Systems and devices for strain mitigation of magnetic cores and assemblies

Abstract

Systems and devices for strain mitigation for magnetic cores and assemblies are disclosed. An example device includes a mounting structure including a first material having a first coefficient of thermal expansion (CTE). The mounting structure includes a center portion and an outer portion. The device also includes a magnetic core for an electrical component coupled to the outer portion of the mounting structure. The magnetic core includes a second material having a second CTE. The magnetic core is divided into a plurality of segments separated by spaces extending from the center portion to an outer edge of the outer portion. Each of the plurality of segments is individually coupled to the mounting structure, each of the plurality of segments connected to the electrical component.

Description

Technical Field

[0001] This disclosure relates to systems and apparatuses for strain relief in magnetic cores and components. Background Technology

[0002] Unless otherwise specified herein, the material described in this section is not prior art with respect to the claims of this application and is not acknowledged as prior art by virtue of its inclusion in this section.

[0003] Devices with rotating components, such as gyroscope sensing modules or LiDAR (Light Detection and Ranging) devices, may include a fixed end and a rotating end spatially separated. Transformers can be used to transmit power and / or data between the fixed and rotating ends. Some transformers often incorporate brittle materials, such as ferrite materials, that are prone to fracture or fragmentation in response to applied strain. The difference in thermal expansion characteristics between the transformer and the surfaces on which it is mounted can be a source of such strain experienced by the transformer when the device encounters changes in thermal conditions. Summary of the Invention

[0004] In the first example, an apparatus is described. The apparatus includes a mounting structure comprising a first material having a first coefficient of thermal expansion (CTE). The mounting structure includes a central portion and an outer portion. The apparatus also includes a magnetic core for an electrical component, coupled to the outer portion of the mounting structure. The magnetic core comprises a second material having a second CTE. The magnetic core is divided into multiple segments spaced apart by spaces extending from the central portion to the outer edges of the outer portions. Each of the multiple segments is individually coupled to the mounting structure, and each of the multiple segments is connected to an electrical component.

[0005] In a second example, a Light Detection and Ranging (LIDAR) device is described. The LIDAR device includes a first end having a first side of a transformer pair. The first side of the transformer pair is configured to transmit power to a second side of the transformer pair. The LIDAR device includes a second end. The second end includes a plurality of light emitters, a plurality of light detectors, and a second side of the transformer pair. The second side of the transformer pair is configured to supply power to the plurality of light emitters and the plurality of light detectors via the first side of the transformer pair. Both the first and second sides of the transformer pair include a mounting structure comprising a first material having a first coefficient of thermal expansion (CTE). The mounting structure includes a central portion and an outer portion. Both the first and second sides of the transformer pair include a magnetic core for electrical components coupled to the outer portion of the mounting structure. The magnetic core comprises a second material having a second CTE. The magnetic core is divided into a plurality of segments spatially separated by spaces extending from the central portion to the outer edges of the outer portions. Each of the plurality of segments is individually coupled to the mounting structure, and each of the plurality of segments is connected to an electrical component.

[0006] In the third example, a transformer is described. The transformer includes a first side and a second side of a transformer pair. The first side is configured to transmit power to the second side. Both the first and second sides of the transformer pair include a mounting structure comprising a first material having a first coefficient of thermal expansion (CTE). The mounting structure includes a central portion and an outer portion. Both the first and second sides of the transformer pair include a magnetic core coupled to the outer portion of the mounting structure. The magnetic core comprises a second material having a second CTE, wherein the magnetic core is divided into multiple segments spatially separated by spaces extending from the central portion to the outer edges of the outer portions. Each of these multiple segments is individually coupled to the mounting structure, and each of these multiple segments is connected to an electrical component. Both the first and second sides of the transformer pair include windings connected to the magnetic core. Attached Figure Description

[0007] Figure 1 This is a block diagram of an apparatus according to an example embodiment.

[0008] Figure 2 A perspective view of a transformer pair according to an example embodiment is shown.

[0009] Figure 3A A perspective view of one side of a transformer pair according to an example embodiment is shown.

[0010] Figure 3B A perspective view of one side of a transformer pair according to an example embodiment is shown.

[0011] Figure 3C A perspective view of one side of a transformer pair according to an example embodiment is shown.

[0012] Figure 3D A perspective view of one side of a transformer pair according to an example embodiment is shown.

[0013] Figure 3E A perspective view of one side of a transformer pair according to an example embodiment is shown.

[0014] Figure 3F A cross-sectional side view of one side of a transformer pair according to an example embodiment is shown.

[0015] Figure 4 A perspective view of a membrane for one side of a transformer pair according to an example embodiment is shown.

[0016] Figure 5 A perspective view of a membrane covering one side of a transformer pair according to an example embodiment is shown.

[0017] Figure 6A A top view of one side of a transformer pair under a first thermal condition is shown according to an example embodiment.

[0018] Figure 6B A top view of one side of a transformer pair under a second thermal condition is shown according to an example embodiment.

[0019] Figure 7A A top view of one side of a transformer pair under a first thermal condition is shown according to an example embodiment.

[0020] Figure 7B A top view of one side of a transformer pair under a second thermal condition is shown according to an example embodiment.

[0021] Figure 8A A top view of a magnetic core under a first thermal condition is shown according to an example embodiment.

[0022] Figure 8B A top view of a magnetic core under a second thermal condition is shown according to an example embodiment.

[0023] Figure 9A A side view of one side of a transformer pair under a first thermal condition is shown according to an example embodiment.

[0024] Figure 9B A side view of one side of a transformer pair under a second thermal condition is shown according to an example embodiment.

[0025] Figure 10 A block diagram of a method according to an example implementation is shown. Detailed Implementation

[0026] Example methods, apparatus, and systems are described herein. It should be understood that the terms "example" and "exemplary" are used herein to mean "used as an example, instance, or instance." Any implementation or feature described herein as "example" or "exemplary" should not necessarily be construed as preferred or advantageous over other implementations or features. Other implementations and modifications may be utilized without departing from the scope of the subject matter presented herein.

[0027] Therefore, the exemplary embodiments described herein are not intended to be limiting. The aspects of this disclosure, as generally described herein and illustrated in the accompanying drawings, can be arranged, replaced, combined, separated, and designed in a variety of different configurations, all of which are taken into consideration herein.

[0028] Furthermore, unless the context otherwise indicates, the features shown in each figure can be used in combination with each other. Therefore, the figures... Figure 1Generally, features should be considered as components of one or more overall implementations, and it should be understood that not all features shown are necessary for every implementation.

[0029] The use of the terms “about” or “substantially” with respect to the quantities or measurements described herein indicates that the described characteristics, parameters, or values ​​do not need to be precisely achieved, but rather deviations or variations (including, for example, tolerances, measurement errors, measurement accuracy limitations, and other factors known to those skilled in the art) may occur in a quantity that does not preclude the effects that the characteristic is intended to provide.

[0030] I. Overview

[0031] Devices with rotating components, such as gyroscope sensing modules or LiDAR devices, can wirelessly transmit data and / or power from a fixed part of the device to the rotating part. This wireless transmission can be achieved using a transformer with a magnetic core (e.g., a ferrite core). Modulating the signal across the transformer allows data and / or power to be wirelessly transmitted to and from components on the rotating part.

[0032] The magnetic core can be mounted to a relatively stationary part of a system. For example, in the context of a LiDAR device, the magnetic core can be mounted to a structure on the LiDAR device, or to a structure to which the LiDAR device is attached, such as to a vehicle. The mounting structure can be an aluminum structure, or a structure composed of one or more additional or alternative materials (e.g., metals). Because the magnetic core is mounted in a stationary manner relative to the mounting structure, it is subjected to mechanical forces whenever the mounting structure expands or contracts in response to changes in thermal conditions. Specifically, this can be caused by the different coefficients of thermal expansion (CTE) between the magnetic core and the mounting structure. In some contexts, this can lead to excessive strain or breakage of the magnetic core. Furthermore, fragments of the magnetic core that break apart in response to changes in thermal conditions may impede the movement of the device.

[0033] In one example embodiment, the device includes a magnetic core and electrical components (e.g., one or more windings of a transformer) coupled to the magnetic core. The magnetic core can be divided into multiple segments spatially separated by spaces extending from the central portion of the mounting structure to the outer edges of the outer portions of the mounting structure. Each of these segments is individually coupled to the mounting structure, which allows the segments to move relative to each other as the magnetic core expands or contracts in response to thermal conditions. Furthermore, each segment is connected to the electrical components. In this way, the strain experienced by the magnetic core can be reduced while still providing structure for the device.

[0034] In one example implementation, during a first thermal condition, the plurality of segments are spaced apart by a first distance, and during a second thermal condition, the plurality of segments are spaced apart by a second distance different from the first distance. For example, the first thermal condition may correspond to room temperature, at which point each segment may be spaced apart by the first distance, and the second thermal condition may have a higher temperature (e.g., 100°F). Because the core can have a lower CTE than the mounting structure, the segments of the core can expand at a lower rate than the mounting structure. This can result in the segments being spaced apart by a second distance under the second thermal condition, which is greater than the first distance under the first thermal condition.

[0035] In one example implementation, the device is one having a fixed portion and a rotating portion (e.g., a LIDAR device, a gyroscope sensor device, an inertial measurement unit (IMU) device, or another device). In these examples, the electrical components are the primary or secondary windings of a transformer connected to the fixed portion of the device. The windings may be connected to a magnetic core. Although the examples here may describe a LIDAR device, other types of devices such as gyroscope sensors or IMUs are considered.

[0036] In one example implementation, the rotating portion of the LIDAR device may have a first magnetic core corresponding to the primary winding of a transformer, and the stationary portion of the LIDAR device may have a second magnetic core corresponding to the secondary winding of the transformer. Each magnetic core may include a segment aligned with a center point corresponding to the axis of rotation of the rotating portion of the LIDAR device. This allows the two ends of the transformer to remain aligned under varying thermal conditions, thereby continuing to transmit power and / or data across a space separating the primary and secondary windings under varying thermal conditions.

[0037] Even with reduced strain due to dividing the core into multiple segments, the core may still fracture or fragments may detach. In the context of a LiDAR device, this could impede the movement of rotating parts. In this example, an intermediate membrane could be placed between the core and the mounting structure and electrical components to accommodate any broken pieces of the core.

[0038] II. Example System

[0039] Figure 1 This is a block diagram of an apparatus 100 according to an example embodiment. Specifically, Figure 1 A device 100 is shown, having a first end 102 coupled to a fixed surface 104 and a second end 106 movable (e.g., rotatable) relative to the fixed surface 104. In this case, "fixed" refers to the device 100.

[0040] The device 100 also includes a transformer 108 spanning a space 114 (e.g., an air gap) separating a first end 102 and a second end 106. The transformer 108 includes a primary winding 110 disposed at the first end 102 and a secondary winding 112 disposed at the second end 106. Although not described in... Figure 1 As shown, however, each winding can correspond to a separate magnetic core.

[0041] Transformer 108 may include a transformer pair having a first side corresponding to the primary winding 110 and a second side corresponding to the secondary winding 112. Transformer 108 can be used to transmit power and / or data from the primary winding 110 in the first terminal 102 to the secondary winding 112 in the second terminal 106, depending on a modulation scheme. The secondary winding 112 can then transmit power and / or data to one or more components of device 100. Similarly, the secondary winding can transmit data such as sensor data to the first terminal 102 via the primary winding 110. For example, a gyroscope module of a vehicle or a LiDAR device on a vehicle can be configured in this way to allow movement relative to the surface of the vehicle and also to allow the transmission of power and information.

[0042] In the example, device 100 corresponds to a LIDAR device. A first end of the LIDAR device corresponds to a first end 102, and a second end of the LIDAR device corresponds to a second end 106. The first end may include a first side of a transformer pair, and the second end may include a plurality of light emitters, a plurality of photodetectors, and a second side of the transformer pair. In these examples, the second side of the transformer pair is configured to supply power to the plurality of light emitters and the plurality of photodetectors via the first side of the transformer pair.

[0043] although Figure 1 An apparatus 100 having a fixed first end and a movable second end is described in connection with providing a context for the use of a transformer; however, it should be understood that other contexts for using a transformer to transmit electricity and information in space are possible.

[0044] Figure 2 A perspective view of a transformer pair 200 according to an example embodiment is shown. Specifically, Figure 2 A first side 204 connected to the second side 206 is shown. Both sides include a central portion 202 and an outer portion. In this example, the central portion 202 includes an empty space, thereby allowing one or more components to pass through the transformer pair 200.

[0045] Figure 2A mounting structure for a pair of magnetic cores (not shown) is illustrated. The magnetic cores correspond to primary and secondary windings for transmitting power and / or data between a first side 204 and a second side 206. The transformer pair 200 also includes a plurality of mounting elements 208 for connecting the magnetic cores to the mounting structure.

[0046] Figure 3A A perspective view of one side 300 of a transformer pair according to an example embodiment is shown. Specifically, Figure 3A The top surface of a plurality of magnetic cores of an electrical component included in side 300 and a mounting structure 302 is shown. The mounting structure 302 includes a central portion 304 and an outer portion 306. The outer portion 306 is defined by an outer edge 310 and an inner edge 308 corresponding to the central portion 304.

[0047] Mounting structure 302 includes multiple rings configured to provide lateral support to one or more components, such as magnetic cores, and to hold these components in place. However, due to the different CTEs between mounting structure 302 and the components, the rings may exert strain on the components. For brittle components, such as magnetic cores comprising ceramic materials (e.g., ferrite), this strain can lead to fragmentation or cracking that may affect transformer performance. This will be discussed below regarding... Figure 6A , Figure 6B , Figure 7A and Figure 7B It was described in further detail.

[0048] In the example, side 300 can be interchangeably used as either the first or second side of the transformer pair. Therefore, the assembled transformer pair can include both sides, each side being substantially as follows: Figure 3A The configuration is shown. In the assembled state, the top surfaces of these sides face each other and can be arranged similarly. Figure 2 The transformer shown is 200.

[0049] Now refer to Figure 3B-3E It provides a simplified representation of side 300 to more clearly show the plurality of magnetic cores and rings included in side 300.

[0050] Figure 3B A perspective view of side 300 according to an example embodiment is shown. Specifically, Figure 3B It shows Figure 3A The diagram shows a simplified version of side 300. This simplified illustration depicts the first magnetic core 312 and omits other components of side 300. The first magnetic core 312 is configured to hold the first winding 313 in grooves. The first magnetic core 312 is also divided into multiple segments separated by multiple spaces 314. The first winding 313 is held by each segment. (As mentioned above...) Figure 3AThe mounting structure 302 includes multiple rings. In this simplified example, two rings are shown: an outer ring 316 defined by the outer edge 310 of the mounting structure 302 and the outer edge 318 of the first magnetic core 312, and an inner ring 320 defined by the inner edge 308 of the mounting structure 302 and the inner edge 322 of the first magnetic core 312. Although the inner ring 320 is drawn to span the entire space between the inner edge 322 and the inner edge 308, as... Figure 3A As shown, a smaller ring can be used to provide support for the first magnetic core 312 while allowing additional components to be attached to the mounting structure 302.

[0051] It may include additional rings, such as Figure 3A The ones shown provide support for other components, such as the second, third, and fourth magnetic cores nested in the inner ring 320. In these examples, a first transformer including the first magnetic core 312 can be used for power transmission, while another transformer including the other magnetic core can be used for data transmission. Other configurations of the magnetic cores are possible, and other components can be connected to the mounting structure 302.

[0052] In the examples, during assembly, the sides of the transformer pair can rotate relative to each other. For example, the first side can remain stationary while the other side rotates. In these examples, the rotating component can be positioned in the space corresponding to the central portion 304. The stationary side can be part of a stationary portion of the device (e.g., a LIDAR device), while the rotating portion can be part of a rotating portion of the device.

[0053] Figure 3B A plurality of spaces 314 separating different sections of the first magnetic core 312 are also shown. These spaces allow the first magnetic core 312 to experience smaller strains as the mounting structure 302 expands and contracts in response to changing thermal conditions. For example, as the mounting structure 302 expands or contracts, the dimensions of the spaces 314 can expand or contract accordingly, thereby reducing the mechanical forces applied to the first magnetic core 312. This is about Figure 6A , Figure 6B , Figure 7A and Figure 7B It was described in further detail.

[0054] Figure 3C A perspective view of side 300 according to an example embodiment is shown. Specifically, Figure 3C It shows Figure 3A A simplified version of side 300 is shown. This simplified diagram depicts the second magnetic core 324 and omits other components of side 300. The second magnetic core 324 is configured to hold the second winding 325 in grooves. The second magnetic core 324 is also divided into multiple segments separated by multiple spaces 326. The second winding 325 is held by each segment. As mentioned above... Figure 3AThe mounting structure 302 includes multiple rings. In this simplified example, two rings are shown: an outer ring 328 defined by the outer edge 310 of the mounting structure 302 and the outer edge 330 of the second magnetic core 324, and an inner ring 332 defined by the inner edge 308 of the mounting structure 302 and the inner edge 334 of the second magnetic core 324. Although the inner ring 332 is drawn to span the entire space between the inner edge 334 and the inner edge 308, as... Figure 3A As shown, a smaller ring can be used to provide support for the second magnetic core 324 while allowing additional components to be attached to the mounting structure 302. Similarly, although the outer ring 328 is drawn to span the entire space between the outer edges 330 and 310, as... Figure 3A As shown, a smaller ring can be used to provide support for the second magnetic core 324 while allowing additional components (e.g., the first magnetic core 312 and the first winding 313) to be coupled to the mounting structure 302.

[0055] Figure 3C A plurality of spaces 326 separating different sections of the second magnetic core 324 are also shown. These spaces allow the second magnetic core 324 to experience smaller strains as the mounting structure 302 expands and contracts in response to changing thermal conditions. For example, as the mounting structure 302 expands or contracts, the dimensions of the spaces 326 can expand or contract accordingly, thereby reducing the mechanical forces applied to the second magnetic core 324. This is about Figure 6A , Figure 6B , Figure 7A and Figure 7B It was described in further detail.

[0056] Figure 3D A perspective view of side 300 according to an example embodiment is shown. Specifically, Figure 3D It shows Figure 3A The diagram shows a simplified version of side 300. This simplified illustration depicts the third magnetic core 336 and omits other components of side 300. The third magnetic core 336 is configured to hold the grooves of the third winding 337. (As mentioned above...) Figure 3A The mounting structure 302 includes multiple rings. In this simplified example, two rings are shown: an outer ring 338 defined by the outer edge 310 of the mounting structure 302 and the outer edge 340 of the third magnetic core 336, and an inner ring 342 defined by the inner edge 308 of the mounting structure 302 and the inner edge 344 of the third magnetic core 336. Although the inner ring 342 is drawn to span the entire space between the inner edge 344 and the inner edge 308, as... Figure 3A As shown, a smaller ring can be used to provide support for the third magnetic core 336 while allowing additional components to be attached to the mounting structure 302. Similarly, although the outer ring 338 is drawn to span the entire space between the outer edges 340 and 310, as... Figure 3AAs shown, a smaller ring can be used to provide support for the third core 336 while allowing additional components (e.g., the first core 312, the first winding 313, the second core 324, and the second winding 325) to be coupled to the mounting structure 302.

[0057] Figure 3D Multiple spaces separating the different sections of the third magnetic core 336 are not shown. This is because the difference in expansion and contraction between the mounting structure 302 and the magnetic core decreases towards the center of the mounting structure 302. Therefore, in areas such as Figure 3A In the example shown, multiple magnetic cores can be concentrically oriented relative to a center point on the mounting structure 302, and the number of segments of each core can increase as the core moves closer to the outer edge 310 of the mounting structure 302. In this example, this is illustrated with the third core 336 having one segment and the first core 312 and the second core 324 each having four segments. In other examples, the number of segments can vary (e.g., the first core 312 has six segments, the second core 324 has four segments, and so on). This allows for a reduction in the strain on cores that might experience greater strain due to the expansion and contraction of the mounting structure, while allowing other cores to have more support and reducing the total number of components connected to the mounting structure 302.

[0058] Figure 3E A perspective view of side 300 according to an example embodiment is shown. Specifically, Figure 3E It shows Figure 3A The diagram shows a simplified version of side 300. This simplified illustration depicts the fourth magnetic core 346 and omits other components of side 300. The third magnetic core 336 is configured to hold the grooves of the fourth winding 347. (As mentioned above...) Figure 3A The mounting structure 302 includes multiple rings. In this simplified example, two rings are shown: an outer ring 348 defined by the outer edge 310 of the mounting structure 302 and the outer edge 350 of the fourth magnetic core 346, and an inner ring 352 defined by the inner edge 308 of the mounting structure 302 and the inner edge 354 of the fourth magnetic core 346. Although the outer ring 348 is drawn to span the entire space between the outer edge 350 and the outer edge 310, as... Figure 3A As shown, a smaller ring can be used to provide support for the fourth core 346 while allowing additional components (e.g., the first core 312, the first winding 313, the second core 324, the second winding 325, the third core 336, and the third winding 337) to be coupled to the mounting structure 302.

[0059] Similar to Figure 3D , Figure 3EMultiple spaces separating the different sections of the fourth magnetic core 346 are not shown. This is because the difference in expansion and contraction between the mounting structure 302 and the magnetic core decreases towards the center of the mounting structure 302.

[0060] As described above, the different magnetic cores of mounting structure 302 can correspond to different functions. For example, the first transformer associated with the first magnetic core 312 can be used for power transmission between the two sides of the transformer pair, and the third transformer associated with the third magnetic core 336 can be used for data transmission between the two sides of the transformer pair. Other variations in the functions of the magnetic cores and windings are possible.

[0061] Figure 3F A cross-sectional side view of side 300 according to an example embodiment is shown. Specifically, Figure 3F It shows Figure 3A The simplified version of side 300 shown omits the loops surrounding the core and windings. Although Figure 3B-3E The magnetic core and windings are drawn to be basically arranged on a plane, but the magnetic core and windings can have different heights. Figure 3F An example is shown in which the first magnetic core 312 and the second magnetic core 324 are arranged at a first height, the third magnetic core 336 is at a second height, and the fourth magnetic core 446 is at a third height.

[0062] Arranging the magnetic cores at different heights allows for improved adaptability in transmitting power and / or data from one side 300 of the transformer pair to the other. For example, the first magnetic core 312 and the second magnetic core 324 can be used for power transmission, while the third magnetic core 336 and the fourth magnetic core 446 are used for data transmission. Using different heights for the first and second magnetic cores, as well as the third and fourth magnetic cores, can reduce interference in data communication. Similarly, using different heights for the third magnetic core 336 and the fourth magnetic core 346 can reduce crosstalk between separate communication channels.

[0063] although Figure 3F An example configuration of the height of the cores and windings relative to a common substrate is shown, but different height configurations are possible. For example, each core may have a different height relative to the mounting structure, or the core used for data communication may have a different height than the core used for power transmission. More generally, one side of a transformer pair may include multiple cores coupled to an outer portion of the mounting structure, with the first core having a first height and the second core having a second height different from the first height.

[0064] Figure 4 A perspective view of a membrane 400 for one side of a transformer pair according to an example embodiment is shown. For example, the membrane 400 may be... Figure 3A and Figure 3B The drawn side is aligned 300 degrees.

[0065] In some examples, even with reduced strain applied to the core, the core may still crack or break, and fragments of the core may fall into the transformer pair or the apparatus comprising the transformer pair. In examples where the sides of the transformer pair rotate relative to each other, these fragments may impede the rotation of the transformer pair or the apparatus.

[0066] Membrane 400 is configured to accommodate fragments of the magnetic core and can be applied to the top surface of one side of the transformer pair. For example, membrane 400 may include an adhesive for attaching membrane 400 to one side of the transformer pair. For example, membrane 400 may be a plastic or silicone material, with the adhesive applied to one side facing the top surface of one side of the transformer pair. Fragments detached from the magnetic core may adhere to the adhesive or fall into a space within the mounting structure of the transformer pair that does not affect the rotation of the transformer pair or the device. In other examples, membrane 400 may include tabs that can be attached to the mounting structure using tape, adhesive, or other means of attaching the tabs to the mounting structure.

[0067] Other methods are possible for capturing fragments from the magnetic core. For example, a potting material can be applied around each core to prevent fragments from detaching from the core due to strain from the expansion and contraction of the mounting structure.

[0068] Figure 5 A perspective view of a membrane 400 covering side 300 of a transformer pair according to an example embodiment is shown. The membrane 400 includes an inner edge 402 aligned with the inner edge of the mounting structure (e.g., inner edge 308) and an outer edge 404 aligned with the outer edge of the mounting structure (e.g., outer edge 310). Aligning the edges of the membrane 400 with the edges of the mounting structure on side 300 prevents core fragments from falling out of the transformer pair, thus facilitating rotation of the transformer pair or corresponding device.

[0069] Figure 6A A top view of one side 600 of a transformer pair under a first thermal condition is shown according to an example embodiment. Specifically, Figure 6A An example is shown where the core 604 does not include any space. Side 600 includes a mounting structure having an outer ring 602 and an inner ring 606 surrounding the core 604. This arrangement around the core holds it in place and maintains alignment between the core 604 and its corresponding core on the corresponding side of the transformer pair, thereby allowing the transformer pair to operate efficiently.

[0070] Figure 6A Side 600 is shown under typical thermal conditions (e.g., at room temperature). In this example, the mounting surfaces, including the outer ring 602 and the inner ring 606, are made of aluminum and have a 21 × 10 -6 / ℃ and 25×10 -6The first CTE is between / ℃, and the magnetic core 604 is made of 15×10. -6 / ℃ and 19×10 -6 The second CTE is composed of ferrite material between / ℃. Other materials (e.g., other metals) may be used for the outer ring 602 and the inner ring 606, and other materials (e.g., other magnetic materials) may be used for the core 604.

[0071] Figure 6B A top view of side 600 of a transformer pair under a second thermal condition is shown according to an example embodiment. Specifically, Figure 6B The effect of elevated temperature (e.g., from room temperature to 50°C) on the outer ring 602, inner ring 606, and magnetic core 604 is shown. Figure 6B The diagram illustrates that both the mounting structure and the magnetic core 604 expand due to increased temperature. However, because the outer ring 602 has a higher CTE than the magnetic core 604, it expands much more significantly. Furthermore, because the inner ring 606 has a higher CTE than the magnetic core 604, it is constrained by the magnetic core 604. This constraint is shown by a nominal edge 608, which indicates how far the inner ring 606 would expand if it were not constrained by the magnetic core 604. This difference in expansion results in a mechanical force 610 being applied between the inner ring 606 and the magnetic core 604. This could cause strain in the magnetic core 604 and potentially lead to its breakage.

[0072] Figure 6A and Figure 6B The diagram illustrates the added strain on the magnetic core 604 caused by a temperature rise. Similar strain may be imparted when the temperature is lowered beyond the operating temperature (e.g., below room temperature). In these examples, the added force and the resulting strain can be supplied to the magnetic core 604 from the outer ring 602.

[0073] Figure 7A A top view of one side 700 of a transformer pair under a first thermal condition is shown according to an example embodiment. Specifically, Figure 7A An example of a magnetic core 702 including a space 704 is shown. The space 704 extends from the center point 708 of the central portion 706 of the mounting structure to the outer edge 714 of the mounting structure. The mounting structure of the side 700 includes an outer ring 712 and an inner ring 716 surrounding the magnetic core 702.

[0074] Figure 7A Side 700 is shown under typical thermal conditions (e.g., at room temperature). In this example, the mounting surfaces, including the outer ring 712 and the inner ring 716, are made of aluminum and have a 21 × 10 -6 / ℃ and 25×10 -6 The first CTE is between / ℃, and the magnetic core 702 is made of 15×10. -6 / ℃ and 19×10-6 The second CTE consists of ferrite materials between / ℃.

[0075] Figure 7B A top view of side 700 of a transformer pair under a second thermal condition is shown according to an exemplary embodiment. Specifically, Figure 7B The effect of elevated temperature (e.g., from room temperature to 50°C) on the outer ring 712, inner ring 716, and magnetic core 702 is shown. Figure 7B The diagram shows that both the mounting structure and the magnetic core 702 expand due to the increased temperature, and the dimensions of the space 704 increase accordingly. Therefore, during the first thermal condition, multiple segments of the magnetic core 702 are separated by a first distance, and during the second thermal condition, the multiple segments are separated by a second distance different from the first distance.

[0076] Space 704 allows core 702 to expand at a rate similar to that of the mounting surface, even though the outer ring 712 and inner ring 716 have a higher CTE than core 702. This reduces the mechanical forces and consequent strain applied to core 702. This is shown as a nominal edge 720, which is aligned with the inner edge 718 of core 702. Different sections of core 702 remain aligned with center point 708 under varying thermal conditions. Further details regarding the effect of space 704 on the thermal expansion of core 702 are provided below. Figure 9A and Figure 9B Described.

[0077] Figure 7A and Figure 7B The reduced strain on the magnetic core 702 caused by space 704 is shown. Similar strain reduction can be achieved by lowering the temperature beyond the operating temperature (e.g., below room temperature). In these examples, space 704 contracts without allowing adjacent sections of the magnetic core 702 to contact each other. This prevents the force and consequent strain exerted on the magnetic core 702 from the outer ring 712.

[0078] Figure 8A A top view of a magnetic core 800 under a first thermal condition, according to an example embodiment, is shown. Specifically, Figure 8A A magnetic core 800 is shown under typical thermal conditions (e.g., at room temperature). The magnetic core 800 includes multiple segments 802 separated by spaces 804. A transformer winding 806 is connected to the multiple segments 802.

[0079] Figure 8B A top view of a magnetic core 800 under a second thermal condition, according to an example embodiment, is shown. Specifically, Figure 8BThe effect of elevated temperature (e.g., from room temperature to 50°C) on the magnetic core 800 is illustrated. At the elevated temperature, space 804 expands, and multiple segments 802 expand as well. Winding 806 may include wound wire configured to expand at the elevated temperature such that it spans space 804 even when space 804 is expanded. Therefore, the transformer winding 806 is configured to adjust in response to changes in the dimensions of space 804 between the multiple segments 802. This allows the transformer to continue operating even when the multiple segments 802 are further separated from each other.

[0080] Figure 9A A side view of one side 900 of a transformer pair under a first thermal condition is shown according to an example embodiment. Specifically, Figure 9A Side 900 is shown under typical thermal conditions (e.g., at room temperature). Side 900 includes a substrate 902, a magnetic core 904 mounted on the substrate 902, and a space 906, the substrate 902 being part of the mounting structure of side 900. For simplicity, additional portions of side 900 are omitted. The substrate 902, the outer ring of the mounting structure, and the inner ring of the mounting structure may all comprise the same material, such that they expand or contract at similar rates under varying thermal conditions.

[0081] Figure 9B A side view of side 900 of a transformer pair under a second thermal condition is shown according to an example embodiment. Specifically, Figure 9B The effect of elevated temperature (e.g., from room temperature to 50°C) on side 900 is shown. At the elevated temperature, substrate 902 expands. Because core 904 is divided into multiple segments separated by space 906, and each segment is coupled to substrate 902, the segments become further spaced apart as substrate 902 expands, and the dimensions of space 906 increase. While this subjectes core 904 to mechanical forces from substrate 902, other mechanical forces from the inner ring of the mounting structure and the resulting strain are reduced. To further reduce the forces on core 904, a flexible adhesive can be used to bond core 904 to substrate 902. For example, a rubber-coated adhesive can be used for bonding to allow further flexibility of core 904 relative to substrate 902, thereby further reducing the applied strain.

[0082] As described above, a transformer pair may include multiple electrical components (e.g., multiple transformers) connected to the mounting structure in a manner similar to that of a magnetic core described herein. Each electrical component may similarly include multiple segments spaced apart by spaces that allow the component to operate with reduced strain under varying thermal conditions.

[0083] III. Example Method

[0084] Figure 10 This is a block diagram of a method according to an example implementation. Specifically, Figure 10 A method 1000 for assembling, manufacturing, or installing an apparatus (e.g., device 100) is illustrated. Functional aspects of method 1000 may be executed automatically by a computing device or a computing device of a control mechanism (e.g., a robot or a controllable arm), while other aspects may be executed manually.

[0085] A computing device for performing method 1000 may include one or more processors, memory, and instructions stored in the memory and executable by the processor(s) to perform functions. The processor(s) may include one or more processors, such as one or more general-purpose microprocessors and / or one or more special-purpose microprocessors. The one or more processors may include, for example, application-specific integrated circuits (ASICs) or field-programmable gate arrays (FPGAs). Other types of processors, computers, or devices configured to execute software instructions are also considered herein.

[0086] Memory may include computer-readable media such as non-transitory computer-readable media, which may include, but are not limited to, read-only memory (ROM), programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), non-volatile random access memory (e.g., flash memory), solid-state drives (SSD), hard disk drives (HDD), compact discs (CD), digital video discs (DVD), digital magnetic tape, read / write (R / W) CDs, R / W DVDs, etc. Other types of storage devices, memories, and media are considered herein.

[0087] At block 1002, method 1000 includes providing a mounting structure comprising a first material having a first coefficient of thermal expansion (CTE). The mounting structure includes a central portion and an outer portion.

[0088] At block 1004, method 1000 includes coupling a magnetic core for an electrical component to an outer portion of a mounting structure. The magnetic core comprises a second material having a second CTE and is divided into a plurality of segments spaced apart by spaces extending from a central portion to the outer edges of the outer portions. Each of the plurality of segments is individually coupled to the mounting structure, and each of the plurality of segments is connected to an electrical component. For example, the electrical component may be a transformer winding.

[0089] In the example, method 1000 may further include determining the size of the space based on a first material and a second material. For example, the computing device may access a database of materials and corresponding CTEs, determine a first CTE for the first material (e.g., the material of the mounting structure), determine a second CTE for the second material (e.g., the material of the magnetic core), and select the size of the space based on the first CTE and the second CTE. This may be further based on: determining the strain tolerance characteristics of the magnetic core (e.g., a ferrite core); determining the projected force exerted on the component by the mounting surface based on the CTE of the mounting surface and the CTE of the component for different sizes of the space; and determining whether the projected force exceeds a threshold force associated with the strain tolerance.

[0090] The specific arrangements shown in the accompanying drawings should not be considered limiting. It should be understood that other embodiments may include more or less each of the elements shown in a given drawing. Furthermore, some of the shown elements may be combined or omitted. Additionally, illustrative embodiments may include elements not shown in the drawings.

[0091] A step or block representing information processing may correspond to circuitry configurable to perform a specific logical function of the method or technique described herein. Alternatively or additionally, a step or block representing information processing may correspond to a module, segment, physical computer (e.g., a field-programmable gate array (FPGA) or application-specific integrated circuit (ASIC)) or a portion of program code (including associated data). The program code may include one or more instructions executable by a processor to implement a specific logical function or action in the method or technique. The program code and / or associated data may be stored on any type of computer-readable medium, such as storage devices including disks, hard disks, or other storage media.

[0092] Computer-readable media may also include non-transitory computer-readable media, such as computer-readable media that store data for short periods, such as register memory, processor cache, and random access memory (RAM). Computer-readable media may also include non-transitory computer-readable media that store program code and / or data for longer periods. Therefore, computer-readable media can include secondary or permanent long-term storage, such as, for example, read-only memory (ROM), optical discs or magnetic disks, and compact disc read-only memory (CD-ROM). Computer-readable media can also be any other volatile or non-volatile storage system. Computer-readable media can be considered, for example, computer-readable storage media or tangible storage devices.

[0093] While various examples and implementations have been disclosed, other examples and implementations will be apparent to those skilled in the art. The various disclosed examples and implementations are for illustrative purposes and are not intended to be limiting; the true scope is indicated by the appended claims.

Claims

1. A wireless transmission device comprising: a mounting structure comprising a first material having a first coefficient of thermal expansion, wherein the mounting structure comprises: an outer ring, an intermediate ring, and an inner ring; a first magnetic core coupled to the mounting structure between the outer ring and the intermediate ring, the first magnetic core comprising a second material having a second coefficient of thermal expansion, wherein the first magnetic core is divided into a plurality of segments separated by a space, wherein each of the plurality of segments is individually coupled to the mounting structure, and wherein each of the plurality of segments is connected to a first electrical component; and a second magnetic core coupled to the mounting structure between the intermediate ring and the inner ring, the second magnetic core comprising the second material having the second coefficient of thermal expansion, wherein the second magnetic core is connected to a second electrical component.

2. The wireless transmission device of claim 1, wherein during a first thermal condition, the plurality of segments are separated by a first distance, and during a second thermal condition, the plurality of segments are separated by a second distance different from the first distance.

3. The wireless transmission device of claim 2, wherein the plurality of segments are aligned with a center point of the mounting structure such that during the first thermal condition and during the second thermal condition, an outer edge of each segment is equidistant from the center point.

4. The wireless transmission device of claim 3, further comprising a stationary portion and a rotating portion, wherein the mounting structure corresponds to the stationary portion of the wireless transmission device, and wherein the rotating portion is configured to rotate along an axis aligned with the center point of the magnetic cores.

5. The wireless transmission device of claim 1, wherein the first electrical component comprises a first winding of a first transformer, and the second electrical component comprises a second winding of a second transformer.

6. The wireless transmission device of claim 5, wherein the first winding of the first transformer is configured to adjust in response to a changing size of the space between the plurality of segments.

7. The wireless transmission device of claim 1, wherein each magnetic core is circular.

8. The wireless transmission device of claim 1, wherein the mounting structure comprises aluminum, and each of the first magnetic core and the second magnetic core comprises a ceramic material.

9. The wireless transmission device of claim 1, further comprising an intermediate film disposed between the mounting structure and the first magnetic core and the second magnetic core, wherein the intermediate film is configured to contain one or more broken pieces of the first magnetic core and the second magnetic core.

10. The wireless transmission device of claim 1, wherein the wireless transmission device comprises a light detection and ranging device having a stationary portion and a rotating portion, and wherein the first magnetic core and the second magnetic core are coupled to the stationary portion of the light detection and ranging device.

11. The wireless transmission device of claim 1, wherein the mounting structure further comprises: a base, wherein the first magnetic core and the second magnetic core are coupled to the base.

12. The wireless transmission device of claim 11, wherein the base is configured to expand or contract in response to changing thermal conditions, thereby changing a size of the spaces separating the plurality of segments of the first magnetic core.

13. The wireless transmission device of claim 11, wherein the base, the outer ring, the middle ring, and the inner ring comprise a same material.

14. The wireless transmission device of claim 1, wherein the first magnetic core has a first height, and wherein the second magnetic core has a second height different from the first height.

15. A light detection and ranging device, comprising: a first end comprising a first side of a transformer pair, wherein the first side of the transformer pair is configured to transmit power to a second side of the transformer pair; and a second end comprising: a plurality of light emitters; a plurality of light detectors; and the second side of the transformer pair, wherein the second side of the transformer pair is configured to power the plurality of light emitters and the plurality of light detectors via the first side of the transformer pair, wherein the first side of the transformer pair and the second side of the transformer pair each comprise: a mounting structure comprising a first material having a first coefficient of thermal expansion, wherein the mounting structure comprises: an outer ring, a middle ring, and an inner ring; a first magnetic core coupled to the mounting structure between the outer ring and the middle ring, the first magnetic core comprising a second material having a second coefficient of thermal expansion, wherein the first magnetic core is divided into a plurality of segments separated by spaces, wherein each of the plurality of segments is individually coupled to the mounting structure, and wherein each of the plurality of segments is connected to a first electrical component; and a second magnetic core coupled to the mounting structure between the middle ring and the inner ring, the second magnetic core comprising the second material having the second coefficient of thermal expansion, wherein the second magnetic core is connected to a second electrical component.

16. The light detection and ranging device of claim 15, wherein during a first thermal condition, the plurality of segments are separated by a first distance, and during a second thermal condition, the plurality of segments are separated by a second distance different from the first distance.

17. The light detection and ranging device of claim 16, wherein the plurality of segments are aligned with a center point of the mounting structure such that during the first thermal condition and during the second thermal condition, an outer edge of each segment is equidistant from the center point.

18. The light detection and ranging device of claim 17, wherein the first end is fixed in place, and wherein the second end is configured to rotate along an axis aligned with the center point of the mounting structure.

19. The light detection and ranging device of claim 15, wherein the mounting structure further comprises: a base, wherein the first magnetic core and the second magnetic core are coupled to the base.

20. A transformer, comprising: a first side of a transformer pair and a second side of the transformer pair, wherein the first side is configured to transmit power to the second side, and wherein the first side of the transformer pair and the second side of the transformer pair each comprise: a mounting structure comprising a first material having a first coefficient of thermal expansion, wherein the mounting structure comprises: an outer ring, an intermediate ring, and an inner ring; a first magnetic core coupled to the mounting structure between the outer ring and the intermediate ring, the first magnetic core comprising a second material having a second coefficient of thermal expansion, wherein the first magnetic core is divided into a plurality of segments separated by spaces, wherein each of the plurality of segments is individually coupled to the mounting structure, and wherein each of the plurality of segments is connected to a first electrical component; a second magnetic core coupled to the mounting structure between the intermediate ring and the inner ring, the second magnetic core comprising the second material having the second coefficient of thermal expansion, wherein the second magnetic core comprises one segment connected to a second electrical component; and a first winding connected to the first magnetic core and a second winding connected to the second magnetic core.

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