Stacked Magnetic Core Alignment for Lower Core Loss
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Solution Overview
Problem
Existing magnetic core designs face challenges in maintaining precise alignment of end faces during assembly, leading to increased lacing load, deformation, and higher core loss due to positional offsets, and they often fail to simultaneously achieve effective cooling and noise suppression in transformers.
Innovation Solution
A magnetic core configuration with specifically arranged corner areas and parallelepiped parts, where end parts of soft magnetic sheets are bent and stacked to ensure precise alignment and contact, reducing positional offsets and core loss, and incorporating a third part that contacts the inner surfaces of the core to prevent deformation and enhance cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If soft magnetic sheets are bent and stacked with end faces offset in a stepped manner to reduce lacing load, then the lacing load is reduced, but the end faces cannot be reliably aligned and joined, causing deformation and increased core loss
Solution Approach 1:
A positioning protrusion is provided on one soft magnetic sheet and a positioning recess on the other, acting as intermediary elements that guide and constrain the relative positioning of the sheets. This ensures the end faces abut at the same position without requiring high precision stacking, while still reducing lacing load through the stepped configuration.
Solution Approach 2:
The positioning protrusion and recess are provided only at specific local areas of the soft magnetic sheets rather than along the entire edge. This localized positioning feature maintains alignment precision where needed while allowing the overall stepped configuration to reduce lacing load.
2Manufacturing precision
If positioning protrusions and recesses are provided on soft magnetic sheets to improve alignment precision, then the alignment precision is improved, but the device complexity increases
Solution Approach 1:
The positioning feature is segmented into two simple components: a protrusion on one sheet and a corresponding recess on the other. This segmentation allows each component to remain simple in structure while together they achieve precise alignment, avoiding the need for complex integrated positioning mechanisms.
3Volume of moving object
If the magnetic core uses a compact design with bent corner areas, then the core size is reduced, but heat generation increases due to worsened core loss at bent parts
Solution Approach 1:
The positioning protrusion and recess act as intermediary elements that enable precise alignment without requiring excessive overlap or compression, thereby reducing strain on the bent parts and minimizing core loss while maintaining compact dimensions.
Data Source
AI summary
When joining end faces of a plurality of soft magnetic sheets which are superposed in the sheet thickness direction and which are bent at parts forming corner areas of a core, offset of positions of the end faces from the desired positions is suppressed.In a region of a window part comprised of a region inside of a first part 110 and second part 120, a third part 130 with a length in a longitudinal direction (X-axial direction) the same as a length in the X-axial direction of the window part at the position where the third part 130 is arranged is arranged so as to contact the region of the inner circumferential surface between the first corner area 101 and third corner area 103.