Composite Core Coil Structure for High-Frequency Rust Suppression
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Solution Overview
Problem
Iron cores in coil components, particularly dust cores, are prone to black rust formation under high-temperature environments, leading to increased eddy current loss and AC resistance, which worsens at higher drive frequencies.
Innovation Solution
A coil component design incorporating a dust core with a surface resistance of at least 5Ω after high-temperature storage, utilizing a combination of high- and low-magnetic permeability cores and a specific winding configuration, along with a case structure that enhances heat dissipation and minimizes exposure to air, to stabilize characteristics at high drive frequencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a dust core is used in the coil component, then the magnetic properties are improved, but black rust is more likely to be produced on the core under high-temperature environments
Solution Approach 1:
The patent combines a dust core (first core) with a cast core (second core) to form a composite core structure. The dust core provides superior magnetic properties while the cast core offers rust resistance. This composite approach allows the system to benefit from both materials' strengths, resolving the contradiction between magnetic performance and corrosion resistance.
Solution Approach 2:
The patent applies different materials to different regions of the core structure. The dust core is positioned where magnetic performance is critical, while the cast core is positioned where rust resistance is more important. This local differentiation allows each material to perform its optimal function in the appropriate location.
2Loss of energy
If black rust is produced on the core, then eddy current loss increases, but the drive frequency requirement demands stable characteristics
Solution Approach 1:
The composite core structure prevents rust formation that would otherwise increase eddy current losses. By using the rust-resistant cast core in conjunction with the dust core, the system maintains low eddy current losses while achieving the characteristic stability required for high-frequency operation.
3Loss of energy
If the AC resistance increases due to black rust, then the coil component performance deteriorates, but high drive frequency operation is required
Solution Approach 1:
The composite core structure maintains low AC resistance by preventing rust formation through the use of the cast core. This enables the coil component to operate reliably at high drive frequencies without the performance deterioration that would result from increased AC resistance due to rust.
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 design ensures stable coil component characteristics by suppressing black rust formation and maintaining low AC resistance even at high drive frequencies, effectively managing changes in magnetic properties.
Implementation Method 1
a conductor which generates a magnetic flux by being energized
Implementation Method 2
a core which is provided around the conductor and forms a magnetic path through which the magnetic flux circulates
Implementation Method 3
A surface resistance of the dust core between two points that are 20 mm away from each other is not less than 5Ω after a high-temperature storage test
Data Source
AI summary
The coil component includes a coil, a first core having a first magnetic permeability, and a second core having a second magnetic permeability lower than the first magnetic permeability. The first core and the second core form a magnetic path. The coil forms two or more winding windows. The first core contacts with an entirety of one side line extending in a second direction of each of the winding windows, and protrudes from both ends of one side line of at least one of the winding windows. The second core contacts with three side lines other than the one side line of each of the winding windows. A surface resistance of the first core between two points that are 20 mm away from each other is not less than 5 Ω after a high-temperature storage test. A drive frequency of the coil component is not less than 20 kHz.