Induction Charging Coil Composite Core
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Solution Overview
Problem
Existing hand tool inductive charging coil devices face challenges in efficiently and cost-effectively bundling and transmitting alternating magnetic fields for energy transfer, particularly in terms of mechanical robustness, magnetic properties, and material efficiency.
Innovation Solution
The use of a core unit formed by microscopic core elements embedded in a binder, which can include sintered pieces or ferrite materials, with varying permeabilities and densities, and a core jacket for structural support, allows for efficient energy transmission and mechanical robustness, while minimizing material usage and ensuring reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a core unit is formed from traditional sintered ferrite material, then magnetic properties are improved, but mechanical robustness and break resistance deteriorate
Solution Approach 1:
The core unit is formed as a composite material consisting of sintered ferrite pieces embedded in a plastic matrix material. This composite structure combines the magnetic properties of ferrite with the mechanical robustness and break resistance of plastic, resolving the contradiction between magnetic performance and mechanical strength.
2Ease of manufacture
If microscopic core elements are used, then material efficiency and manufacturing simplicity are improved, but magnetic field bundling capability worsens
Solution Approach 1:
The invention specifies optimal parameter ranges for the microscopic core elements, including particle size (0.1-2.0 mm), volume fraction (30-70%), and magnetic permeability (100-5000). By optimizing these parameters, the composite core unit achieves both ease of manufacture and effective magnetic field bundling capability.
3Reliability
If sintered ferrite material is used, then magnetic properties are improved, but manufacturing complexity and cost worsen
Solution Approach 1:
The core unit is segmented into discrete sintered ferrite pieces rather than using a monolithic sintered component. This segmentation allows the ferrite particles to be mixed with plastic matrix material and formed using simple injection molding or compression molding processes, dramatically reducing manufacturing complexity while maintaining magnetic properties.
4Strength
If a solid core unit structure is used, then mechanical strength is improved, but flexibility and adaptability worsen
Solution Approach 1:
The plastic matrix material provides flexibility and adaptability to the core unit structure, allowing it to be molded into various shapes and configurations, while the embedded sintered ferrite pieces provide the necessary magnetic properties and structural integrity.
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 enhances the magnetic properties and mechanical robustness of the core unit, enabling effective energy transfer and reducing material costs, with improved durability and efficiency in hand tool battery packs.
Implementation Method 1
The coil unit is preferably provided for converting an alternating electrical current into an alternating magnetic field and/or vice versa
Implementation Method 2
the core unit is provided for bundling an electromagnetic alternating field
Data Source
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AI summary
The invention relates to an induction charging coil device (10a-b), especially an induction charging coil device for a hand tool, comprising at least one coil unit (12a-b) and at least one core unit (14a-b). According to the invention, the core unit (14a-b) is at least partially constituted by microscopic core elements (24a-b) embedded in a binder (22a-b).