Surface-Mount Inductor With Parallel Winding Axis
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Solution Overview
Problem
Conventional surface-mount inductors face issues with increased parts and manufacturing costs, defects due to thermal and mechanical stresses from welding, and require polarity indication due to directional winding axes.
Innovation Solution
A surface-mount inductor design featuring a coil wound with rectangular wire in a two-roll arrangement, integrated with a mounting body and magnetic cores, where the winding axis is parallel to the mounting body, eliminating the need for a metal frame and reducing mechanical stresses, and using sealant to seal the coil and magnetic cores for simplified manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coil ends are welded to metal pieces to connect the coil to the metal frame, then the coil is securely mounted, but the contacting portions are exposed to thermal and mechanical stresses causing defects
Solution Approach 1:
The invention extracts and eliminates the metal frame and welding process from the inductor structure. Instead of welding coil ends to metal pieces, the coil is directly mounted on the circuit board via lead ends, removing the source of thermal and mechanical stress that caused defects in conventional designs.
Solution Approach 2:
The invention replaces the mechanical welding system with a direct mechanical mounting system. The coil's lead ends are directly connected to the circuit board, substituting the complex welding process and metal frame structure with a simpler direct-mount approach that avoids thermal and mechanical stress.
2Device complexity
If the winding axis of the coil is set orthogonally to the circuit wiring board, then the coil structure is simplified, but the electric characteristics become directional requiring polarity indication
Solution Approach 1:
The invention uses asymmetric winding arrangement where the first and second rolls are positioned at different locations along the winding axis. This asymmetric configuration creates inherent polarity indication through the physical arrangement of the rolls, eliminating the need for additional polarity markers while maintaining simplified coil structure.
Solution Approach 2:
The invention uses the positional arrangement of the first and second rolls as a visual indicator system. The different positions and orientations of the rolls serve as inherent polarity indicators, similar to how color changes indicate polarity in other components, eliminating the need for separate polarity markings.
3Ease of manufacture
If conventional surface-mount inductor design is used, then the inductor can be manufactured, but the number of parts increases and manufacturing costs increase
Solution Approach 1:
The invention merges the coil mounting structure with the circuit board by eliminating the separate metal frame. The coil is directly mounted on the board, combining what were previously separate components (coil, metal frame, mounting structure) into a more integrated assembly, reducing the total number of parts.
Solution Approach 2:
The lead ends of the coil serve multiple functions: they provide electrical connection to the circuit board, serve as mounting elements, and eliminate the need for separate terminal structures. This multi-functionality reduces the number of dedicated parts needed for connection and mounting.
Data Source
AI summary
A surface-mount inductor including a coil formed by winding a rectangular wire, and a mounting body for accommodating the coil, the coil having first rolls of the wire wound in a two-roll arrangement, second rolls being wound at positions shifted away from the first rolls along the winding axis, and lead ends brought out from the outermost turn of the second rolls; the mounting body containing a protruded portion for inserting into the winding axis of the coil, and a pair of bottomed magnetic cores having slits respectively, the protruded portion being inserted into the winding axis of the coil so that the mounting body is embedded in the coil with sealant to incorporate the magnetic cores with the coil and to expose the core mounting face of the magnetic cores therefrom, as well as a method for manufacturing the same.