Magnetic Circuit Component with Localized Soft Magnetic Material
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Solution Overview
Problem
In magnetic circuit components like reactors and transformers, high-frequency operation leads to increased alternating-current resistance due to eddy-current loss, particularly exacerbated by proximity effects and magnetic saturation in coils with magnetic plating, which complicates downsizing efforts.
Innovation Solution
A magnetic circuit component configuration featuring a coil wound around a magnetic core with a soft magnetic material section covering the coil surface, away from the core, to reduce magnetic flux density and eddy-current loss, thereby mitigating magnetic saturation without increasing the quantity of magnetic material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a winding wire is plated with a magnetic material to reduce eddy-current loss, then eddy-current loss is reduced, but magnetic saturation occurs and alternating-current resistance increases
Solution Approach 1:
The patent applies magnetic material only to specific high-flux-density regions (coil corners and ends) rather than uniformly plating the entire wire surface. This localized application provides sufficient magnetic shielding where needed while avoiding magnetic saturation in other regions, thereby reducing eddy-current loss without triggering the harmful effects of saturation.
Solution Approach 2:
The magnetic material is applied in segmented form at discrete locations (four corners and two ends of the coil) rather than as a continuous coating. This segmentation allows the magnetic flux to be controlled and distributed more effectively, preventing the concentration of flux that leads to saturation while still providing shielding against eddy currents.
2Volume of moving object
If operating frequency is increased to achieve downsizing, then component size is reduced, but alternating-current resistance increases due to eddy-current loss
Solution Approach 1:
The patent changes the operational parameters by introducing magnetic material at specific locations, which alters the magnetic flux distribution and density parameters. This enables the system to operate at higher frequencies with reduced eddy-current loss, achieving downsizing without the penalty of increased alternating-current resistance.
3Reliability
If magnetic material quantity is increased to prevent magnetic saturation, then magnetic saturation is reduced, but device complexity and material cost increase
Solution Approach 1:
Instead of uniformly increasing magnetic material throughout the coil, the patent applies magnetic material selectively at locations where flux density is highest (corners and ends). This localized approach provides adequate saturation prevention with minimal material, avoiding the complexity and cost associated with comprehensive magnetic material application.
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 effectively reduces eddy-current loss and alternating-current resistance in coils, maintaining efficiency while preventing magnetic saturation, even at high frequencies, without the need for additional magnetic material.
Implementation Method 1
a magnetic field generated in another conductive material can pass not through the own conductive material but through a soft magnetic material
Implementation Method 2
eddy-current loss caused by skin effect, proximity effect, or leakage flux in a copper wire or a coil increases with the increase of frequency
Implementation Method 3
magnetic saturation is likely to occur in view of the fact that a magnetic flux of a large density passes through the plating
Implementation Method 4
since a magnetic field generated in another conductive material can pass not through the own conductive material but through a soft magnetic material, the magnetic field acting in the interior of the conductive material can be reduced
Data Source
AI summary
A magnetic circuit component includes a magnetic core and a coil formed by winding a conductor around the magnetic core. The magnetic circuit component includes a magnetic material section that is formed from a soft magnetic material, and that covers a part of a surface of the coil or the entire surface of the coil and is disposed away from the magnetic core.