Adjustable Inductor with Compressible Gap Core
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Solution Overview
Problem
Existing distributed and discretely gapped toroidal core inductors can only be adjusted by adding or removing turns or repositioning wires, which is limited to integer changes and lacks fine control, often resulting in parts that cannot achieve the needed inductance value and must be scrapped or rewound.
Innovation Solution
A toroidal core is cut into pieces with non-magnetic, compressible material in the gaps and an adjustable clamp to allow for adjustment of inductance before and after winding, enabling a wide range of inductance adjustments by altering the gap size through the use of removable core sections and force-applying structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If turns are added or removed to adjust inductance, then inductance value can be changed, but only integer changes are possible and fine control is lost
Solution Approach 1:
The patent changes the adjustable parameter from discrete turn count to continuous gap dimension. By modifying the gap size between core sections, the inductance can be finely tuned without changing the number of wire turns, enabling precise control while maintaining ease of adjustment.
Solution Approach 2:
The toroidal core is segmented into separate sections with gaps between them. This segmentation allows independent adjustment of gap sizes to control inductance, decoupling the adjustment mechanism from the wire winding and enabling continuous variation rather than discrete steps.
2Manufacturing precision
If repositioning of windings is attempted for adjustment, then inductance may be slightly modified, but the effect is negligible and not easily repeatable
Solution Approach 1:
Instead of repositioning windings, the patent changes the core gap dimension as the adjustment parameter. This provides a reliable, repeatable method for controlling inductance through precise mechanical positioning of core sections rather than manipulating wire positions.
3Manufacturing precision
If careful gap or material selection is made for ±3% tolerance, then consistent winding turns and positions are required, but the part cannot attain the needed value and must be scrapped or disassembled and rewound
Solution Approach 1:
The core structure incorporates movable sections that allow dynamic adjustment of gap sizes after the winding is complete. This transforms a static core into a dynamically adjustable structure, enabling fine-tuning of inductance values without scrapping or rewinding the entire component.
Solution Approach 2:
The core is divided into separable sections with adjustable gaps, allowing post-winding adjustment of inductance by repositioning core sections. This segmentation enables the inductor to be tuned to exact specifications after manufacturing, eliminating the need to scrap parts that don't meet tolerance requirements.
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 design allows for precise and repeatable adjustment of inductance values, enabling ±3% tolerance and fine control, reducing the need for scrapping or rewinding, and allowing for inductance adjustments after the coil is wound.
Implementation Method 1
a non-magnetic, compressible material is positioned in the gaps between pieces, and an adjustable clamp clamps the gapped core together
Implementation Method 2
force-applying structure operable to apply a force to the removable core section to adjust the gaps and thereby an inductance of the inductor
Data Source
AI summary
An adjustable inductor and a method of assembling such an inductor. The inductor may include a toroidal core defining a pair of gaps to provide a removable core section, the core also including a rigid core section; compressible gap material positioned in the gaps; windings wound on the rigid core section; and force-applying structure operable to apply a force to the removable core section to adjust the gaps and thereby the inductance.