Cubic Inductor Device with Orthogonal Winding Channels
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Solution Overview
Problem
Existing inductor devices face challenges in achieving precise orthogonality and isotropy of magnetic fields due to core imperfections and asymmetries, making it difficult to accurately detect and transmit position and movement data in applications like virtual reality systems.
Innovation Solution
A cubic inductor device with a magnetic core housed in a single-part electrically insulating support, featuring orthogonal winding channels and corner protuberances, allows for high-speed automatic winding and ensures uniformity and symmetry of the windings, thereby generating isotropic electromagnetic fields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If windings are manually positioned on a bare or thin-layer insulated core, then orthogonality precision can be achieved, but the manufacturing process becomes slow and difficult to implement industrially
Solution Approach 1:
The patent applies preliminary action by pre-forming the core with integrated winding channels and positioning protrusions before the winding process. These pre-formed structural features guide the windings into precise orthogonal positions automatically, eliminating the need for slow manual positioning while maintaining high orthogonality precision in industrial manufacturing
Solution Approach 2:
The patent introduces an intermediary structural layer (the winding channels and positioning protrusions formed in the core) that mediates between the core and the windings. This intermediary structure provides automatic geometric constraint and positioning, enabling both high precision and automated high-speed winding processes
2Ease of manufacture
If core imperfections and asymmetries are present, then manufacturing is easier, but magnetic field orthogonality and isotropy cannot be ensured
Solution Approach 1:
The patent deliberately introduces controlled asymmetry in the form of non-circular winding channels and positioning protrusions that compensate for core imperfections. These asymmetric features are designed to geometrically constrain the windings into precise orthogonal positions, ensuring magnetic field orthogonality even when the core itself has manufacturing tolerances and imperfections
Solution Approach 2:
The patent changes the geometric parameters of the winding support structure (channel shapes, protrusion positions and dimensions) to compensate for core imperfections. By adjusting these parameters during core fabrication, the system ensures that the final winding positions achieve the required orthogonality and isotropy despite variations in core quality
3Strength
If two hollow half cubes are used to support windings, then structural support is provided, but non-coplanarity and positioning errors occur
Solution Approach 1:
The patent merges the two separate half-cube support structures into a single integrated core structure with winding channels formed directly in it. This unified structure eliminates the positioning errors and non-coplanarity issues that arise from assembling two separate halves, while still providing the necessary structural support for the windings
Solution Approach 2:
The patent segments the winding support function into distinct geometric features (winding channels, positioning protrusions, and support surfaces) integrated into the core. This segmentation allows each feature to perform its specific function precisely, ensuring proper winding positioning and coplanarity while maintaining structural integrity
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 enables precise detection and transmission of position and movement data with improved orthogonality and symmetry, enhancing the accuracy and industrial feasibility of the inductor device for applications requiring precise spatial coordination.
Implementation Method 1
the response in terms of voltage induced by the magnetic field induction unit of a low-frequency inductor is directly proportional to the relative position thereof with respect to the field source
Data Source
AI summary
The present invention relates to an inductor device, a method of manufacturing same and antenna. The proposed inductor device comprising a magnetic core (1), an electrically insulating support (10) with a cavity (11) arranged around said magnetic core (1), and three windings (DX, DY, DZ) of conductive wire arranged orthogonal to one another, wherein said electrically insulating support (10) is made of a single part and completely houses the magnetic core (1) which is accessible through an opening, the three windings (DX, DY, DZ) being supported on winding supporting faces (12X, 12Y and 12Z) of the electrically insulating support, confined between winding limiting edges (22) defined by lower corner protuberances (20) and centered with respect to the three orthogonal axes (X, Y, Z) such that said electrically insulating support (10) assures symmetry and orthogonality of said electromagnetic field vectors generated by the mentioned inductor device.