Integrated Magnetic Device Fourth Column Flux Path
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Solution Overview
Problem
Existing integrated magnetic (IM) devices face challenges in miniaturization and cost reduction due to the large thickness of E-type magnetic cores, which restricts further size reduction and increases manufacturing costs.
Innovation Solution
The IM device incorporates a magnetic core with a fourth magnetic column that extends in the width direction, overlapping with the first and second magnetic columns, creating a T-shaped configuration that increases the magnetic flux path and cross-sectional area, allowing for a reduction in thickness and size while preventing magnetic saturation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an E-type magnetic core is used in IM devices, then the magnetic flux path is established, but the thickness becomes large resulting in increased size and manufacturing cost
Solution Approach 1:
The magnetic core is divided into multiple magnetic columns (first, second, third, and fourth magnetic columns) arranged in a specific configuration. This segmentation allows the magnetic flux to be distributed across multiple paths, reducing the required thickness of each individual column while maintaining overall magnetic performance.
Solution Approach 2:
The patent introduces a fourth magnetic column that extends in the width direction and overlaps with the first and second magnetic columns in the length direction. This dimensional arrangement creates additional magnetic flux paths without increasing the thickness, effectively utilizing spatial arrangement to resolve the contradiction.
2Reliability
If the cross-sectional area of magnetic columns is increased to prevent magnetic saturation, then magnetic saturation is prevented, but the overall size of the IM device increases
Solution Approach 1:
The magnetic flux is segmented across multiple magnetic columns rather than concentrating it in a single column. This distribution allows each column to have a smaller cross-sectional area while the collective arrangement prevents magnetic saturation, thereby reducing the overall device volume.
Solution Approach 2:
Multiple magnetic columns are merged into a unified magnetic core structure where the first, second, third, and fourth magnetic columns work together. This merging creates multiple parallel magnetic flux paths, effectively increasing the total magnetic flux handling capacity without requiring any single column to be oversized.
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 configuration effectively reduces the thickness of the magnetic core, minimizing the size of the IM device and lowering manufacturing costs, while maintaining efficient magnetic flux and preventing saturation.
Implementation Method 1
a first coil wound around the first magnetic column to generate a closed magnetic flux loop
Implementation Method 2
a second coil wound around the second magnetic column to generate a closed magnetic flux loop
Implementation Method 3
the magnetic core further includes a fourth magnetic column... creating a T-shaped configuration that increases the magnetic flux path and cross-sectional area, allowing for a reduction in thickness and size while preventing magnetic saturation
Data Source
AI summary
An IM device includes a magnetic core including a base plate, a cover plate, and first, second and third magnetic columns. A straight line defined by positions of the first and second magnetic columns is parallel to a length direction, and the third magnetic column is between the first and second magnetic columns, and extends in a width direction. A first coil is wound around the first magnetic column to generate a closed magnetic flux loop, a second coil wound around the second magnetic column to generate a closed magnetic flux loop. The magnetic core includes a fourth magnetic column between the base plate and the cover plate, and close to a first terminal of the third magnetic column in the width direction. In the length direction, the fourth magnetic column overlaps with at least a portion of the first magnetic column and at least a portion of the second magnetic column.