Dual-Core Magnetic Element for High-Current Coiling Space

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Solution Overview

Problem

Magnetic elements with traditional coiling configurations face limitations in space and temperature management, leading to reduced inductance and potential short circuits due to high temperatures, especially when operating with high currents, as the magnetic core's permeability decreases near the Curie temperature.

Innovation Solution

A magnetic element design featuring two parallel magnetic cores with protruding portions and connection nodes allows for coiling wires on both cores, enabling the use of thicker wires to prevent overheating while maintaining inductance and footprint compatibility, achieved through specific electrode and connection node arrangements and spinning directions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If wires with greater diameter are used to prevent overheating, then temperature control is improved, but the space required for accommodating the same number of coils increases

Engineering Contradiction:

Improvemagnetic core temperatureVSAvoidcoiling space

Core Design Contradiction:

TemperatureVSVolume of stationary object

Solution Approach 1:

The single magnetic core is segmented into two separate magnetic cores (first magnetic core and second magnetic core), each capable of accommodating coils independently. This segmentation allows the use of thicker wires in each core while maintaining the same total inductance, thereby preventing overheating without requiring a significant increase in total coiling space.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention transitions from a single-core configuration to a dual-core configuration, effectively adding a dimensional aspect to the coiling arrangement. By distributing coils across two separate cores rather than concentrating them in one, the design accommodates thicker wires while maintaining compact footprint compatibility.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Volume of stationary object

If the length of the magnetic core is increased to increase coiling space, then coiling space is improved, but the footprint of the magnetic element changes causing hardware incompatibility

Engineering Contradiction:

Improvecoiling spaceVSAvoidfootprint

Core Design Contradiction:

Volume of stationary objectVSArea of stationary object

Solution Approach 1:

Instead of increasing the length of a single magnetic core, the invention segments the magnetic path into two separate cores with protruding portions that can be arranged in a compact configuration. This maintains the overall footprint while providing sufficient coiling space through the distributed core structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The two magnetic cores with their protruding portions are arranged in a nested or interlocked configuration where the cores share space efficiently. The protruding portions connect the cores in a manner that minimizes the overall footprint while maximizing the available coiling volume.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 effectively prevents overheating, reduces copper loss, and enhances high-frequency transmission characteristics by allowing the use of thicker wires without increasing the magnetic element's footprint, thereby improving operational stability and performance under high current conditions.

Implementation Method 1

The first coiling body and the second coiling body are magnetically conductive

Methodology Applied

Scientific EffectMagnetic conduction: Ferromagnetism

Implementation Method 2

Each of the plurality of wires is coiled on the first coiling body or the second coiling body

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 3

when the temperature of the magnetic core reaches the Curie temperature (ex., the Curie temperature of a high magnetically conductive material of Ni—Zn Ferrite may be about 110° C.), the magnetic core may nearly lose its magnetic permeability

Methodology Applied

Scientific EffectCurie temperature effect: Curie Point (ferromagnetic)

Data Source

PatentUS9859050B2Method for producing magnetic element with two magnetic cores for increasing coiling space and magnetic element thereof

Publication Date: 2018.01.02 CYNTEC

AI summary

A magnetic element includes a first magnetic core, a second magnetic core and a plurality of conducting wires. The first magnetic core includes a first coiling body, a first protruding portion and a second protruding portion. The second magnetic core includes a second coiling body, a third protruding portion and a fourth protruding portion. A soldering surface of the first protruding portion is parallel and next to a soldering surface of the fourth soldering surface. Since an extension direction of the first magnetic core is extended from the soldering surface of the first protruding portion, an extension direction of the second magnetic core is extended from the soldering surface of the second protruding portion, and the plurality of conducting wires can be coiled on the first and the second coiling bodies respectively, the transformer can provide more space for coiling than the prior art.