Magnetic Core Elements with Discrete Gaps via Laminated Green Sheets
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Solution Overview
Problem
The challenge lies in fabricating miniaturized magnetic core elements with discretely distributed gaps, which require uniform gap widths, as existing methods struggle to maintain parallel gaps and minimize energy loss due to magnetic flux distribution.
Innovation Solution
The method involves preparing magnetic and non-magnetic green sheets, alternately laminating them, and subjecting them to sintering or curing processes to form magnetic core elements with discretely distributed gaps, using techniques such as diamond wire sawing or embedding ashable patterns to create cavities filled with adhesive, ensuring precise gap formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a relatively large gap is divided into multiple discretely distributed gaps, then magnetic flux distribution is reduced and energy loss is minimized, but manufacturing precision and uniformity of gap width become more difficult to achieve
Solution Approach 1:
The patent divides a single large gap into multiple smaller discretely distributed gaps along the magnetic core. This segmentation reduces magnetic flux distribution outside the gaps, thereby minimizing energy loss and inductance shift while maintaining the beneficial effects of gapping.
Solution Approach 2:
The patent introduces non-magnetic green sheets as intermediary materials between magnetic green sheets during lamination. These non-magnetic sheets serve as spacers that define and maintain uniform gap widths, ensuring precise gap formation while enabling the discrete gap configuration needed for reduced energy loss.
2Loss of energy
If miniaturized magnetic core elements with multiple discretely distributed gaps are fabricated, then energy loss is reduced, but the complexity of maintaining parallel gaps with highly uniform gap width increases
Solution Approach 1:
The patent combines multiple magnetic green sheets with non-magnetic green sheets into a single laminated structure before sintering. This merging of layers simplifies the manufacturing process by establishing all gap positions and dimensions during the lamination stage, rather than requiring complex post-processing to create multiple discrete gaps.
Solution Approach 2:
The patent performs gap formation during the lamination stage by inserting non-magnetic green sheets between magnetic green sheets before sintering. This preliminary action establishes uniform gap widths and parallel alignment early in the manufacturing process, avoiding the need for complex post-sintering operations to create discrete gaps.
3Manufacturing precision
If green sheets are alternately laminated and sintered to form discrete gaps, then uniform gap width is achieved, but the number of manufacturing steps increases
Solution Approach 1:
The patent uses composite green sheet structures combining magnetic and non-magnetic materials that are laminated together and sintered as a single unit. This approach achieves precise uniform gap widths through the layered composite structure while maintaining manufacturing efficiency by completing gap formation during the single sintering cycle rather than requiring additional processing steps.
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 approach enables the production of miniaturized magnetic core elements with reduced and uniform gap widths, minimizing energy loss and maintaining magnetic flux directionality, thus enhancing the performance of magnetic components like inductors and transformers.
Implementation Method 1
sintering the individual bodies, thereby forming a magnetic core element with discretely distributed gaps
Implementation Method 2
the ashable patterns that are interposed between the magnetic green sheets are burned out during the sintering process, thereby forming cavities in the laminate
Implementation Method 3
filling the cavities with an adhesive
Data Source
AI summary
A method of manufacturing magnetic core elements includes preparing a plurality of magnetic green sheets and a plurality of non-magnetic green sheets; along a laminating direction, alternately laminating the plurality of magnetic green sheets and non-magnetic green sheets, thereby forming a green sheet laminate; along the laminating direction, cutting the green sheet laminate into a plurality of bodies with desired dimension; and sintering each of the bodies, thereby forming a plurality of magnetic core elements respectively having a plurality of discretely distributed gaps formed by the non-magnetic green sheets.