Bar-Shaped Inductive Component with Overlapping Ferrite Cores
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Solution Overview
Problem
The production of long ferrite rod antennas is hindered by the technical difficulty of producing coherent ferrite cores and the resulting high production costs, as well as the issue of excessive air gaps between lined-up cores, which reduces the communication range.
Innovation Solution
The ferrite rod antenna is designed with individual cores arranged in overlapping layers, fixed by a holding element, allowing for increased length without stability issues, with the cores nested both in length and height, and the geometry of the holding element adjusted to provide magnetic closure and minimize air gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If individual ferrite cores are lined up in a row to increase antenna length, then the antenna length increases, but excessive air gaps between cores reduce communication range
Solution Approach 1:
The patent transitions from a one-dimensional linear arrangement of ferrite cores to a two-dimensional overlapping configuration. Individual cores are arranged in multiple layers with offset positions, creating a brick-wall pattern that extends in both length and height dimensions. This dimensional change allows cores to overlap in the longitudinal direction while maintaining close magnetic coupling, thereby increasing antenna length without creating excessive air gaps that would degrade communication range.
Solution Approach 2:
The patent implements a nested arrangement where individual ferrite cores are positioned within and overlapping each other in a hierarchical structure. The cores are arranged in multiple layers with each layer offset relative to the previous one, creating a nested configuration that maximizes spatial utilization. This nesting approach ensures continuous magnetic path coverage along the antenna length while minimizing air gaps between adjacent cores.
2Length of moving object
If coherent ferrite cores are produced in great lengths, then antenna length increases, but production difficulty and costs increase
Solution Approach 1:
The patent divides the long ferrite core structure into multiple shorter individual core segments that can be manufactured separately using conventional processes. These segmented cores are then assembled in an overlapping configuration to achieve the desired total antenna length. This segmentation approach enables production of long antennas without requiring complex or costly processes for manufacturing single-piece long cores, as each segment can be produced with standard ferrite core manufacturing capabilities.
Solution Approach 2:
The patent resolves manufacturing difficulties by transitioning from producing one long core to producing multiple shorter cores arranged in a two-dimensional overlapping pattern. This dimensional arrangement allows the antenna to achieve great length through lateral extension and stacking rather than through producing a single lengthy core, thereby avoiding the production challenges and high costs associated with manufacturing long coherent ferrite cores.
3Ease of manufacture
If individual cores are lined up butt together, then production is simpler, but stability of the rod-shaped component decreases
Solution Approach 1:
The patent enhances component stability by arranging individual ferrite cores in a two-dimensional overlapping configuration rather than a simple one-dimensional linear sequence. The offset multi-layer arrangement creates a brick-wall structure where cores are interlocked both laterally and vertically, providing mechanical stability and structural integrity. This dimensional arrangement prevents the component from becoming top-heavy or unstable while maintaining production simplicity through modular assembly of individual cores.
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 enables the production of antennas longer than 100 mm with maintained stability and improved communication range, offering flexibility and cost-effective production options.
Implementation Method 1
The overlapping of the individual cores advantageously corresponds to at least half the area of the end face of the individual cores, so that not only is stability achieved in the longitudinal direction, but also the necessary magnetic closure in the area of the overlap.
Implementation Method 2
Such inductive components are used, for example, as rod antennas with a ferrite core for the contactless exchange of information and signals
Data Source
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AI summary
The invention relates to a bar-shaped inductive component consisting of a core of magnetic material and of a holding element (12) for the core, the core being divided into a series of individual cores (20). The individual cores are arranged and fastened in relation to each other by means of the holding element (12) in such a way that the ends (22) of the holding elements that adjoin each other overlap. According to the invention, the individual cores (20) are arranged offset to each other in at least two layers.