Magnetic Core Device Fixation Leg Integration
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Solution Overview
Problem
Existing power converter magnetic core devices face challenges in maintaining fixation during vibrations, impacts, and high temperatures, leading to performance degradation or malfunction, and the use of glue increases manufacturing costs.
Innovation Solution
A magnetic core device with integrally formed fixation legs that extend from the body to securely attach to a housing, eliminating the need for glue and enhancing robustness, using auxiliary fasteners and a positioning module for stable attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional fixation mechanisms (glue, snapping, clipping) are used to attach the magnetic core device to the housing, then the manufacturing cost is reduced or simplified assembly is achieved, but the robustness and reliability of the fixation under vibrations, impacts, and high temperatures deteriorates
Solution Approach 1:
The magnetic core device is segmented into a body and separate fixation legs that extend from the body. The fixation legs are configured to be inserted into corresponding fixation holes in the housing, creating a modular attachment system that combines simple assembly with reliable fixation under adverse conditions.
Solution Approach 2:
The fixation legs are pre-positioned on the magnetic core device body, and the housing is designed with corresponding fixation holes in advance. This preliminary arrangement of fixation elements enables both simple assembly and reliable fixation without requiring complex mechanisms or additional materials like glue.
2Object-affected harmful factors
If heavy magnetic core devices are used to improve electromagnetic shielding performance, then the EMI protection is enhanced, but the fixation robustness under vibrations and impacts deteriorates
Solution Approach 1:
By separating the magnetic core device into a body and fixation legs, the design allows the body to be optimized for electromagnetic shielding (can be heavy) while the fixation legs provide dedicated mechanical attachment functionality. This segmentation enables the heavy device to be securely fixed without compromising fixation robustness.
3Reliability
If multiple fixation mechanisms are used to improve fixation robustness under vibrations and impacts, then the reliability is enhanced, but the manufacturing cost and device complexity increase
Solution Approach 1:
The fixation legs are integrally combined with the magnetic core device body, forming a unified structure. This merging eliminates the need for separate fixation components and mechanisms, achieving reliable fixation under vibrations and impacts while keeping the device simple and manufacturing cost low.
Solution Approach 2:
The fixation legs serve multiple functions: they provide mechanical attachment to the housing, distribute mechanical stresses from vibrations and impacts, and maintain the magnetic core device in its predetermined position. This multi-functionality achieves robust fixation without adding complex mechanisms.
Data Source
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AI summary
The invention concerns a magnetic core device (1) to be used in a power converter (100), comprising at least one fixation leg (7), and a body (51) comprising a magnetic core (3). The at least one fixation leg (7) extends from the body (51), and is configured to firmly fixate the magnetic core device (1) to a target component (110) such as a housing (110) of the power converter (100). The at least one fixation leg (7) and the body (51) are integrally formed as one-piece.