Pedestal Mounting for Conical Inductor Precision
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Solution Overview
Problem
Existing methods for mounting conical inductors on circuit boards are labor-intensive, costly, and result in inconsistent height and angle, leading to variance in system operation and increased labor costs due to the multi-step process of building a platform and curing epoxy multiple times.
Innovation Solution
A pedestal is permanently attached to the circuit board with adhesive, allowing the conical inductor to be mounted at a consistent angle between 25 and 65 degrees, with only one epoxy application between the pedestal and the board and one between the inductor and pedestal, ensuring precise alignment and reduced installation time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a multiple-step process is used to build up a platform and secure the inductor, then the inductor can be mounted at the required height and angle, but the process becomes time-consuming and labor-intensive
Solution Approach 1:
The pedestal is pre-formed with the exact height and angle specifications required for the inductor mounting. This preliminary preparation of the mounting structure eliminates the need for multiple iterative epoxy applications and platform building steps, allowing the inductor to be mounted directly at the correct position and orientation in a single operation.
2Manufacturing precision
If manual platform building with multiple epoxy applications is used, then the inductor can be secured at the specified position, but the process requires numerous assembly stations and increases labor costs
Solution Approach 1:
The complex platform building process and multiple epoxy application steps are extracted and replaced by a single pre-formed pedestal component. This extraction of the mounting function into a dedicated component eliminates the need for multiple assembly stations and complex manual procedures, reducing both device complexity and labor requirements.
3Length of stationary object
If multiple epoxy dabs are applied to build the platform, then the required height can be achieved, but the cure time between each application increases the total assembly time
Solution Approach 1:
The pedestal is pre-formed to the exact required height before assembly. This preliminary creation of the mounting structure eliminates the need for multiple sequential epoxy applications with cure times between each step. The height dimension is established in advance during pedestal manufacturing, not during the assembly process, thereby eliminating time loss.
4Ease of manufacture
If manual platform building is used, then the inductor can be mounted, but the height and angle vary from inductor to inductor due to non-controllable factors
Solution Approach 1:
Instead of manually creating a unique platform for each inductor with varying dimensions, a standardized pedestal design is used that provides consistent height and angle specifications across all assemblies. This standardized component ensures uniform inductor placement geometry, eliminating the variability introduced by manual platform building while maintaining ease of manufacture through standardization.
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
The solution provides consistent and repeatable placement of inductors, minimizing labor costs and ensuring accurate electrical lead length and alignment across different circuit boards, improving installation efficiency and reducing variance in system operation.
Implementation Method 1
The pedestal is permanently attached with adhesive to the conical inductor mounting location on the circuit board. The conical inductor permanently mounts on the pedestal with adhesive at an angle
Data Source
AI summary
A system and method for placing an inductor on a circuit board. This method includes providing a circuit board, a pedestal, and an inductor, the pedestal has a top surface and a bottom surface and the circuit board has one or more electrical conductors, the inductor having a first inductor terminal and a second inductor terminal. Adhesive is placed on the circuit board and the bottom surface of the pedestal is placed on the adhesive located on the circuit board to secure the pedestal to the circuit board. Next, adhesive is placed on the top surface of the pedestal and the inductor is placed on the adhesive located on the top surface of the pedestal to secure the inductor to the pedestal. The inductor is electrically connected to the circuit board.