Choke Core Pillar Non-Circular Cross Section
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Solution Overview
Problem
Conventional chokes with circular or rectangular pillars face limitations in saturation current due to restricted winding space, leading to suboptimal performance in electronic devices where size and weight minimization are critical, and can result in wire damage at sharp corners.
Innovation Solution
A choke core with a non-circular and non-rectangular pillar cross-section, made of magnetic material, featuring intersecting axes and a combination of arc and straight edges, allowing for increased winding space and smoother wire attachment, thereby enhancing saturation current and reducing direct current resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the pillar cross section is circular, then the shape is simple and manufacturing is easy, but the winding space is limited and saturation current cannot be raised effectively
Solution Approach 1:
The patent applies asymmetry by changing the pillar cross-section from a symmetric circular shape to a non-circular shape with curved sides. This asymmetric design optimizes the winding space configuration, allowing wire to be wound more effectively around the pillar while maintaining manufacturing feasibility through mold-based formation processes.
2Quantity of substance
If the pillar cross section is rectangular, then the winding space is increased, but the wire may be damaged at sharp corners and choke characteristics deteriorate
Solution Approach 1:
The patent applies spheroidality by replacing the sharp corners of a rectangular cross-section with curved surfaces. The pillar cross-section features curved sides that eliminate sharp angles, preventing wire damage during winding while maximizing the winding space. This curvature is achieved through mold-based formation processes, combining the benefits of increased winding area with improved wire handling and choke performance.
3Quantity of substance
If the pillar cross section area is increased, then saturation current is improved, but the device size and weight increase
Solution Approach 1:
The patent applies dimensionality change by optimizing the pillar cross-section geometry in the horizontal plane rather than simply increasing the vertical height. By creating a non-circular cross-section with curved sides, the design efficiently utilizes the available horizontal space, increasing the effective winding area and saturation current capability without proportionally increasing the overall device volume and weight.
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 non-circular and non-rectangular pillar design increases the cross-sectional area, improving saturation current and magnetic flux density while preventing wire damage, resulting in better choke performance in compact electronic devices.
Implementation Method 1
the choke stores the same by a magnetic field
Implementation Method 2
The pillar and the two boards are made of magnetic material
Implementation Method 3
a winding space being located among the two boards and the pillar
Data Source
AI summary
A choke includes a single-piece core entirely made of a same material, the single-piece core having two boards and a pillar located between the two boards, a winding space being located among the two boards and the pillar, wherein the pillar has a non-circular and non-rectangular cross section along a direction substantially perpendicular to an axial direction of the pillar, the cross section of the pillar has a first axis and a second axis intersecting with each other at a center of the cross section of the pillar and are substantially perpendicular with each other, the first axis is longer than the second axis, and the cross section of the pillar is substantially symmetrical to both of the first axis and the second axis.