Inductive Device Coil Former Segmentation for Insulation
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Solution Overview
Problem
Current inductive devices face challenges in achieving efficient manufacturing and assembly while maintaining compactness, efficiency, and cost-effectiveness, particularly in designs that provide adequate insulation and accommodate various applications.
Innovation Solution
The design incorporates a coil former with inner and outer walls that form a void to separate the winding from the magnetic core, allowing for efficient assembly and insulation, and uses a magnetic core with a potcore type design that can be manufactured using compressed soft magnetic powder, with features like recesses and apertures to simplify production and reduce material biasing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional coil bobbin design is used, then assembly is simplified, but insulation between winding and magnetic core is insufficient
Solution Approach 1:
The coil former is divided into multiple functional walls: an inner wall separating the winding from the inner core portion, an outer wall separating the winding from the outer core portion, and end walls closing the structure. This segmentation provides comprehensive insulation while maintaining a relatively simple overall design.
Solution Approach 2:
The coil former acts as an intermediary component between the magnetic core and the winding, providing electrical insulation and mechanical support. The walls of the coil former create intermediate spacing and isolation, ensuring reliable insulation without requiring complex additional insulating structures.
2Volume of moving object
If compact design is pursued, then volume and weight are reduced, but manufacturing and assembly efficiency may be compromised
Solution Approach 1:
The coil former combines multiple functions into a single component: it provides electrical insulation between the winding and magnetic core, offers mechanical support for the winding, defines the void space, and enables efficient assembly. This merging achieves compactness without sacrificing manufacturing efficiency.
Solution Approach 2:
The coil former serves multiple purposes simultaneously: insulation barrier, structural support, space definition, and assembly facilitator. This multi-functionality allows the device to remain compact while maintaining ease of manufacturing and assembly.
3Object-affected harmful factors
If pot core design with inner and outer core portions is used, then electromagnetic shielding is improved, but device complexity increases
Solution Approach 1:
The magnetic core is segmented into an inner core portion and an outer core portion that define an annular void. This segmentation provides effective electromagnetic shielding by containing fields within the magnetic path while allowing the coil former and winding to be positioned in the void, maintaining a relatively simple overall structure.
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3~4
AI summary
Disclosed herein are embodiments of an inductive device comprising: a winding defining an axial direction; a coil former; and a magnetic core comprising a base core portion from which an outer core portion and an inner core portion extend in the axial direction so as to form a void for accommodating the coil former and the winding; wherein the coil former comprises one or more walls together defining a void for receiving the winding and separating the winding from the inner core portion and from the outer core portion.