Grooved Magnetic Core Inductor for Shorter Coil Winding
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Solution Overview
Problem
Inductive devices in existing technology face issues such as stress damage to coils due to sharp corners on magnetic cores, increased winding length and resistance, and inefficient space utilization due to supporting frames, limiting modular design capabilities.
Innovation Solution
The inductive device features a columnar magnetic core with grooves and a frame assembly with embedding portions that fit into these grooves, allowing the coil to be wound smoothly and securely without sharp corners, reducing stress and space, and enabling modular design through identical frames.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the magnetic core has sharp folded corners, then the structure is simple and easy to manufacture, but the coil experiences excessive local pressure causing stress damage and shortened service life
Solution Approach 1:
The patent applies curvature by replacing the sharp folded corners of the magnetic core with rounded arc-shaped surfaces. This allows the coil to be wound smoothly without excessive local pressure at corners, eliminating stress concentration points while maintaining manufacturing feasibility through standard molding processes.
Solution Approach 2:
The patent implements beforehand cushioning by pre-installing embedding portions (buffer structures) at the corners of the magnetic core before coil winding. These embedding portions act as cushioning elements that distribute and reduce local pressure on the coil during winding, preventing stress damage before it occurs.
2Ease of manufacture
If the coil cannot be closely attached to the side surface of the magnetic core, then the magnetic core structure is simple, but the winding length and resistance increase
Solution Approach 1:
The patent uses arc-shaped embedding portions with rounded surfaces that enable the coil to wrap closely around the magnetic core corners. This curved geometry eliminates gaps between the coil and magnetic core surface, reducing the required winding length and associated resistance while maintaining simple magnetic core construction.
Solution Approach 2:
The embedding portions are nested into grooves on the magnetic core surface, creating a layered structure where the embedding portion fits within the magnetic core profile. This nested arrangement allows the coil to follow the contours closely, minimizing winding length without complicating the basic magnetic core structure.
3Stability of the object's composition
If frames are used to support the magnetic core, then the magnetic core is stable and secure, but the overall size of the inductive device increases reducing space utilization rate
Solution Approach 1:
The patent merges the support function into the magnetic core itself by integrating embedding portions directly onto the magnetic core surface. These embedding portions provide structural support and stability for the coil while being part of the magnetic core assembly, eliminating the need for separate external frames and thus reducing overall device volume.
Solution Approach 2:
The patent applies local quality by adding support features (embedding portions) only at specific locations (corners and edges) where structural reinforcement is needed, rather than using a complete surrounding frame. This localized approach provides necessary stability while minimizing the addition of material and device volume.
4Ease of manufacture
If the magnetic core is in a cuboid shape, then manufacturing is simple, but inductive devices with many different characteristics cannot be manufactured by modular design
Solution Approach 1:
The patent segments the magnetic core into modular components by introducing grooves that accommodate separate embedding portions. This segmentation allows different embedding portion configurations to be combined with standard magnetic core blocks, enabling modular assembly of inductive devices with various characteristics while maintaining simple manufacturing of individual components.
Solution Approach 2:
The patent implements universality by designing standardized magnetic core blocks with generic groove patterns that can accommodate multiple types of embedding portions. This universal interface allows the same basic magnetic core to be used in different modular configurations to create inductive devices with diverse electrical characteristics.
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 enhances coil attachment, reduces resistance and volume, prolongs device life, and allows for cost-effective production of inductive devices with varied electrical properties.
Implementation Method 1
an inductive coil wound onto the side surfaces of the columnar magnetic core
Data Source
AI summary
The utility model provides an inductive device, including a columnar magnetic core provided with grooves on side surfaces thereof; a frame assembly including embedding portions adapted to the grooves in shape, the embedding portions being embedded in the grooves; and an inductive coil wound onto the side surfaces of the columnar magnetic core. The inductive device of the utility model has the advantages of saved winding use amount and prolonged service life.