Interlocking Magnetic Core Sections for Bobbin-Free Windings
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Solution Overview
Problem
Conventional magnetic core designs for transformers and inductors require additional space and weight due to bobbins needed for winding and assembly, which limits effective heat transfer and increases manufacturing complexity and weight.
Innovation Solution
A magnetic core section with interlocking features allows direct winding onto the core without bobbins, simplifying assembly and reducing weight by using complementary core sections that interlock to form desired shapes, such as EE, CI, or UU configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If bobbins are used for winding and assembly, then the windings can be kept around the core parts, but the bobbins take up space that could otherwise be used for more windings and limit effective heat transfer
Solution Approach 1:
The invention extracts and removes the bobbin component from the transformer structure entirely. Instead of using separate bobbins to hold windings, the core legs themselves are designed with integrated winding retention features, eliminating the need for additional bobbin structures and freeing up space for more windings.
Solution Approach 2:
The invention merges the function of bobbin support with the core legs by integrating winding retention features directly into the core structure. This consolidation eliminates the separate bobbin component and improves thermal coupling between the windings and core.
2Ease of operation
If bobbins are used for winding and assembly, then the windings can be kept around the core parts, but the bobbins add to the overall weight of the core
Solution Approach 1:
The invention extracts and removes the bobbin component from the transformer structure entirely. Instead of using separate bobbins to hold windings, the core legs themselves are designed with integrated winding retention features, eliminating the need for additional bobbin structures and freeing up space for more windings.
3Ease of manufacture
If the manufacturing process includes machining, winding onto bobbins, and assembling core parts with metal straps, then the transformer can be constructed, but the process requires multiple steps and adds to the overall weight
Solution Approach 1:
The invention merges the function of bobbin support with the core legs by integrating winding retention features directly into the core structure. This consolidation eliminates the separate bobbin component and improves thermal coupling between the windings and core.
Solution Approach 2:
The invention discards the traditional multi-step process of machining, winding onto bobbins, and assembling with metal straps. Instead, it recovers a simplified process where core sections with integrated features are assembled directly, eliminating unnecessary intermediate steps and components.
4Stability of the object's composition
If metal straps are used to secure core parts together, then the core structure is stabilized, but the straps add to the overall weight of the core
Solution Approach 1:
The invention extracts and removes the bobbin component from the transformer structure entirely. Instead of using separate bobbins to hold windings, the core legs themselves are designed with integrated winding retention features, eliminating the need for additional bobbin structures and freeing up space for more windings.
Data Source
AI summary
A magnetic core section of a transformer or an inductor, includes a substantially rectangular core section body having opposing sides joined by opposing ends, and further comprising interlocking features provided at each of the ends, shaped to interlock with interlocking features of complementary core sections.