PCB Inductor Carrier with Recesses for Wire End Segments
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Solution Overview
Problem
The assembly of inductive components on printed circuit boards, particularly those with thick wires for high-power applications, is complex due to alignment issues with guide means such as holes or recesses, leading to mechanical stress and increased assembly time, which complicates the process and requires robust carriers to manage restoring forces.
Innovation Solution
An inductive component design featuring a carrier with recesses for guiding end segments of coils, where pairs of end segments are fixed using common closures, reducing the need for precise alignment and mechanical stress, and allowing for simpler assembly by using either separate fasteners or pivotally connected carrier parts, optimizing material usage and assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If guide means (holes or recesses) are used to align wire end segments with carrier positions, then the electrical connection positions can be precisely controlled, but the assembly process becomes complex and time-consuming due to the need for precise alignment of multiple thick wires
Solution Approach 1:
The carrier is designed with pre-formed recesses at the exact positions where wire end segments need to be located. These recesses are created during carrier manufacturing, so the positioning function is prepared in advance rather than requiring alignment during assembly. This allows workers to simply place wires into the pre-positioned recesses without complex alignment operations.
Solution Approach 2:
The recesses act as intermediary structures that mediate between the carrier and the wire end segments. Instead of directly aligning thick wires with holes or positions on the carrier, the recesses provide a intermediate receptacle that guides and positions the wire ends, simplifying the assembly operation while maintaining precision.
2Reliability
If multiple wires need to be aligned and inserted through the carrier simultaneously, then the electrical connections can be established, but the assembly process requires special attention and becomes tedious
Solution Approach 1:
The assembly process is segmented into two independent steps: first, the choke is mounted on the carrier; second, the wire end segments are inserted into the recesses. This segmentation allows each step to be performed separately without the complexity of simultaneous multi-wire alignment, making the process easier and more reliable.
Solution Approach 2:
The recesses are pre-formed in the carrier before wire insertion, so the positioning function is prepared in advance. This allows workers to simply place wires into the pre-positioned recesses without complex alignment operations, significantly improving ease of manufacture while maintaining connection reliability.
3Power
If thick wires are used for high-power applications, then the current carrying capacity is sufficient, but the alignment and insertion into guide means becomes awkward and difficult
Solution Approach 1:
The recesses provide a flexible accommodation space that can easily receive wire end segments of various diameters, including thick wires for high-power applications. The recesses are designed with sufficient depth and width to accommodate thick wires without requiring precise alignment, making insertion easy while maintaining the current carrying capacity enabled by the thick wires.
Data Source
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AI summary
The invention relates to an inductive component (10) mounted on a printed circuit board, comprising a substantially flat carrier (20) and an inductor (12). The inductor (12) is mounted on an upper side of the carrier (20) and comprises a core (14) and at least two coils (16) wound around the core (14). The wires of the at least two coils (16) have end segments (18) that pass through the carrier (20) and terminate on a lower side of the carrier (20) opposite the upper side. The carrier (20) includes recesses (24) for guiding the end segments (18) through the carrier (20) and fasteners (26) for securing the end segments (18) of the wires in the recesses (24). Pairs of end segments (18) are arranged in pairs of recesses (24) and secured by common fasteners (26). The invention further relates to an inverter comprising an inductive component (10).