Coil Device With Nested Core Members For Inductance And Rust
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Solution Overview
Problem
Existing coil devices with embedded magnetic materials face issues of short circuit defects and magnetic property deterioration due to positional deviations and contact between the magnetic materials, leading to inductance value degradation and rusting.
Innovation Solution
A coil device configuration featuring a first core member with a winding core portion, a second core member of high magnetic permeability embedded within the first core member, and a third core member covering both, which prevents contact and positional deviations, enhancing magnetic permeability and preventing rust while allowing for easy attachment and positioning of the coil portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a second magnetic material is disposed inside an air core coil and embedded in a first magnetic material to increase effective magnetic permeability, then the inductance value is improved, but positional deviation occurs and short circuit defects arise from contact between the second magnetic material and the coil
Solution Approach 1:
The second core member (high magnetic permeability material) is nested inside the winding core portion of the first core member, which itself is embedded in the third core member. This nested structure allows the second core member to be positioned precisely within the coil portion while being protected from contact, thereby maintaining high inductance values without short circuit defects or positional deviation
Solution Approach 2:
The first core member acts as an intermediary structure between the second core member and the coil portion. The winding core portion of the first core member provides a dedicated recessed portion that accommodates the second core member, preventing direct contact with the coil while maintaining the magnetic coupling necessary for high inductance
2Reliability
If a high-magnetic permeability metallic magnetic material is used as the second magnetic material to increase effective magnetic permeability, then the inductance value is improved, but rusting occurs on the surface of the second magnetic material
Solution Approach 1:
The second core member made of high-magnetic permeability metallic magnetic material is nested inside the winding core portion of the first core member, which is itself embedded in the third core member. This nested structure provides protective coverage that prevents direct exposure to the external environment, thereby preventing rusting while maintaining the high inductance value
Solution Approach 2:
The first and third core members create a protected environment around the second core member, isolating the metallic magnetic material from moisture and oxygen in the external environment. This isolation prevents oxidation and rusting of the second core member's surface while preserving its magnetic properties
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 configuration increases effective magnetic permeability, prevents short circuit defects and rust, and improves inductance values, enabling a coil device with enhanced magnetic properties and reliability.
Implementation Method 1
a magnetic material higher in magnetic permeability than the first magnetic material is used as the second magnetic material, and thus the effective magnetic permeability of the coil device is increased
Data Source
AI summary
An inductor has a coil portion made of a wire wound in a coil shape and an element body in which the coil portion is provided. The element body has a first core member, a second core member, and a third core member. The first core member has a winding core portion configured to be positioned inside the coil portion. The second core member is accommodated in the winding core portion. The third core member covers the coil portion and the first core member in which the second core member is accommodated in the winding core portion.