Magnetic Component Terminal Base Mold Design
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Solution Overview
Problem
The existing methods for forming terminal bases of magnetic components, such as solenoids, face challenges in preventing burrs, ensuring dimensional accuracy, and extending mold lifespan, while also accommodating size reduction demands, particularly in electronic components for vehicles.
Innovation Solution
The terminal base design features a step on the terminal base main body near the connector portion, with a planar portion of the shaft portion exposed over a greater length, and an r-shaped portion at the corner, allowing for reliable contact during molding and minimizing burr formation, while the mold device employs a slide mold for improved dimensional accuracy and reduced mold wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the distance between the top surface portion of the terminal base main body and the lower end surface of the grasping claw is increased to prevent burr formation, then manufacturing quality improves, but the overall size of the terminal base increases
Solution Approach 1:
The patent divides the terminal base main body into different level surfaces (first level surface and second level surface) at different heights. The shaft portion is positioned at the first level surface while the grasping claw extends to the second level surface, creating a stepped structure that allows sufficient distance for burr prevention without increasing the overall footprint of the terminal base.
Solution Approach 2:
Instead of increasing the vertical distance between the top surface and grasping claw in a single dimension, the patent introduces a stepped structure with different level surfaces at different heights. This multi-level arrangement effectively utilizes vertical space differentiation to provide the necessary molding distance while maintaining a compact overall size.
2Volume of moving object
If the shaft portion is fully enclosed in the terminal base main body, then the structure appears compact, but burr formation occurs during molding and dimensional accuracy deteriorates
Solution Approach 1:
The patent applies different structural treatments to different portions of the shaft portion. The shaft portion is partially exposed at the first level surface where dimensional accuracy is critical, while other portions may be enclosed or positioned at different levels. This localized exposure ensures accurate molding dimensions at critical interfaces without requiring the entire shaft to be exposed, maintaining overall structural compactness.
3Reliability
If a fastening tool is used to mount the shaft portion onto the shaft fixing unit, then connection reliability improves, but the assembling operation becomes complicated
Solution Approach 1:
The patent integrates the shaft portion directly with the terminal base main body through a unified molding process, eliminating the need for separate fastening operations. The shaft portion and terminal base main body form an integrated structure where the shaft portion is positioned at the first level surface and the grasping claw extends to the second level surface, ensuring both connection reliability and simplified assembly.
Solution Approach 2:
The shaft portion is pre-positioned and integrated with the terminal base main body during the molding process itself, rather than requiring subsequent fastening operations. This preliminary integration ensures proper positioning and connection reliability while eliminating the need for additional fastening tools and operations.
Data Source
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AI summary
The terminal base 20 of a magnetic component comprises a conductive terminal unit (a clip terminal 12), and a terminal base main body 16. The clip terminal 12 is connected with a coil 10c wound around a cylindrical bobbin 10, and the clip terminal 12 carries out electrical connection with respect to a user-side terminal unit. Furthermore, a terminal base main body 16 is arranged at a flange unit 10b of the bobbin 10 for holding a shaft portion 14 of the conductive terminal unit 12. And the conductive terminal unit 12 is formed in an L-shape as a whole such that that a connector portion 18 thereof having a connection structure with respect to the user-side terminal unit protrudes toward the orthogonal direction of the shaft portion 14. The conductive terminal unit 12 and the terminal base main body 16 are formed integrally using molding. A step 16a is provided on a part of the terminal base main body 16 near the protruding side of the connector portion 18 so that this part becomes one step lower than the other parts of the terminal base main body 16. And the shaft portion 14 is exposed over a greater part of its length from the step 16a of the terminal base main body 16 than from the other parts of the terminal base main body 16a.