Magnetic Core Assembly With Flexible Buffering for Edgewise Coils
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Solution Overview
Problem
Existing methods for manufacturing magnetic elements with edgewise coils face issues such as magnetic core offset, low coil filling rate, and thermal expansion-induced cracking, due to the use of metal ties and uneven magnetic core divisions, which reduce production efficiency and inductance.
Innovation Solution
Dividing the magnetic core into two components with flexible materials on their inner surfaces, allowing the components to assemble without additional ties and accommodating thermal expansion, thus improving coil filling rate and inductance while preventing core cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If metal ties with buckles are used to fix the magnetic core parts, then the magnetic core can be assembled, but the buckle occupies filling space of the coil and reduces coil filling rate
Solution Approach 1:
The invention extracts and removes the metal tie and buckle from the magnetic core assembly structure. Instead of using external fastening components, the patent uses adhesive glue to directly bond the magnetic core parts together, eliminating the buckle that would occupy coil filling space and thereby improving coil filling rate while maintaining assembly ease
Solution Approach 2:
The invention merges the function of magnetic core assembly with the adhesive bonding process. The adhesive glue serves both as the bonding agent for assembling magnetic core parts and as a filler material, combining multiple functions into a single material system, thus eliminating the need for separate metal ties and buckles that would reduce coil filling rate
2Ease of manufacture
If metal ties are used to fix the magnetic core parts, then the magnetic core can be assembled, but manual operation is required which reduces production efficiency
Solution Approach 1:
The invention replaces the mechanical fastening system (metal ties with buckles requiring manual operation) with a chemical bonding system (adhesive glue). This substitution enables automated application of the adhesive and automated assembly processes, eliminating manual labor and significantly improving production efficiency while maintaining the assembly function
3Productivity
If the magnetic core is divided into two approximately equal parts and assembled with adhesive glue, then manual operation is reduced, but a gap may be formed at the contact surfaces resulting in decreased inductance
Solution Approach 1:
The invention applies local quality by using a protrusion structure on one magnetic core part that fits into a corresponding recess on the other part. This localized geometric feature ensures precise alignment and contact at the bonding interface, preventing gaps at the contact surfaces and maintaining high inductance while still allowing for automated adhesive application and assembly
4Productivity
If the magnetic core is divided into two approximately equal parts and assembled with adhesive glue, then production efficiency is improved, but the coil cannot be disposed in the breach when assembling, leading to decreased coil filling rate
Solution Approach 1:
The invention applies preliminary action by pre-forming the protrusion and recess structures on the magnetic core parts before assembly. This preliminary geometric configuration ensures that when the parts are bonded with adhesive, the coil can be properly positioned and disposed in the assembly without obstruction, maintaining high coil filling rate while enabling automated production through efficient assembly
5Temperature
If thermal conduction glue is used to pot the magnetic element, then thermal conduction is improved, but thermal expansion of the glue causes deformation and cracking of the magnetic core
Solution Approach 1:
The invention applies beforehand cushioning by incorporating a flexible material layer between the magnetic core parts. This flexible layer acts as a buffer that can accommodate thermal expansion of the thermal conduction glue during operation, absorbing the expansion forces and preventing them from transmitting to and deforming or cracking the magnetic core, thus maintaining both thermal conduction and core integrity
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 enhances coil filling rate, inductance, and production efficiency by buffering thermal expansion forces and eliminating the need for metal ties, facilitating automated production and reducing labor costs.
Implementation Method 1
a flexible material with deformable property is disposed on the inner surface of each component. Therefore, during the operation of the potting magnetic element, when the thermal conduction glue between the coil and the magnetic core expands due to the heating generated by the coil and core, thus dilate the magnetic core, the flexible material can buffer the deformation of the thermal conduction glue and absorb the expansion force from the thermal conduction glue applied to the magnetic core
Implementation Method 2
the thermal conduction glue between the coil and the magnetic core expands due to the heating generated by the coil and core
Implementation Method 3
when the thermal conduction glue between the coil and the magnetic core expands due to the heating generated by the coil and core, thus dilate the magnetic core
Data Source
AI summary
The present disclosure provides a magnetic element and a manufacturing method thereof. The manufacturing method including steps of: (a) dividing a magnetic core into a first component and a second component, wherein the first and second components have two connecting surfaces on the split section respectively, and the first and second components have an inner and an outer surfaces; (b) disposing a flexible material on the inner surfaces of the first and second components respectively; (c) sleeving a coil on the first and second components; (d) connecting the two connecting surfaces of the first component to the two connecting surfaces of the second component to assemble the first and second components; (e) utilizing a thermal conduction glue to pot the magnetic element; and (f) curing and forming the thermal conduction glue after a curing time.