Magnetic Core Gap Structure for Precise Spacing and Heat Distribution
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Solution Overview
Problem
Conventional magnetic cores face challenges in miniaturization and heat management, with existing methods for controlling the size of gaps between outer legs being inaccurate and leading to concentrated heat generation.
Innovation Solution
A magnetic core design featuring outer-leg gap portions filled with spherical fillers in an adhesive, allowing precise control of the external gap size and maintaining the center gap, thereby achieving uniform heat distribution and reduced size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the size of the ferrite core is reduced for miniaturization, then the device size is reduced, but the amount of heat generated increases
Solution Approach 1:
The magnetic core is divided into multiple core parts with gaps formed between center legs and outer legs. This segmentation allows heat to be distributed across multiple regions rather than concentrated in a single area, enabling miniaturization while managing heat generation through spatial distribution of thermal load.
Solution Approach 2:
Different gap configurations are applied to different regions of the core: center gaps between center legs and external gaps between outer legs. This local differentiation optimizes heat dissipation in specific high-heat-generation areas while maintaining overall core compactness, resolving the contradiction between size reduction and heat management.
2Ease of manufacture
If a center gap is formed only between center legs for simplicity, then the manufacturing process is simplified, but heat becomes concentrated in the center legs
Solution Approach 1:
The gap structure is segmented into multiple locations: center gaps between center legs and external gaps between outer legs. This multi-location gap segmentation distributes the heat generation across different regions, preventing heat concentration in center legs while maintaining manufacturing feasibility through standardized gap formation processes.
3Temperature
If an external gap is added between outer legs to distribute heat, then heat distribution is improved, but the control precision of gap size deteriorates
Solution Approach 1:
The gap size parameter is precisely controlled by adjusting the thickness of the adhesive layer used to bond core parts. By changing the adhesive thickness parameter, accurate gap dimensions can be achieved in both center and external gaps, maintaining manufacturing precision while enabling improved heat distribution through multiple gap locations.
Data Source
AI summary
The present invention relates to a magnetic core capable of precisely maintaining the size of a gap, and to a magnetic element comprising same. A magnetic core according to one embodiment comprises: an upper core having at least a first outer leg and a second outer leg; a lower core having at least a third outer leg facing the first outer leg and a fourth outer leg facing the second outer leg; outer leg gap parts disposed between the first outer leg and the third outer leg, and between the second outer leg and the fourth outer leg. The outer leg gap parts may comprise: an adhesive; and a plurality of spherical fillers dispersed in the adhesive.