Linear Electromagnetic Device With Stacked Core Slots
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Solution Overview
Problem
Existing electromagnetic devices, such as transformers and inductors, suffer from inefficiency due to magnetic flux escaping into free space, requiring larger and heavier cores and additional windings to achieve desired energy conversion or transfer.
Innovation Solution
A linear electromagnetic device with a core composed of stacked plates or laminates, where primary and secondary conductors pass through elongated slots in the core, allowing for the absorption and containment of nearly all magnetic flux, resulting in a highly efficient transformer with reduced volume and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional electromagnetic devices use windings wrapped around ferromagnetic cores, then energy conversion or transfer can be achieved, but magnetic flux escapes into free space causing inefficiency and requiring larger, heavier cores
Solution Approach 1:
The core is segmented into stacked plates or laminates with elongated slots, creating a structured magnetic path that confines flux. This segmentation allows the magnetic flux to be directed through specific pathways in the stacked plates, preventing escape into free space while maintaining a compact, lighter core structure.
Solution Approach 2:
The invention transitions from conventional three-dimensional wound cores to a two-dimensional planar structure with stacked plates. The elongated slots in each plate create a layered magnetic circuit that confines flux within the plane of the plates, eliminating vertical flux leakage and reducing the overall volume and weight of the core.
2Loss of energy
If conventional electromagnetic devices use windings wrapped around cores, then energy transfer can be achieved, but larger and heavier cores are required to contain the magnetic flux
Solution Approach 1:
The core is divided into multiple stacked plates, each with elongated slots that create discrete magnetic pathways. This segmentation confines the magnetic flux to specific regions within each plate, preventing flux leakage and allowing for a more compact overall volume while maintaining effective flux containment.
Solution Approach 2:
By transitioning to a two-dimensional stacked plate structure, the magnetic flux is confined within the planar geometry of each plate. This dimensional change eliminates the need for large three-dimensional core structures, significantly reducing the overall volume while maintaining effective flux containment through the layered architecture.
3Productivity
If conventional electromagnetic devices use traditional core structures, then electromagnetic function can be achieved, but additional windings are required to provide desired energy conversion
Solution Approach 1:
The stacked plate structure with elongated slots creates inherent magnetic coupling between adjacent plates. This segmentation provides multiple magnetic pathways that enhance energy transfer efficiency, reducing the need for additional windings while maintaining or improving productivity.
Solution Approach 2:
The elongated slots in the stacked plates serve multiple functions: they provide magnetic flux pathways, enable coupling between primary and secondary circuits, and eliminate the need for separate winding structures. This multi-functionality simplifies the overall device while maintaining high energy conversion efficiency.
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 solution achieves a minimum 50% reduction in volume and weight while ensuring high efficiency energy transfer with low copper losses and minimal radiated emissions, as the magnetic field is substantially contained within the core.
Implementation Method 1
The core may be sized or include dimensions so that substantially the entire magnetic field or at least about 96% of the magnetic field generated by the current in the primary is absorbed by the core to generate a magnetic flux in the core and so that the magnetic flux is substantially completely contained with the core
Implementation Method 2
An alternating current may be conducted through the primary. A magnetic field from the current in the primary is absorbed by the core
Implementation Method 3
When the current in the primary decreases the core transmits an electromotive force (desorbs) into the secondary wires
Data Source
Figure 1
Figure 2A
Figure 2B~2C
AI summary
A linear electromagnetic device (200), such as an inductor (202), transformer or the similar device, may include a core in which a magnetic flux (106) and (108) is generable. The device may also include an opening (208) through the core (204). The device may additionally include a primary conductor (212) received in the opening (208) and extending through the core (204). The primary conductor (212) may include a substantially square or rectangular (206) cross-section. An electrical current flowing through the primary conductor (212) generates a magnetic field about the primary conductor (212), wherein substantially the entire magnetic field is absorbed by the core (204) to generate the magnetic flux in the core (204).