Flexible Magnetic Core Single-Gap Design
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Solution Overview
Problem
Existing magnetic cores with multiple gaps, such as those with hinges or cut into halves, suffer from low magnetic permeability, increased core losses, and performance issues due to discontinuities, making them inefficient and difficult to replace without disassembling entire assemblies.
Innovation Solution
A magnetic core design featuring a single gap between the outer and inner surfaces of a flexible package, with a clamp to control the gap's size and a movable member to facilitate wire passage, allowing for easy replacement without disturbing other components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If a magnetic core is cut into two halves connected by a hinge to facilitate replacement, then ease of repair is improved, but magnetic permeability deteriorates due to multiple gaps
Solution Approach 1:
The core is divided into two halves that can be separated for replacement, but the segmentation is designed to minimize disruption to magnetic flux paths. The halves are connected by a hinge that maintains alignment and minimizes air gaps, allowing the core to be pried open for wire access while preserving magnetic integrity during operation.
Solution Approach 2:
The hinge connection is designed with specific local characteristics - a narrow gap and precise alignment features - to minimize the impact on magnetic permeability. The hinge location and geometry are optimized to create the smallest possible discontinuity in the magnetic path while still allowing for practical assembly and disassembly.
2Reliability
If a magnetic core is designed as a solid toroid, then magnetic permeability is improved, but ease of repair deteriorates as the entire assembly must be disassembled for replacement
Solution Approach 1:
The solid toroid is segmented into two halves that are joined together, allowing one half to be removed and replaced independently. This segmentation enables core replacement without disassembling the entire harness or connector assembly, significantly reducing repair time and complexity.
Solution Approach 2:
The hinge connection provides dynamic capability for the core halves to be pried open and closed, transitioning from a closed magnetic circuit during operation to an open state during replacement. This dynamic feature maintains magnetic integrity during use while enabling easy maintenance.
3Ease of operation
If multiple gaps are introduced in a magnetic core to enable assembly and wire passage, then ease of operation is improved, but core losses increase due to discontinuities
Solution Approach 1:
Wire passage capability is extracted from the core body itself and provided through the package structure. The package includes a movable member that can be actuated to create an opening for wire insertion, while the core remains intact with minimal gaps, thereby reducing core losses while maintaining ease of operation.
Solution Approach 2:
The package structure acts as an intermediary between the core and the wire insertion process. The movable member in the package creates a temporary opening for wire passage without requiring gaps in the core itself, thus preserving magnetic integrity while enabling operation.
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 single-gap design minimizes performance losses and simplifies core replacement by maintaining magnetic integrity and allowing for easy access without disassembling the entire assembly, reducing time and costs associated with maintenance.
Implementation Method 1
the material is a flexible magnetic material
Implementation Method 2
a clamp having a first position in which the clamp secures the core in a closed position wherein the gap is decreased
Implementation Method 3
magnetic cores have magnetic material inside such as soft iron, laminated silicon steel, carbonyl iron, iron powder, ferrite and vitreous material
Data Source
AI summary
The disclosure provides a core, comprising a body formed from a winding of tape shaped material, and a package encasing the body. A single gap is formed in the body and the package. A clamp is connected to the package to flex a flexible section of the package to reduce the gap.