Segmented Magnetic Sheet Inductor Assembly for Coil Protection

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Solution Overview

Problem

Conventional inductor manufacturing methods face challenges such as space limitations in single-piece molds, particle size restrictions for magnetic powder, glue material issues, and deformation of coils leading to short circuits and increased resistance, especially in smaller components.

Innovation Solution

A method for forming multiple inductors in a single process by assembling separately formed parts, using magnetic sheets to create a magnetic body with different magnetic materials for each part, allowing for adjustable inductance and avoiding mold limitations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a single-piece mold is used for forming inductors, then the manufacturing process is simplified, but the particle size of magnetic powder must be kept below an appropriate size to avoid bridging effect and increase filling density

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidmagnetic powder particle size flexibility

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The magnetic body is divided into multiple separate parts (first part with base, second part with pillar, third part with through opening, fourth part with cover) that are formed separately and then assembled. This segmentation eliminates the need for a single-piece mold, allowing magnetic powder of various particle sizes to be used without bridging effects, while still enabling efficient manufacturing through modular assembly.

Inventive Principle:

Principle #1Segmentation

2Strength

If glue material is used to bind magnetic powder, then the powder particles are bound together, but the glue material must be held below an appropriate ratio to avoid sticking to the mold and causing damage

Engineering Contradiction:

Improvebinding strength of magnetic powderVSAvoidmold damage from glue material

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The magnetic body is segmented into multiple parts formed separately without requiring excessive glue material for binding. The modular structure reduces the total volume of glue needed compared to forming a complete magnetic body in a single mold, thereby minimizing glue-related mold damage while still achieving sufficient binding strength between parts.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The harmful element (excessive glue material) is extracted from the system by adopting a segmented construction approach. By forming parts separately and assembling them, the patent eliminates the need for large amounts of glue material that would otherwise be required to bind densely packed magnetic powder in a single-piece mold, thus preventing mold damage.

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of manufacture

If a lead frame is used for forming electrodes, then the electrodes are formed, but a large amount of space is required which is not suitable for smaller electrical components

Engineering Contradiction:

Improveelectrode formationVSAvoidspace occupied by electrodes

Core Design Contradiction:

Ease of manufactureVSArea of stationary object

Solution Approach 1:

The electrode structure is merged with the magnetic body parts themselves. The base, pillar, and cover parts are formed with integrated electrode structures, eliminating the need for separate lead frames. This integration significantly reduces the space occupied by electrodes, making the inductor suitable for smaller component sizes while maintaining ease of manufacture.

Inventive Principle:

Principle #5Merging (Combining)

4Quantity of substance

If high-tonnage pressing is used to form the magnetic body, then the magnetic powder is compacted, but the coil is easily deformed after heating and pressing, causing particles to penetrate into the insulating layer and cause short circuits

Engineering Contradiction:

Improvemagnetic powder densityVSAvoidcoil integrity and insulation

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The coil is pre-positioned and secured within the magnetic body structure before the final high-tonnage pressing operation. The separate parts (base, pillar, through opening, cover) are assembled with the coil in place, and then bonded together. This preliminary positioning prevents coil deformation during pressing and heating, eliminating the risk of magnetic powder particles penetrating into the insulating layer and causing short circuits.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The magnetic body is segmented into multiple parts that are assembled around the coil before final bonding. This segmentation allows the coil to be protected and secured in position during the forming process, preventing deformation and particle penetration issues that occur when using a single-piece mold with high-tonnage pressing.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12518917B2Method to form multiple electrical components and a single electrical component made by the method

Publication Date: 2026.01.06 CYNTEC

AI summary

A method to form a plurality of inductors in a single process by stacking multiple magnetic sheets, wherein each sheet is made to form a particular part in quantities, which can be a base part, a pillar part, a hollow part, or a cover part, for forming a magnetic body of an inductor.