Magnetic Core Structure with Convex Pillars for Air Gap Control
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Solution Overview
Problem
Existing electromagnetic coupling devices face challenges in precisely controlling the size of air gaps between magnetic cores due to the complexity and imprecision of using insulating gaskets and glue, leading to difficulties in maintaining consistent air gap heights.
Innovation Solution
A magnetic core structure with convex structures on the side pillars of one core that abut against the second core, allowing the air gap to be adjusted by the height of the convex structures, eliminating the need for additional glue and simplifying the assembly process, thereby improving precision control of the air gap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an insulating gasket and glue are used to form an air gap between magnetic cores, then the air gap can be created, but the precision control of the air gap size deteriorates due to the complexity of the process and the difficulty in controlling glue thickness
Solution Approach 1:
The patent extracts and removes the insulating gasket and glue from the air gap formation process. Instead of using these additional components, the air gap is directly formed by the magnetic core structure itself, where the end surface of the side pillar abuts against the second magnetic core to create a precise air gap without requiring external insulating materials or adhesive substances.
Solution Approach 2:
The magnetic core structure performs the dual function of providing both the magnetic path and the air gap formation. The side pillar's end surface directly creates the air gap through its own geometric structure, eliminating the need for separate insulating gaskets and glue applications. The structure serves itself to define the air gap precision through its inherent geometry rather than relying on external components.
2Manufacturing precision
If an insulating gasket and glue are used to form an air gap, then the magnetic cores can be separated, but the total height of the air gap becomes difficult to control precisely due to the combined thickness of multiple components
Solution Approach 1:
The patent removes the insulating gasket and glue from the air gap formation system. The air gap height is now determined solely by the geometric dimensions of the magnetic core's side pillar end surface, eliminating the need to sum multiple component thicknesses (gasket + glue) to achieve the desired air gap height.
Solution Approach 2:
The air gap height parameter is directly controlled by modifying the geometric parameters of the magnetic core structure itself, specifically the dimensions of the side pillar's end surface. This allows for direct and precise control of the air gap height through a single parameter (the pillar's end surface dimension) rather than through the combined thickness of multiple layers.
3Strength
If excessive glue is used to bond the insulating gasket, then the components can be securely fixed, but the air gap size becomes inaccurate due to the added glue thickness
Solution Approach 1:
The patent extracts and eliminates the glue from the assembly process. The magnetic core components are bonded or positioned without requiring adhesive substances. The air gap is formed by the direct abutment of the side pillar's end surface against the second magnetic core, completely removing the source of dimensional error that glue thickness would introduce.
Solution Approach 2:
Instead of using glue as an intermediary bonding agent that introduces dimensional uncertainty, the patent uses the magnetic core's own geometric structure (the side pillar's end surface) as the intermediary that directly defines the air gap. This eliminates the need for a separate bonding material that would compromise precision.
Data Source
AI summary
A magnetic core structure and an electromagnetic coupling device are provided by the present application. Wherein the magnetic core structure includes a first magnetic core and a second magnetic core; the first magnetic core includes a main portion and two side pillars fixedly connected to the main portion. Convex structures are set on end surfaces of the two side pillars away from the main portion, respectively; and the convex structures abut against a surface of the second magnetic core after the first magnetic core and the second magnetic core are assembled together, so as to form a gap between the end surfaces of the two side pillars away from the main portion and the surface of the second magnetic core. The magnetic core structure and the electromagnetic coupling device disclosed by the present application can precisely control an air gap between the two magnetic cores.