Inductive Filter Toric Core Without Air Gap
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Solution Overview
Problem
Nanocrystalline materials used in inductive filtering devices are difficult to machine, making it challenging to produce magnetic cores with air gaps, which affects the flexibility and performance of the filtering devices.
Innovation Solution
A filtering device design that utilizes toric magnetic cores without air gaps, allowing coils to be wound outside the magnetic circuit, and optionally using multiple cores with shims to enhance inductance and heat dissipation, while maintaining the benefits of nanocrystalline materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If nanocrystalline materials are used to form toric magnetic cores, then saturation induction is improved (1.3 T vs 0.7 T), but the materials become difficult to machine, making it impossible to produce air gaps in the magnetic circuit
Solution Approach 1:
The magnetic circuit is divided into multiple separate toric magnetic cores instead of forming a single integrated core with air gaps. Each core is manufactured independently without air gaps using nanocrystalline materials, and then multiple cores are assembled together to create the magnetic circuit with effective air gaps between them. This segmentation allows the material's high saturation induction to be preserved while achieving the necessary magnetic circuit design.
Solution Approach 2:
Non-magnetic spacers or shims are introduced as intermediary elements between the toric magnetic cores to create the required air gaps in the magnetic circuit. These spacers serve as mediators that prevent direct magnetic coupling between cores, enabling the magnetic circuit to function with effective air gaps while maintaining the integrity of the difficult-to-machine nanocrystalline material cores.
2Manufacturing precision
If coils are wound by passing through the central void of toric magnetic cores, then the magnetic circuit is closed and inductance is maximized, but the manufacturing process becomes complex and difficult to achieve
Solution Approach 1:
Instead of winding coils by passing them through the central void of toric magnetic cores (conventional approach), the invention inverts the process by winding coils around the external surface of the cores. The coils are wrapped around the outside of each toric core rather than being threaded through the center, which dramatically simplifies the winding operation while still achieving effective magnetic coupling when multiple cores are assembled together.
Solution Approach 2:
The magnetic circuit is segmented into multiple independent toric cores, each with its own coil wound externally. This segmentation allows each core-coil assembly to be manufactured and tested independently, then assembled together to form the complete magnetic circuit. The segmentation eliminates the need for complex through-hole winding operations while maintaining magnetic circuit functionality.
3Adaptability or versatility
If air gaps are introduced in the magnetic circuit to improve flexibility, then adaptability is improved, but nanocrystalline materials cannot be used due to machining difficulties
Solution Approach 1:
The magnetic circuit is divided into multiple separate toric magnetic cores that can be independently manufactured from nanocrystalline materials without air gaps. By assembling these segmented cores with spacers between them, the magnetic circuit achieves flexibility and adaptability in design while avoiding the need to machine air gaps into the difficult-to-machine nanocrystalline material.
Solution Approach 2:
Non-magnetic spacers serve as intermediary elements that provide the necessary air gaps between nanocrystalline magnetic cores. These spacers enable magnetic circuit flexibility and adaptability in terms of gap adjustment and design variations, while the nanocrystalline cores themselves remain intact and unmodified, preserving their superior magnetic properties.
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
The design achieves higher inductance values and improved heat dissipation, with increased flexibility in manufacturing, particularly suitable for nanocrystalline materials, by winding coils around toric magnetic cores without passing through central voids, enhancing the overall performance of inductive filtering devices.
Implementation Method 1
a first cylindrically shaped toric magnetic core without an air gap being wound around an axis of the first core and formed around a central void also lying along the axis of the first core
Implementation Method 2
a first electrical conductor formed of turns that are wound around the first magnetic core without passing through the central void
Data Source
AI summary
An inductive filtering device includes a first toric magnetic core without an air gap formed around a central void; a first electrical conductor formed of turns that are wound around the first magnetic core without passing through the central void, wherein no electrical conductor passes through the central void.