Composite Magnetic Device With Partitioned Core And Gaps
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Solution Overview
Problem
The existing composite magnetic devices for AV equipment require separate molds and winding for each core, increasing manufacturing costs and necessitating adjustments for matching inductor characteristics, which complicates the process and increases expenses.
Innovation Solution
A composite magnetic device design featuring a first core with a tubular shape and partitioning, second core members with flange portions, and coils arranged between these flanges, allowing independent magnetic flux flow and preventing magnetic coupling, with strategically placed clearances to enhance direct-current-superposed characteristics and reduce manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate molds and winding processes are used for each core (second core and third core), then manufacturing flexibility is improved, but manufacturing cost increases
Solution Approach 1:
The patent merges the second core and third core into a single integrated core structure with one common mold. The coil is wound once to form both magnetic elements simultaneously, eliminating the need for separate molding and winding processes. This reduces manufacturing cost while maintaining the ability to produce two distinct magnetic elements with different characteristics through strategic placement of magnetic gaps and adjustment of winding parameters.
2Stability of the object's composition
If two inductors are designed with same characteristics, then design consistency is improved, but manufacturing complexity increases due to need for adjusting winding number and dimensions
Solution Approach 1:
The patent applies local quality by introducing magnetic gaps at specific locations within the integrated core structure. By placing magnetic gaps differently for each magnetic element (e.g., different positions, sizes, or numbers of gaps), the patent achieves different inductance characteristics for the two inductors without requiring complex adjustments to winding numbers or core dimensions. This maintains design consistency while simplifying manufacturing.
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 reduces manufacturing costs, allows for easier matching of magnetic element characteristics, and minimizes magnetic coupling and leakage, while maintaining high direct-current-superposed characteristics by using a single composite device equivalent to mounting two magnetic elements.
Implementation Method 1
the partition portion is provided in the inner space of the first core member, and hence it is possible to prevent a magnetic coupling from occurring between the two coils
Implementation Method 2
the magnetic gap is provided in the inside of the first core member, and hence magnetic leakage to an outside is hard to occur in comparison with a case where the magnetic gap is exposed to the outside
Implementation Method 3
magnetic fluxes generated in the coils present in the respective second core members flow, in a state in which the magnetic fluxes do not influence with each other, into an inside of the first core member and the second core members
Data Source
AI summary
To provide a composite magnetic device having characteristics of two magnetic elements, being capable of reducing a manufacturing cost, and preferably enabling the respective magnetic elements to easily exhibit the same characteristics. The composite magnetic device includes: a first core member which includes an outer tube portion having a tubular shape and a partition portion partitioning an inner space (P) of the outer tube portion into two inner spaces; second core members each including a first flange portion and a second flange portion, the second core members being arranged in a state in which a magnetic gap is formed at least between the partition portion and the second flange portion, and being arranged in each of the two inner spaces (P) on each side of the partition portion; coils each arranged on a spool portion present between the first flange portion and the second flange portion; and terminal members arranged on an outer peripheral surface of the outer tube portion and electrically connected to ends of the coils.