Inductive Component Segmented Permanent Magnet Unit
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Solution Overview
Problem
The use of individual permanent magnet pieces in inductive components leads to increased eddy current losses due to high-frequency alternating currents, and their assembly and fixation are cumbersome, resulting in a poor fill factor and higher production effort.
Innovation Solution
Stacking individual permanent magnet pieces laminated as strips or lamellae in a specific direction orthogonal to the gap's longitudinal extension, with optional insulators, and using rare earth magnetic materials to form a permanent magnet unit that can be easily handled and assembled, such as a comb structure, to reduce eddy current losses and simplify production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If permanent magnets are used in the gap of the magnetic circuit, then the magnetic hub is significantly increased, but eddy current losses increase with high-frequency alternating current
Solution Approach 1:
The permanent magnet is divided into multiple individual permanent magnet pieces arranged in the gap. This segmentation interrupts the eddy current paths, reducing eddy current losses while maintaining the magnetic hub. The patent specifies that the permanent magnet pieces are arranged with their magnetization directions aligned, creating a segmented structure that addresses the energy loss issue.
2Loss of energy
If individual permanent magnet pieces are arranged in the gap, then eddy current losses are reduced, but assembly and fixation become problematic and involve increased effort
Solution Approach 1:
Multiple individual permanent magnet pieces are combined into a single integrated permanent magnet unit with a unified magnetization direction. This merging approach maintains the eddy current reduction benefits of segmented magnets while eliminating the assembly and fixation problems of multiple separate pieces. The permanent magnet unit is inserted as one piece into the gap, simplifying manufacturing.
3Stability of the object's composition
If individual permanent magnet pieces are arranged aligned, then magnetization directions are aligned, but repulsion occurs between magnet pieces with the same polarity
Solution Approach 1:
Insulating layers or spacing structures are introduced as intermediaries between adjacent permanent magnet pieces with the same polarity. These intermediaries prevent direct contact and reduce repulsion forces, enabling the permanent magnet pieces to be arranged in an aligned configuration while maintaining structural stability during assembly.
4Loss of energy
If a large number of individual permanent magnet pieces are used, then eddy current losses are reduced, but the fill factor becomes increasingly unfavorable
Solution Approach 1:
The permanent magnet is segmented into pieces arranged in a specific pattern within the gap, optimizing both eddy current reduction and space utilization. The segmentation is designed to maintain a high fill factor by efficiently packing the magnet pieces within the available gap volume while still interrupting eddy current paths.
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 significantly reduces eddy current losses while maintaining a high fill factor and simplifying the assembly process, achieving low power losses even at high frequencies with minimal increase in manufacturing complexity.
Implementation Method 1
the possible magnetic hub, i. H. the possible maximum change in magnetic induction is significantly increased by the provision of the permanent magnetic material in the gap
Implementation Method 2
undesirable eddy currents form as soon as the inductive component carries high-frequency alternating current components
Implementation Method 3
These eddy currents become larger, the higher the frequency of the alternating magnetic field and the higher the energy of the alternating field
Data Source
Figure 1~2a
Figure 2b~2c
Figure 2d~2e
AI summary
The invention relates to an inductive component (1) with the following features: - a magnetic circuit (10) made of a magnetically soft core material, - said magnetic circuit (10) having at least one gap (20) which extends in the Y direction (1) from a first end-side free end (12) of the core material to an opposite second end-side end (14) of the core material, - at least one coil (30) which is wound around at least one part of the core material, and - a permanent magnet unit (50) which consists of multiple mutually spaced individual permanent magnet elements (51), each of which has a magnetizing direction, said directions being oriented in an at least approximately identical manner to the Y direction (Y). According to the invention, the individual permanent magnets (51) are stacked next to one another in a mutually spaced manner primarily in a direction which is at least approximately orthogonal to the Y direction (Y). The advantages of the invention are high magnetic biasing of the inductor by means of the permanent magnets, little power loss, a simple production, and a high fill factor.