Magnetic Core Signal Modulation via Modular Winding
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Solution Overview
Problem
Existing electromagnetic devices, such as transformers and inductors, suffer from inefficiency due to magnetic flux leakage, requiring larger and heavier cores and additional windings to achieve desired energy conversion, leading to increased volume and weight.
Innovation Solution
The design incorporates a magnetic core with elongated openings through which primary and secondary conductor windings pass, allowing for a linear configuration that absorbs and transmits magnetic fields efficiently, reducing copper losses and emissions, and utilizing a modular winding to modulate current signals for enhanced energy transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If magnetic flux is allowed to flow in free space about the electromagnetic device, then the device can operate with simpler core structure, but energy coupling and transfer efficiency decreases
Solution Approach 1:
The patent converts the harmful magnetic flux leakage into beneficial energy transfer by directing the flux through a controlled path that includes both the core and free space. The magnetic flux generator creates flux that flows through the core and then couples into the secondary winding through the strategically positioned opening, transforming what would normally be wasted leakage flux into useful energy transfer.
Solution Approach 2:
The patent introduces an intermediary magnetic flux generator and a specifically positioned opening as a mediator between the primary and secondary windings. This intermediary structure enables magnetic flux to couple from the primary winding through the core and opening to the secondary winding, facilitating efficient energy transfer without requiring direct winding-to-winding coupling.
2Loss of energy
If larger and heavier electromagnetic cores are used to compensate for flux leakage, then energy transfer capability improves, but device volume and weight increase
Solution Approach 1:
The patent changes the magnetic flux flow path parameters by introducing a controlled opening and positioning the secondary winding to utilize both core-conducted flux and free-space coupled flux. This parameter change allows efficient energy transfer with a smaller, lighter core compared to traditional designs that rely solely on core-conducted flux.
Solution Approach 2:
The patent converts the previously harmful flux leakage through free space into a beneficial contribution to energy transfer. By positioning the secondary winding to capture both core-conducted flux and free-space coupled flux, the design achieves high energy transfer capability without requiring excessive core mass.
3Loss of energy
If additional windings are added to improve energy conversion, then energy transfer efficiency improves, but device complexity and volume increase
Solution Approach 1:
The patent introduces an intermediary magnetic flux generator and opening structure that simplifies the winding arrangement. Instead of requiring multiple complex windings to achieve flux coupling, the intermediary opening allows straightforward primary and secondary windings to couple magnetically through the core and free space path.
Solution Approach 2:
The magnetic flux generator serves multiple functions: it establishes the magnetic flux path through the core, enables coupling between primary and secondary windings, and utilizes free-space flux for energy transfer. This multi-functional element reduces the need for additional specialized windings or structures.
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 configuration results in a highly efficient transformer with reduced volume and weight, achieving low copper losses, high efficiency energy transfer, and minimal radiated emissions, with the magnetic field being substantially contained within the core.
Implementation Method 1
A primary electrical current signal flowing through the primary conductor winding generates a magnetic field about the primary conductor winding and a first magnetic flux flow in the core
Implementation Method 2
A first modulation signal flowing through the first modular conductor winding modulates the primary electrical current signal to provide a modulated output current signal at an output of the secondary conductor winding
Data Source
AI summary
A electromagnetic device may include a core in which a magnetic flux is generable and an opening through the core. A primary conductor winding may be received in the opening and extend through the core. A primary electrical current signal flowing through the primary conductor winding generates a magnetic field about the primary conductor winding and a first magnetic flux flow in the core. A secondary conductor winding may be received in the opening and extend through the core. A first modular conductor winding may extend through the opening and encircle a first outer core portion of the core. A first modulation signal flowing through the first modular conductor winding modulates the primary electrical current signal to provide a modulated output current signal at an output of the secondary conductor winding.