Magnetic Core Element with Spherical Joints for Gap-Free Antennae
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Solution Overview
Problem
Conventional magnetic core antennae for motor vehicles face challenges such as deformation-induced stress, high production costs, complex manufacturing processes, and instability due to mechanical strains and air gaps, particularly in bent or long ferrite core rods, which affect magnetic properties and coverage.
Innovation Solution
A magnetic core element with spherical or cylindrical recesses and protrusions allows for a variably adjustable, gap-free connection of multiple rod-shaped core elements, enhancing mechanical stability and reducing magnetic leakage, enabling the construction of long, flexible rod core coils and antennae with small cross-sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If ferrite core rods are made long and bent to increase antenna coverage, then the coverage area is improved, but the core becomes prone to breakage and mechanical strain
Solution Approach 1:
The patent divides the long ferrite core rod into multiple shorter core elements (first core element, second core element, etc.) that can be connected together. This segmentation allows each individual core element to maintain its mechanical strength while the assembled structure achieves the required length and coverage area for the antenna application.
Solution Approach 2:
The patent uses spherical connecting protrusions and recesses that allow core elements to be nested and connected in series. The spherical geometry enables smooth mechanical coupling between elements, distributing mechanical stresses and preventing the breakage that would occur in a single long rigid core.
2Adaptability or versatility
If conventional tape cores are used to accommodate bent door handles, then the antenna can be installed in bent locations, but the core is subjected to stress that alters magnetic properties
Solution Approach 1:
The segmented core design allows each element to be independently positioned and oriented, enabling the antenna to adapt to bent door handle geometries without subjecting any single core element to excessive stress that would alter its magnetic properties.
Solution Approach 2:
The spherical connecting protrusions and recesses create a mechanically flexible joint that allows the core elements to be positioned at various angles, providing the adaptability needed for bent door handle installations while maintaining stable magnetic properties in each rigid core element.
3Strength
If adhesive bonding is used to connect core elements, then the connection strength is improved, but air gaps are created that deteriorate antenna efficiency
Solution Approach 1:
The spherical connecting protrusions and recesses are designed to mate with minimal clearance, creating nearly gap-free magnetic joints when assembled. The curved spherical geometry allows the core elements to be pressed together with uniform contact pressure, eliminating the air gaps that would occur with flat adhesive-bonded surfaces and minimizing magnetic energy loss.
4Volume of moving object
If ferrite core rods are made with small cross-sections to reduce size, then the compactness is improved, but the production becomes subject to restrictive technical rules
Solution Approach 1:
The patent produces multiple small cross-section core elements using standard manufacturing processes, then connects them to achieve the required total length. This avoids the restrictive technical rules that apply to producing single long thin cores, as each short element can be manufactured within standard process capabilities.
Solution Approach 2:
The spherical connecting protrusions and recesses provide a standardized mechanical coupling mechanism that simplifies the assembly of multiple small cross-section elements into a complete antenna core structure, making the overall production process more feasible despite the small individual element dimensions.
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 solution enables the cost-effective production of flexible, long rod core antennae with improved magnetic properties and reduced magnetic leakage, providing greater coverage and stability against deformations and temperature fluctuations, while eliminating the need for adhesive bonding and minimizing air gaps.
Implementation Method 1
A magnetic core element with spherical or cylindrical recesses and protrusions allows for a variably adjustable, gap-free connection of multiple rod-shaped core elements, enhancing mechanical stability and reducing magnetic leakage
Data Source
AI summary
A rod-shaped magnetic core element, having a first end with a spherical or cylindrical recess or a spherical or cylindrical connecting protrusion, and a second end with a spherical or cylindrical recess or a spherical or cylindrical connecting protrusion so that a bent connection of at least two magnetic core elements is variably adjustable. Magnetic core elements comprising spherical or cylindrical magnetic core ends of this type allow a nearly gap-free construction with little magnetic leakage due to slightly larger end surfaces in comparison with ferrite rods having beveled plane end section surfaces. The enlarged end surface of the spherical surface advantageously allows a more stable connection of individual magnetic core elements without adhesive bonding. This allows the construction of flexible, multiple-member and inexpensive rod core coils and antennae.