Thin Inductor Coil Support During Magnetic Powder Pressing
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Solution Overview
Problem
Conventional thin-type inductors face issues with mechanical deformation due to unsupported coils, leading to decreased production yields and increased parasitic capacitance, which affects their performance and reliability.
Innovation Solution
The method involves coiling an enameled wire around a magnetic core, fixing the wire ends, filling with magnetic powder, and forming a semi-finished product that is then abraded and plated to create electrodes, ensuring the wire ends are supported and reducing parasitic capacitance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the coil is vertically wound to reduce total height, then the inductor can be made thin for various applications, but the coil becomes mechanically unsupported and may deform during pressing
Solution Approach 1:
The patent applies preliminary action by providing mechanical support structures (support posts or fixture) before the pressing operation. The coil is positioned and supported in advance on the magnetic powder within the mold, preventing deformation during the subsequent pressing step. This resolves the contradiction by enabling vertical winding for thin height while maintaining production yield through pre-established mechanical support.
2Length of stationary object
If the coil is vertically wound to reduce total height, then the inductor can be made thin, but the coil is mechanically unsupported leading to deformation
Solution Approach 1:
The patent introduces intermediary elements (support posts or fixture structures) that act as mediators between the vertically wound coil and the mold/pressing mechanism. These intermediaries provide the necessary mechanical support to the unsupported coil, preventing deformation while maintaining the thin profile enabled by vertical winding. The support posts transfer and distribute pressing forces, resolving the strength deficiency.
3Ease of manufacture
If magnetic powder is filled and pressed to form the inductor body, then the coil is enclosed, but the unsupported coil deforms during pressing
Solution Approach 1:
The patent applies preliminary action by establishing coil support structures before the magnetic powder filling and pressing operations. The support posts or fixture are positioned in advance to maintain coil geometry, ensuring that when magnetic powder is pressed into the mold, the coil remains undeformed. This resolves the contradiction between ease of manufacture (simple molding) and manufacturing precision (coil shape accuracy).
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 prevents deformation, increases manufacturing yield, reduces parasitic capacitance, and enhances electrical connection reliability by supporting the enameled wire and optimizing the inductor's design for thin-type applications.
Implementation Method 1
pressing the magnetic powder material with the magnetic core and the coiled enameled wire in the container to form semi-finished product
Implementation Method 2
subjecting the semi-finished product to a plating treatment so as to respectively form two electrodes on the first end and the second end
Data Source
AI summary
The method for making the inductor includes coiling a enameled wire around a main section of a magnetic core and fixing two wire ends of the enameled wire on two end sections of the magnetic core, the two wire ends of the enameled wire being opposite to each other, the end sections being located at two opposite ends of the main section; putting the magnetic core coiled with the enameled wire into a container, filling the container with a magnetic powder material, and pressing to form semi-finished product having a first end, and a second end that is opposite to the first end; abrading the first and second ends of the semi-finished product until the wire ends are partially exposed; and performing a plating treatment to form two electrodes that are electrically connected to the two wire ends on the first and second ends.