Resin-Housed Magnetic Core With Visual Heat Deterioration Indication
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Solution Overview
Problem
Current noise suppression elements in switching power supplies, particularly those using Co-based amorphous magnetic alloys, face challenges in maintaining magnetic characteristics under high-temperature conditions, making it difficult to determine the degree of deterioration and requiring additional insulation which can lead to dimensional issues and reduced noise suppression effectiveness.
Innovation Solution
A magnetic component with a hollow container made of resin, housing a doughnut-shaped magnetic core, where the resin is colored to facilitate visual determination of discoloration and deterioration, and the container is designed for easy bending to form a lid, ensuring secure housing and reduced weight, using Co-based or Fe-based amorphous alloys with specific compositions for improved magnetic characteristics and heat resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If magnetic alloy (Co-based amorphous or Fe-based amorphous/microcrystals) is used for noise suppression, then noise reduction effect is improved, but insulation requirements increase leading to dimensional variation and manufacturing complexity
Solution Approach 1:
The patent combines the magnetic alloy core with the resin case into a single integrated structure. The resin case serves dual functions as both structural housing and insulating layer, eliminating the need for separate insulation components. This merging approach maintains the excellent noise suppression properties of magnetic alloys while simplifying the overall device structure and reducing manufacturing complexity.
Solution Approach 2:
The patent applies insulation properties locally where needed by using the resin case material itself as the insulating layer. Instead of adding global insulation structures, the resin material is selected to provide necessary electrical insulation at the interface between the conductive magnetic alloy and external components, particularly at winding areas, thereby maintaining dimensional stability without excessive insulation thickness.
2Object-generated harmful factors
If thick cord winding is performed around magnetic component, then electrical insulation is improved, but resistance to stress and dimensional stability worsen due to stress concentration
Solution Approach 1:
The resin case acts as an intermediary layer between the magnetic alloy core and the thick insulation cord. This intermediary structure distributes the stress from the wound cord evenly across the magnetic component surface, preventing stress concentration that would cause dimensional variation. The resin case provides a smooth, uniform surface for cord winding while maintaining electrical insulation properties.
3Reliability
If magnetic component is used in high-temperature environment, then noise suppression function is maintained, but magnetic characteristics deteriorate over time making deterioration detection difficult
Solution Approach 1:
The patent incorporates a color indicator system into the resin case that changes color in response to thermal stress and magnetic property deterioration. This visual indicator allows easy detection of when the magnetic component has been exposed to high temperatures for extended periods, providing a simple method to assess deterioration without complex measurement equipment while the magnetic component continues to provide noise suppression.
4Object-generated harmful factors
If insulating resin case is used to house magnetic alloy, then electrical insulation is improved, but weight and manufacturing complexity increase
Solution Approach 1:
The resin case is designed to perform multiple functions simultaneously: it provides structural housing for the magnetic alloy core, serves as the electrical insulating layer, and acts as the outer protective casing. This multi-functional design eliminates the need for separate insulating components, reducing overall weight while maintaining necessary electrical insulation properties.
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
The solution allows for effective noise suppression while enabling easy determination of magnetic component deterioration through color changes, maintaining magnetic characteristics under high temperatures, and reducing manufacturing complexity and weight by ensuring secure and efficient housing of the magnetic core.
Implementation Method 1
Co-based amorphous is excellent in magnetic characteristics, the noise reduction effect is superior to that of the ferrite beads
Implementation Method 2
maintaining magnetic characteristics under high temperatures
Implementation Method 3
it is necessary to store the magnetic alloy in an insulating resin case or to provide exterior insulation such as epoxy coating
Data Source
AI summary
A magnetic component of an embodiment has a resin-made hollow container that houses a doughnut-shaped magnetic core, and the resin forming the hollow container exhibits a white color to gray color having a chromatic value C of 0 (achromatic) to 2 and a lightness V or 8 or higher as defined by JIS Z8721 “Color specification—Specification according to their three attributes”. The hollow container has an inner wall portion formed to form a hollow portion, an outer wall portion formed to surround the inner wall portion, and a bottom portion provided at one end of each of the inner wall portion and the outer wall portion to close a space between the inner wall portion and the outer wall portion, and houses the doughnut-shaped magnetic core between the inner wall portion and the outer wall portion.