Antenna Coil Foam Compression for Magnetic Core Protection
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Solution Overview
Problem
Existing antenna coils in short-distance communication systems using the LF-band are prone to magnetic core breakage due to inadequate deformation and load absorption, particularly when using defoamed rubber materials for potting, which can transmit static deformation and loads to the magnetic core, leading to potential breakage and reduced deformation absorption capabilities.
Innovation Solution
An antenna coil design featuring a wound body with a magnetic core, bobbin, and coil, where a foam is compressed between the wound body and case to absorb impacts and loads, with a preferred compression rate of 45% to 65% to effectively prevent magnetic core breakage, and optionally includes a cap and gel for additional support and cushioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a defoamed rubber material is used for potting between the case and wound body, then high flexibility and static deformation absorption are improved, but the response to momentary deformation is too poor and breakage of the magnetic core cannot be reliably prevented
Solution Approach 1:
The patent changes the material parameter from defoamed rubber to foam material with specific compression rate characteristics. The foam material is configured to be compressed at a rate of 10% to 50% in response to momentary deformation, providing both static deformation absorption and rapid response to momentary loads, thereby preventing magnetic core breakage while maintaining flexibility.
2Manufacturing precision
If the defoamed body is filled in the case by vacuum injection, then filling completeness is improved, but deformation generated upon curing may shift the position of the wound body and reduce the ability to absorb deformation and load
Solution Approach 1:
The patent applies preliminary action by pre-compressing the foam material to a compression rate of 10% to 50% before the wound body is subjected to operational loads. This pre-compression ensures that the foam is already in an optimal state to absorb subsequent deformations, preventing position shifts and maintaining load absorption capability throughout the product lifecycle.
3Area of stationary object
If the defoamed body is filled without leaving gaps between the case and wound body, then complete coverage is improved, but upon deformation of the case or application of load, the defoamed body is not deformed and the deformation is transmitted to the magnetic core
Solution Approach 1:
The patent changes the physical parameter of the potting material from defoamed rubber to foam material with controlled compression rate. The foam material's cellular structure allows it to deform under compression, creating gaps and voids that absorb deformation energy, thereby preventing deformation transmission to the magnetic core while maintaining complete coverage of the wound body.
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
The foam compression rate of 45% to 65% optimizes impact absorption, significantly reducing the probability of magnetic core breakage, even under increased impact and load conditions, ensuring the antenna coil's reliability in short-distance communication systems.
Implementation Method 1
the foam is compressed at a rate of about 45% to about 65% on the basis of a thickness of the foam in a non-load state
Implementation Method 2
the foam is compressed at a rate of about 45% to about 65% on the basis of a thickness of the foam in a non-load state
Data Source
AI summary
An antenna coil includes a wound body including a magnetic core, a bobbin surrounding the magnetic core, and a coil wound around the bobbin, a case in which the wound body is placed, and a foam disposed in a gap between the wound body and the case. The foam is compressed at a rate of about 45% to about 65% on the basis of a thickness of the foam in a non-load state. The antenna coil prevents breakage of the magnetic core and is suitable for use in a short-distance communication system in an LF-band.