Interlocking Magnetic Core Assembly Without Bobbins
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Solution Overview
Problem
Conventional magnetic core designs for transformers and inductors require additional space and weight due to bobbins used for winding, limit effective heat transfer, and involve complex assembly processes with multiple steps and mechanical fastening.
Innovation Solution
A magnetic core design featuring a substantially rectangular core section with interlocking ends that allows direct winding without bobbins, simplifying assembly and reducing weight by using interlocking features to secure complementary core sections, thereby eliminating the need for mechanical straps and enhancing heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If bobbins are used for winding conductors around core parts, then the windings can be kept around the adjoining 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 bobbins from the transformer core assembly. Instead of using separate bobbins to hold windings, the core parts themselves are designed with protrusions and recesses that directly hold the windings in place, eliminating the need for additional bobbin components and freeing up space.
Solution Approach 2:
The invention merges the holding function previously performed by separate bobbins into the core parts themselves. The protrusions on one core part and recesses on adjacent core parts create an integrated holding structure that combines the core's structural function with the winding retention function.
2Strength
If bobbins are used for winding conductors, then the windings can be secured, but the bobbins limit effective heat transfer between the windings and the cores
Solution Approach 1:
The invention removes the bobbins that were acting as thermal barriers between the windings and core parts. By eliminating these intermediate components, direct thermal contact is established, improving heat transfer efficiency and reducing energy loss.
Solution Approach 2:
The invention merges the winding-holding function directly into the core structure through protrusions and recesses, eliminating the need for separate bobbins. This integration allows windings to be in direct contact with the core parts, enhancing thermal coupling and heat dissipation.
3Ease of manufacture
If the conventional three-step manufacturing process is used (machining, winding onto bobbin, assembling with metal straps), then the transformer can be manufactured, but the process is complex and adds to the overall weight
Solution Approach 1:
The invention extracts and eliminates the metal straps and bobbin components from the assembly process. The protrusions and recesses on the core parts directly secure the windings without requiring additional fastening components, simplifying both the manufacturing process and the final assembly.
Solution Approach 2:
The invention combines the winding-retention function into the core parts themselves through integrated protrusions and recesses. This eliminates the need for separate metal straps and bobbins, reducing the number of assembly steps and components while maintaining the ability to securely hold windings.
4Strength
If metal straps are used to secure core parts together, then the core parts can be held together, but this adds to the overall weight of the core
Solution Approach 1:
The invention removes the metal straps from the core assembly. Instead of using separate fastening components, the core parts themselves are designed with protrusions and recesses that interlock to provide structural integrity without additional weight.
Solution Approach 2:
The invention merges the structural joining function into the core parts through complementary protrusions and recesses. This integration eliminates the need for separate metal straps while maintaining the structural integrity needed to hold core parts together securely.
Data Source
Figure 1~2B
Figure 3A~3C
AI summary
A magnetic core section of a transformer or an inductor, comprising a substantially rectangular core section body having opposing sides (20a, 20b) joined by opposing ends (20c, 20d), and further comprising interlocking features (30a, 30b) provided at each of the ends, shaped to interlock with interlocking features of complementary core sections (12a, 12b).