Embedded Magnetic Device Gapping via Laser Ablation

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Solution Overview

Problem

Conventional magnetic components face challenges in efficiently handling both AC and DC currents, leading to magnetic saturation and reduced inductance, especially in power converters, due to the lack of effective methods for gapping ferromagnetic cores to accommodate DC currents without degrading AC filtering capabilities.

Innovation Solution

The integration of embedded magnetic components within a substrate, where toroid cores are gapped using precision techniques like laser cutting, allowing for the creation of a magnetic device with a controlled gap that reduces core permeability and reluctance, enabling operation with higher currents before saturation occurs, while maintaining efficiency in filtering AC currents and noise reduction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If ferromagnetic core is used to provide high permeability for AC current handling, then inductance is improved, but magnetic saturation occurs when DC current is applied

Engineering Contradiction:

ImproveinductanceVSAvoidDC current handling capability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The ferromagnetic core is segmented by introducing one or more gaps that divide the continuous magnetic path into separate sections. This segmentation prevents magnetic saturation by breaking the closed magnetic loop, allowing the device to handle DC currents while maintaining controlled inductance characteristics for AC signals.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The gap is strategically positioned at specific locations within the core structure where magnetic flux density is highest. This local modification creates a non-uniform magnetic path with different permeability characteristics in different regions, enabling the core to handle DC bias currents while maintaining effective AC filtering performance in the gap region.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If gap is introduced to prevent magnetic saturation, then DC current handling is improved, but core permeability and inductance are reduced

Engineering Contradiction:

ImproveDC current handling capabilityVSAvoidinductance

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The gap dimensions (width, length, position) are precisely controlled and optimized to achieve the desired balance between DC current handling and inductance maintenance. By adjusting gap parameters, the magnetic circuit reluctance is modified to prevent saturation while preserving sufficient inductance for AC filtering applications.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If precision gapping technique like laser cutting is used, then manufacturing precision is improved, but device complexity increases

Engineering Contradiction:

Improvegap controlVSAvoidgapping process

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Traditional mechanical gapping methods are replaced with laser cutting technology to create precise gaps in the core. This substitution eliminates the need for complex mechanical adjustment mechanisms and provides consistent, repeatable gap dimensions through controlled thermal processing, reducing overall device complexity while maintaining high manufacturing precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 approach enhances the magnetic device's ability to handle DC currents without saturating the core, thereby improving inductance and filtering performance, reducing noise emissions, and increasing system efficiency by containing magnetic flux within the core structure.

Implementation Method 1

gapped using precision techniques like laser cutting

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

containing magnetic flux within the core structure

Methodology Applied

Scientific EffectMagnetic confinement: Magnetic Field

Data Source

PatentUS10431367B2Method for gapping an embedded magnetic device

Publication Date: 2019.10.01 RADIAL ELECTRONICS

AI summary

A method for gapping a magnetic component is disclosed. The method includes: forming a feature on a substrate, the feature being a depression defining an inside surface; disposing a first conductive pattern on the substrate and the inside surface of the feature; disposing a permeability material on the inside surface of the feature and the first conductive pattern; disposing a substrate material on the substrate and the feature; disposing a second conductive pattern on the substrate material to wrap the permeability material between the first conductive pattern and the second conductive pattern to define at least one electrical circuit to facilitate a magnetic field in the permeability material; and gapping the permeability material to remove at least a portion of the permeability material to produce a gap in the at least a portion of the permeability material.