Magnetic Coupling Coil Structure With Adjustable Spacer Positioning
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Solution Overview
Problem
Conventional magnetic coupling coil components face challenges in adjusting the coupling coefficient due to the brittleness of integrated intermediate flanges, making it difficult to accurately position and maintain the desired thickness, which affects the coupling coefficient and mechanical strength.
Innovation Solution
A magnetic coupling coil component design featuring a drum core with separate, adjustable spacers made of flexible materials like resin or insulating sheets, allowing for precise positioning and adjustment of the coupling coefficient without risking mechanical breakdown.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an intermediate flange is integrated with the winding core to adjust the coupling coefficient, then the coupling coefficient can be adjusted, but the intermediate flange is prone to breaking due to the brittleness of fired ferrite
Solution Approach 1:
The intermediate flange is divided into two separate parts: a winding core without an integrated flange and a separate intermediate flange component. This segmentation allows the flange to be positioned and adjusted independently without compromising the structural integrity of the winding core, thereby preventing breakage while maintaining coupling coefficient adjustability.
Solution Approach 2:
A separate intermediate flange component acts as an intermediary element between the winding core and the coil conductors. This mediator can be precisely positioned at desired locations on the winding core to control the coupling coefficient, while its separate construction avoids the brittleness issue of integrated fired ferrite flanges.
2Adaptability or versatility
If the intermediate flange is formed with small thickness to achieve desired coupling coefficient, then the coupling coefficient increases, but the intermediate flange becomes prone to breaking
Solution Approach 1:
The intermediate flange is designed with adjustable positioning capabilities, allowing its effective thickness and position to be dynamically optimized. This enables achieving the desired coupling coefficient without requiring minimal fixed thickness, thereby maintaining adequate mechanical strength.
3Manufacturing precision
If the intermediate flange is formed at a desired position on the winding core, then accurate positioning is achieved, but it is difficult to form the flange at the desired position due to production constraints
Solution Approach 1:
By separating the intermediate flange from the winding core, each component can be manufactured independently using optimized processes. The winding core can be formed by conventional pressing and firing, while the separate flange can be precisely positioned and attached, achieving accurate positioning without complicating the core manufacturing process.
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
Enables easy adjustment of the coupling coefficient and accurate positioning of the spacer on the winding core, enhancing the magnetic coupling efficiency while minimizing the risk of mechanical failure.
Implementation Method 1
a magnetic coupling coil component including a pair of coil conductors magnetically coupled to each other
Data Source
AI summary
One object of the present invention is to provide a magnetic coupling coil component having a coupling coefficient that can be readily adjusted. A coil component according to one embodiment of the present invention includes: a drum core including a winding core, a first flange, and a second flange, the first flange being provided on one axial end of the winding core, the second flange being provided on another axial end of the winding core; a spacer provided on a surface of the winding core between the first flange and the second flange, the spacer being separate from the winding core; a first winding wire wound around the winding core between the first flange and the spacer; and a second winding wire wound around the winding core between the second flange and the spacer.