentiation allows the simplified monolithic structure to meet both electrical and magnetic requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables inductive components that can withstand drop tests without additional cushioning, simplifies manufacturing, and maintains performance metrics like inductance and sensitivity while reducing costs and environmental impact through the use of injection moulding and recycled materials.
Implementation Method 1
an injection mouldable polymer body including magnetic charges, comprised between 70% and up to a maximal proportion by weight of 85% selected to provide magnetic inductance
Implementation Method 2
assure electrical isolation between the connecting interfaces that are integrated in the monolithic core
Data Source
AI summary
A surface mounting inductive coiled component for printed circuit boards, the component has at least one winding groove for the arrangement of at least one conductive coil to be wounded around a monolithic core (1), and several connecting interfaces (2) attached to the monolithic core (1) for connecting the at least one conductive coil to the tracks of a circuit board, wherein the monolithic core is made of an injection mouldable polymer body including magnetic charges in a proportion comprised between 70% up to 85% by weight, selected to provide magnetic inductance and assure electrical isolation between the connecting interfaces that are integrated in the monolithic core which is thermally conductive and wherein the magnetic charges include powdered magnetic charges or the magnetic charges include powdered magnetic charges and further include at least one solid sintered core (3) of magnetic material embedded in the polymer body.