Ferrite Core Aggregate for High Power Inductance Heat Management
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Solution Overview
Problem
High power inductance devices with ferrite magnetic cores face challenges in heat radiation efficiency and reliability due to magnetic saturation, deformation, and increased temperature differences, leading to potential core cracks and manufacturing issues.
Innovation Solution
A high power inductance device with a ferrite magnetic core aggregate of multiple cores arranged side by side and parallel magnetic paths, where a metal plate is inserted between the cores to enhance heat transfer, reducing temperature increases and improving manufacturing yield and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large magnetic path cross-sectional area is ensured to prevent magnetic saturation, then the ferrite magnetic core must be upsized, but this increases the heating value due to large current flowing through the winding wire
Solution Approach 1:
The ferrite magnetic core is divided into multiple small ferrite cores (first through fourth ferrite cores) arranged in a 2x2 matrix configuration. Each small core has a smaller cross-sectional area and generates less heat individually, while the collective arrangement provides the required total magnetic path cross-sectional area to prevent magnetic saturation.
2Reliability
If a large ferrite magnetic core is used to ensure sufficient magnetic path area, then the heat flow path length increases, but this increases the heat resistance and temperature difference between parts
Solution Approach 1:
By segmenting the large core into multiple small cores arranged in a compact 2x2 matrix, the heat flow path length from any point to the cooling surface is significantly reduced compared to a single large core. This segmentation maintains the total magnetic path cross-sectional area while minimizing the maximum heat flow distance, thereby reducing heat resistance and temperature differences.
Solution Approach 2:
The small ferrite cores are arranged in a two-dimensional matrix configuration rather than extending in one dimension. This dimensional arrangement increases the surface area available for heat radiation and creates multiple shorter heat flow paths in parallel, effectively reducing the overall heat resistance and temperature gradients within the core assembly.
3Manufacturing precision
If a large ferrite magnetic core is manufactured as a single sintered body, then dimensional accuracy is difficult to control, but this leads to warpage and cracks during burning
Solution Approach 1:
The magnetic core is manufactured by assembling multiple small ferrite cores rather than creating one large sintered body. Each small core can be precisely controlled during the sintering process, avoiding the warpage and cracking issues that occur with large single-piece sintering. The small cores are then bonded together using adhesive to form the complete magnetic core structure.
Solution Approach 2:
Multiple individually manufactured small ferrite cores are bonded together using adhesive to form the complete magnetic core assembly. This merging process combines the dimensional accuracy advantages of small-core manufacturing with the functional requirements of a large magnetic path area, while avoiding the manufacturing defects associated with large single-piece sintering.
4Reliability
If multiple ferrite cores are arranged in close contact to form a magnetic core aggregate, then the required magnetic path area is achieved, but excessive stress and vibration cause core cracks and breaking
Solution Approach 1:
An adhesive layer is introduced as an intermediary between adjacent ferrite cores. This adhesive layer acts as a buffer that absorbs thermal expansion differences and mechanical stresses, preventing direct stress transmission between rigid ferrite core surfaces. The adhesive bonding maintains the magnetic path continuity while protecting against stress-induced cracks and core breaking.
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 reduces core temperature and enhances heat radiation efficiency, minimizing the risk of core damage and improving the manufacturing process, resulting in a more reliable and cost-effective high power inductance device.
Implementation Method 1
a metal plate is inserted into each of the intervals between the ferrite cores to increase a heat path cross-sectional area and improve heat transfer efficiency to a heat radiation structure
Implementation Method 2
a large magnetic path cross-sectional area must be ensured, which necessarily causes a ferrite magnetic core to be upsized and increases a heating value due to a large current flowing through a winding wire
Data Source
AI summary
A high power inductance device enables a large ferrite magnetic core to be manufactured at low cost and with ease and improves heat radiation efficiency to reduce an increase in the temperature of the core. The inductance device has a ferrite magnetic core and a winding wire wound around the ferrite magnetic core and is mounted on a heat radiation structure through at least one of the front surfaces of the ferrite magnetic core. The ferrite magnetic core is made of a core aggregate obtained by arranging side by side a plurality of ferrite cores 10 having a completely-closed magnetic path structure or a quasi-closed magnetic path structure with a magnetic gap such that an interval is placed between the ferrite cores and magnetic paths are parallel to each other. The inductance device is mounted such that at least one plane surface of the peripheral surfaces of each of the ferrite cores is brought into direct or indirect contact with the heat radiation structure 18 with a metal plate 12 inserted into the interval between the ferrite cores and the common winding wire 14 wound around all the ferrite cores.