Flexible Magnetic Element Flat Plate Helical Weave
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional magnetic elements with rigid structures face challenges in reducing thickness, leading to limited arrangement space in electronic devices, and existing solutions fail to provide flexibility and efficient manufacturing processes.
Innovation Solution
A magnetic element comprising a flexible first flat plate made of magnetic material powders combined with resin and a flexible second flat plate with a helical conductive material, where the second flat plate is slit and coated with insulation, allowing for reduced thickness and improved manufacturing by inserting the magnetic material into the helical structure, enabling flexibility and reduced space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a rigid columnar core material is used for winding conductive wire, then workability during winding is improved, but the thickness of the magnetic element becomes large and arrangement space cannot be secured
Solution Approach 1:
The patent replaces the rigid columnar core material with a flexible flat plate structure. The magnetic element uses thin flexible plates that can be bent and shaped, eliminating the need for thick rigid cores while maintaining workability during assembly. The flexible nature allows the magnetic element to achieve the required magnetic path without excessive thickness.
Solution Approach 2:
The patent transitions from a three-dimensional columnar core structure to a two-dimensional flat plate structure. This dimensional change allows the magnetic path to be formed within a thin profile, reducing the thickness dimension while maintaining the necessary magnetic circuit functionality through the flat plate geometry.
2Stability of the object's composition
If a rigid flat plate structure is used for the magnetic element, then manufacturing stability is improved, but flexibility and adaptability are lost
Solution Approach 1:
The patent employs flexible flat plates instead of rigid structures. The flexible plates can be bent and shaped to create the magnetic circuit path, providing both manufacturing stability through consistent flat plate fabrication and flexibility for adapting to different device configurations and space constraints.
Solution Approach 2:
The magnetic element uses composite construction with flexible plates that may combine magnetic materials with flexible substrates or coatings. This composite approach maintains manufacturing stability through standardized plate production while enabling flexibility and adaptability in the final assembled magnetic circuit configuration.
3Device complexity
If the second flat plate is made without insulation coating, then manufacturing complexity is reduced, but short-circuit risk increases
Solution Approach 1:
The patent introduces an insulation coating as an intermediary layer on the second flat plate. This thin coating serves as a mediator that electrically isolates conductive parts that may come into contact, preventing short circuits while adding minimal complexity to the manufacturing process. The coating can be applied through standard conformal coating or lamination techniques.
4Stability of the object's composition
If the magnetic element uses a wound structure with thick core, then magnetic path stability is improved, but arrangement space becomes insufficient
Solution Approach 1:
The patent transforms the traditional three-dimensional wound magnetic structure into a two-dimensional flat plate configuration. This dimensional transformation maintains magnetic path stability through the flat plate geometry while dramatically reducing the volume and thickness, allowing the magnetic element to fit within constrained arrangement spaces in modern electronic devices.
Solution Approach 2:
The flexible flat plate structure provides a stable magnetic path through its rigid enough construction to maintain magnetic circuit integrity, while its thin film nature reduces the overall volume. The flexibility allows the plates to be assembled into stable magnetic circuits without requiring thick cores or complex wound structures.
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 results in a thinner magnetic element with reduced space requirements, enhanced flexibility, and simplified manufacturing, allowing for efficient arrangement in electronic devices and potential integration into fabrics without compromising flexibility.
Implementation Method 1
the magnetic element is made of the magnetic material formed by combining magnetic material powders with a resin material
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A magnetic element (10) in a flat-plate shape includes a linearly-extending first flat plate (20) being made of one of a magnetic material and a conductive material and a helical second flat plate (30) being made of the other of the magnetic material and the conductive material, and the first flat plate is inserted into the helical structure of the second flat plate so as to alternatively weave front and back surfaces of the second flat plate.