Magnetic Core Compressible Molding for Humming Noise Reduction
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Solution Overview
Problem
Inductive electronic components, such as inductors and transformers, produce disturbing humming noises due to the mechanical movement of their cores during low-frequency activation, which is caused by the air gap in the ferromagnetic core.
Innovation Solution
An electronic component with a compressible molding made from a self-adhesive, prefabricated material web, such as silicone or polyurethane, is placed between the legs of the core to fill the air gap, reducing mechanical movement and noise by compressing to fit the gap and adhering to the core surfaces, eliminating the need for adhesives and additional spacers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an air gap is introduced in the ferromagnetic core to set electrical and magnetic properties, then the inductance and magnetic characteristics are improved, but acoustically audible humming noise is generated due to mechanical movement of the core legs
Solution Approach 1:
A compressible molding made of elastomeric material is introduced as an intermediary element between the core legs. This molding fills the air gap while providing mechanical damping to suppress the humming noise generated by alternating magnetization, thus mediating between the magnetic functionality and noise reduction requirements
Solution Approach 2:
The compressible molding is made from composite elastomeric materials that combine magnetic shielding properties with mechanical damping characteristics. These composite materials allow the structure to simultaneously maintain magnetic field guidance and suppress acoustic vibrations
2Object-generated harmful factors
If adhesive is used to suppress noise by bonding core legs, then noise damping is improved, but the production process becomes more complex due to adhesive curing requirements
Solution Approach 1:
The compressible molding is designed to be self-adhesive through its elastomeric properties, allowing it to bond to the core legs without requiring separate adhesive application or curing processes. The molding serves its own bonding function, simplifying the production process while maintaining noise damping effectiveness
Solution Approach 2:
The adhesive function is extracted from the production process by incorporating self-adhesive properties directly into the compressible molding material itself, eliminating the need for separate adhesive materials and curing steps
3Manufacturing precision
If different gap sizes require different spacers, then manufacturing precision is improved, but storage needs and device complexity increase
Solution Approach 1:
The compressible molding is designed with universal applicability across different gap sizes. Its compressible elastomeric nature allows a single molding design to adapt to various gap dimensions, eliminating the need for multiple specialized spacer components for different gap sizes while maintaining manufacturing precision
4Manufacturing precision
If a rigid structure is used to maintain gap spacing, then manufacturing precision is improved, but noise damping capability is reduced
Solution Approach 1:
The molding material's key parameter is its compressibility, which allows it to change its physical state between a compressed state for precise gap fitting and a dampening state for noise suppression. This parameter change enables the structure to simultaneously achieve manufacturing precision and noise damping that rigid structures cannot provide
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 solution effectively suppresses humming noises by damping the mechanical movement of the core legs, allowing for reproducible and reliable production without the complexity of adhesive curing, and reduces storage needs by using universal moldings for various gap sizes.
Implementation Method 1
at least one compressible molding (20), which is arranged compressed in the gap (S)
Implementation Method 2
The prefabricated material web may for example include silicone or acrylic or polyurethane. Such a prefabricated material web is gel- or elastomer-like and may be slightly tacky, and consequently take a self-adhesive form.
Data Source
AI summary
An electronic component for guiding a magnetic field comprises a core (20) of a magnetizable material, which has at least two spaced-apart legs (11a, 11b) with opposing surfaces (O11a, O11b) separated from one another by a gap (S). The component comprises at least one compressible molding (20), which is arranged compressed in the gap (S), the at least one molding (20) being in contact with the respective surfaces (O11a, O11b) of the at least two spaced-apart legs (11a, 11b).