Magnetic Component With Non-Magnetic Medium Reducing Eddy Current Loss
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Solution Overview
Problem
Conventional magnetic components with air gaps experience significant eddy current losses due to high-frequency magnetic flux diffusion, leading to increased skin and proximity effect losses, which are not effectively mitigated by existing solutions such as using smaller diameter windings or low permeability magnetic cores, and these solutions either compromise the component's volume or are complex and time-consuming to implement.
Innovation Solution
A magnetic component design featuring at least three core columns with a winding and a medium having a relative initial permeability of 1 disposed on at least one side, replacing the conventional magnetic cover board to evenly distribute magnetic flux at air gaps, thereby reducing losses to only skin and proximity effect losses, and potentially reducing the component's volume by eliminating the cover board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an air gap is cut in the ferrite magnetic core to store energy and prevent saturation, then the inductance requirement is met, but magnetic flux diffuses toward the window causing large eddy current loss in the winding
Solution Approach 1:
The patent introduces a non-magnetic material (intermediary substance) with relative initial permeability equal to 1 as a mediator between the ferrite magnetic core and the winding. This intermediary fills the air gap and prevents magnetic flux diffusion toward the window, thereby eliminating eddy current loss in the winding while maintaining the energy storage function of the air gap. The intermediary substance acts as a buffer that redirects magnetic flux back into the core rather than allowing it to diffuse into the winding area.
2Loss of energy
If leeds wire with small diameter is used to form the winding, then eddy current loss is reduced, but the window filling rate is low and fabrication is time consuming
Solution Approach 1:
Instead of changing the winding structure to reduce losses, the patent introduces a non-magnetic intermediary material in the air gap that eliminates the root cause of eddy current loss (magnetic flux diffusion). This allows the use of conventional PCB windings with high filling rates and efficient fabrication processes, while still achieving minimal energy loss. The intermediary substance solves the loss problem without compromising productivity.
3Loss of energy
If multiple distributed air gaps are cut on the ferrite magnetic core, then the effect of the air gap is reduced, but the manufacturing process becomes complex and time consuming
Solution Approach 1:
The patent extracts the air gap function from the ferrite core by introducing a separate non-magnetic intermediary material. Instead of cutting multiple distributed air gaps into the core (which complicates manufacturing), the intermediary material is placed in the air gap region, performing the flux containment function externally. This separates the energy storage function (air gap) from the magnetic flux guidance function (ferrite core), simplifying manufacturing while achieving the desired loss reduction.
4Loss of energy
If the winding is arranged far away from the air gap, then eddy current loss is reduced, but the volume of the magnetic component increases
Solution Approach 1:
The non-magnetic intermediary material acts as a protective barrier between the air gap and the winding, allowing the winding to be positioned close to the air gap without suffering from eddy current losses. The intermediary redirects magnetic flux away from the winding area, enabling compact design with minimal volume while maintaining low energy loss. This mediator allows close proximity arrangement without the harmful effects of flux diffusion.
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 design significantly reduces eddy current losses caused by air gaps without increasing the magnetic component's volume, maintaining or even decreasing its size, and enhances power density by ensuring magnetic flux is distributed evenly, minimizing losses to skin and proximity effects.
Implementation Method 1
the magnetic flux may diffuse toward inside of the window W when the magnetic flux passes through the air gap
Implementation Method 2
a medium having a relative initial permeability equal to 1 is disposed at at least one side of the at least three core columns
Implementation Method 3
Under a high-frequency eddy current effect, not only a skin effect and proximity effect loss of the winding coil may significantly increase, but also a large eddy current loss may be generated by the magnetic flux diffusing in the vicinity of the air gap
Implementation Method 4
a skin effect and proximity effect loss of the winding coil may significantly increase
Implementation Method 5
a skin effect and proximity effect loss of the winding coil may significantly increase
Data Source
AI summary
A magnetic component and a transformer are provided by the present disclosure. The magnetic component includes: at least three core columns; and a winding wound around at least one of the at least three core columns; wherein a medium having a relative initial permeability equal to 1 is disposed on at least one side of the at least three core columns. In the present disclosure, a conventional magnetic cover board with a high relative initial permeability is replaced by a medium with a relative initial permeability (ur) satisfied ur=1, such as air or a cover board.