Coil Component with Segmented Gaps for DC Inductance Control
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Solution Overview
Problem
Existing coil components for electric and hybrid vehicles face challenges in adjusting inductance values across different DC current regions due to magnetic saturation, making it difficult to achieve target inductance values simultaneously at initial and high current conditions.
Innovation Solution
The coil component features a closed magnetic path with multiple types of gaps, including small and large gaps, formed between unit cores, allowing independent control of inductance values in various DC regions by adjusting the gap lengths and areas, preventing magnetic saturation and enabling precise inductance setting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the gap area is increased to adjust DC superposed characteristics, then the inductance curve shape is improved, but the manufacturing complexity increases
Solution Approach 1:
The gap structure is segmented into multiple discrete gaps (first gap and second gap) with different lengths. This segmentation simplifies the adjustment of DC superposed characteristics by allowing independent optimization of each gap's contribution to the magnetic path, thereby achieving desired inductance curve shapes without excessive complexity
Solution Approach 2:
Instead of using a single large gap that would be complex to manufacture and adjust, the invention inverts the approach by using multiple smaller gaps with different lengths. This inverted strategy achieves better control over magnetic flux distribution and DC superposed characteristics while maintaining simpler manufacturing processes for each individual gap
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 configuration allows for the precise adjustment of inductance values across multiple DC regions, enhancing the coil's performance by preventing magnetic saturation and achieving target inductance values effectively.
Implementation Method 1
a coil component formed of a reactor to be mounted on an electric vehicle or a hybrid vehicle
Implementation Method 2
a core part composing a closed magnetic path through which a closed loop of a magnetic flux generated by the coil passes
Implementation Method 3
measures have been applied for reducing an influence of magnetic saturation by providing a suitable gap (void) part on a magnetic path of the magnetic core
Data Source
Figure 1
Figure 2
Figure 3A~3E
AI summary
A coil component has a core part 10 composing a closed magnetic path through which a closed loop of a magnetic flux passes, the magnetic flux being generated by two coils 14A , 14B that are arranged in parallel, and generate a magnetic field, and the core part 10 has a pair of I-type base cores 11A, 11B facing each other, and a pair of coupling core parts 11C, 11D. The coupling core parts 11C, 11D are each formed by linearly aligning three unit coupling cores 12A to 12F, and each of these cores 12A to 12F is formed into a configuration in which a column-shaped projection is provided on a core body, and a two-stage gap including a small gap and a large gap is to be formed mutually in a space in the adjacent unit cores 11A, 11B, and 12A to 12F by the configuration.