Solderable Planar Magnetic Components for PCB Integration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing planar magnetic components for printed circuit boards (PCBs) face challenges in achieving reliable soldering and efficient integration of inductive components, which affects their performance and production speed.
Innovation Solution
The solution involves a printed circuit board with a conductive winding and a core formed by two core members, where one core member is soldered to the PCB and the other is coupled to it, creating a magnetic core that extends through an aperture, facilitating high-speed production and efficient magnetic field concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional planar magnetic components are used, then integration on PCB is achieved, but soldering reliability is insufficient
Solution Approach 1:
The core is divided into multiple core members (first core member, second core member, third core member) that can be separately manufactured and then assembled. Each core member has specific joining surfaces designed for reliable soldering to the PCB, separating the core structure into manageable segments that improve both manufacturability and soldering reliability.
Solution Approach 2:
The patent transitions from planar two-dimensional core structures to three-dimensional core members with vertical legs extending through the PCB aperture. This dimensional change allows the magnetic core to extend through the thickness of the PCB, providing multiple joining surfaces and improving mechanical and electrical connection reliability.
2Reliability
If complex core structures are used to improve magnetic performance, then magnetic field concentration is enhanced, but production speed decreases
Solution Approach 1:
The complex three-dimensional core structure is segmented into multiple core members that can be manufactured using standard PCB fabrication processes. Each core member is formed by depositing conductive material and applying magnetic material, allowing for high-speed automated production while maintaining complex geometric shapes necessary for magnetic field concentration.
Solution Approach 2:
The patent replaces traditional mechanical core assembly methods with a process where conductive windings are printed directly onto the PCB using conductive ink, and magnetic material is deposited through electroplating or similar processes. This substitution of mechanical fabrication with deposition and bonding processes significantly increases production speed while maintaining magnetic performance.
3Strength
If core members are soldered to PCB, then joining strength is improved, but manufacturing complexity increases
Solution Approach 1:
The PCB serves multiple functions: it acts as the substrate for the conductive windings, provides the aperture for core member insertion, and serves as the soldering surface for joining the core members. The conductive windings simultaneously create the electrical circuit and provide the magnetic core structure when magnetic material is applied, reducing overall manufacturing complexity.
Solution Approach 2:
The patent combines the core members, windings, and PCB into a single integrated structure. The core members are soldered directly to the PCB at their joining surfaces, merging the mechanical support function of the PCB with the electrical connection function and the magnetic circuit function, thereby simplifying the overall manufacturing process despite the added joining strength.
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 approach enables reliable soldering and efficient integration of inductive components on PCBs, enhancing their performance and reducing production time by utilizing solderable joining surfaces and adjustable air gaps for optimal magnetic properties.
Implementation Method 1
A first core member is soldered to the first side using a solder material
Implementation Method 2
A conductive winding is printed onto the printed circuit board and surrounds the aperture
Implementation Method 3
The first core member and the second core member, combined, include a magnetic core which extends through the aperture
Data Source
AI summary
An inductive component having a printed circuit board (“PCB”) with a first side and a second side. An aperture extends through the PCB and a conductive winding is printed onto the PCB surrounding the aperture. A core is formed by a first core member and a second core member. The first core member includes a first base member with at least one joining surface which is solderable to the first side. A first core leg extends at least partially through the aperture. The second core member includes at least a second base member and is coupled to the first core member or the second side. To manufacture the PCB, the first core member is soldered to the first side and then the PCB is inverted. The second core member is then coupled to at least one of the first core member or the second side.