Magnetic Core Particle Packing for Stable Voltage Resistance
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Solution Overview
Problem
Existing magnetic cores face challenges in achieving high permeability and voltage resistance while maintaining a small variation in voltage resistance.
Innovation Solution
A magnetic core design with a total area ratio of magnetic powder particles between 75% and 90% and large size particles with an average circularity of 0.70 or more, along with a resin content, to enhance permeability and voltage resistance, and control particle shape to minimize resistance variation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the total area ratio of magnetic powder particles is increased to improve permeability, then permeability is improved, but voltage resistance becomes unstable with large variations
Solution Approach 1:
The patent applies parameter changes by precisely controlling the total area ratio of magnetic powder particles within 75-90% and the average circularity of large size particles at 0.70 or more. These specific parameter ranges optimize both permeability and voltage resistance stability, resolving the contradiction between improving permeability and maintaining voltage resistance stability.
Solution Approach 2:
The patent applies local quality by differentiating between large size particles (with circularity ≥0.70) and other particles in the magnetic powder mixture. This local differentiation in particle shape quality allows the large particles to provide stable voltage resistance while the overall mixture achieves high permeability, thus resolving the contradiction.
2Reliability
If large size particles with high circularity are used to improve voltage resistance, then voltage resistance is improved, but device size increases
Solution Approach 1:
The patent optimizes the balance between voltage resistance and device size by controlling the total area ratio of particles at 75-90% and the average circularity of large particles at 0.70 or more. These parameter optimizations ensure high voltage resistance is achieved without excessive device volume increase.
Solution Approach 2:
The patent uses a composite magnetic powder mixture containing both large size particles (with high circularity ≥0.70) and other particles. This composite structure allows the large circular particles to provide voltage resistance stability while the overall composite mixture maintains compact size and high permeability, resolving the contradiction between voltage resistance and device size.
3Volume of moving object
If the magnetic powder density is increased to reduce device size, then device size is reduced, but manufacturing precision becomes difficult to control
Solution Approach 1:
The patent establishes specific parameter ranges (total area ratio: 75-90%, average circularity of large particles: ≥0.70) that define the optimal manufacturing window. These parameter specifications enable precise control during manufacturing while achieving high density and small device size, resolving the contradiction between device miniaturization and manufacturing precision.
Data Source
AI summary
A magnetic core including a magnetic powder. A total area ratio of particles of the magnetic powder in a cross section of the magnetic core is 75% or more and 90% or less. An average circularity of large size particles is 0.70 or more when the large size particles are particles extracted from the particles of the magnetic powder in the cross section of the magnetic core in the order of size from the largest size until a cumulative area ratio of the extracted particles reaches a smallest area ratio exceeding 20% of the total area ratio of the particles of the magnetic powder.