Coil Component with Protruding Magnetic Gap Layer
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Solution Overview
Problem
Existing coil components face challenges in handling large currents due to magnetic core saturation, and creating a magnetic gap within a molded-cover structure is labor-intensive.
Innovation Solution
A coil component design featuring a columnar magnetic core, a plate-shaped second magnetic core, and a non-magnetic magnetic-gap layer between them, allowing for a magnetic gap that protrudes peripherally, enabling efficient current handling with a simple structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a magnetic gap is provided in the magnetic core to handle large currents, then the current handling capability is improved, but the manufacturing complexity increases due to separate formation requirements
Solution Approach 1:
The magnetic gap formation process is merged with the magnetic molded-body formation process. The non-magnetic material is incorporated into the magnetic molded-body material itself, allowing the magnetic gap to be formed simultaneously with the molded-body during a single injection molding operation, thereby eliminating separate gap formation steps and reducing manufacturing complexity
Solution Approach 2:
The magnetic gap is prepared in advance by incorporating non-magnetic material into the magnetic molded-body material before injection molding. This preliminary inclusion of the gap-forming material ensures that the magnetic gap is already positioned and prepared before the molding process begins, enabling automatic gap formation during molding without subsequent manual intervention
2Strength
If a molded-cover is used to cover the magnetic core and coil, then the structural integrity is improved, but the formation of magnetic gaps becomes labor-intensive
Solution Approach 1:
The magnetic gap formation is combined with the molded-body formation into a single integrated process. By incorporating non-magnetic material into the magnetic molded-body material, the gap is formed automatically during injection molding, eliminating the need for separate gap creation operations and significantly improving ease of manufacture while maintaining structural integrity
Solution Approach 2:
The magnetic molded-body material itself provides the means for creating the magnetic gap through the inclusion of non-magnetic material. The material system is designed to self-organize during molding, with the non-magnetic portions automatically forming the gap structure without requiring external intervention or additional manufacturing steps
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 enhances DC superimposition characteristics and allows for the application of large currents while maintaining a straightforward manufacturing process, improving the coil's performance and ease of assembly.
Implementation Method 1
a magnetic-gap layer which is constituted by a non-magnetic material, which is arranged between the facing surface and the one end surface, and which forms a magnetic gap between the facing surface and the one end surface
Implementation Method 2
a magnetic molded-body which is constituted by a magnetic material and which covers the first magnetic core and the coil
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
A coil component including: a first magnetic core including a columnar portion; a second magnetic core having a facing surface which faces one end surface of the columnar portion; a magnetic-gap layer which is constituted by a non-magnetic material, which is arranged between the facing surface and the one end surface, and which forms a magnetic gap between the facing surface and the one end surface; a coil through which the columnar portion is inserted; and a magnetic molded-body which is constituted by a magnetic material and which covers the first magnetic core and the coil, wherein when watching along the axial center direction of the columnar portion, the magnetic-gap layer protrudes to the periphery of the columnar portion.