Magnetic Element Air Gap Distribution for Leakage Control
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Solution Overview
Problem
Conventional magnetic elements with single air gaps suffer from high magnetic leakage and energy loss, while multiple air gaps on central posts limit magnetic flux diffusion and working efficiency due to restricted air gap distribution.
Innovation Solution
A manufacturing method that forms a plurality of air gaps uniformly on both central and lateral posts, preventing magnetic saturation and controlling magnetic leakage, and includes an isolating member to redirect leaked flux, allowing for increased winding density without a winding frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single air gap is formed between central posts to prevent magnetic saturation, then magnetic saturation is prevented, but magnetic leakage increases and energy loss increases
Solution Approach 1:
The invention divides the single air gap into multiple air gaps distributed across both central posts and lateral posts. This segmentation allows the magnetic flux to be distributed through multiple paths, preventing saturation while reducing leakage loss by dispersing the magnetic field more effectively throughout the magnetic core structure.
Solution Approach 2:
The invention transitions from a single-dimensional air gap arrangement (only on central posts) to a multi-dimensional distribution by adding air gaps on lateral posts as well. This spatial expansion creates additional magnetic flux paths in different directions, reducing magnetic leakage while maintaining saturation prevention.
2Loss of energy
If multiple air gaps are formed on central post to reduce magnetic leakage, then magnetic flux diffusion is reduced, but the distance between adjacent air gaps decreases and working efficiency improvement is limited
Solution Approach 1:
The invention segments the air gap distribution across multiple locations including both central posts and lateral posts. This creates more uniformly spaced air gaps throughout the magnetic core, maintaining effective magnetic flux dispersion while preserving adequate spacing between gaps to sustain working efficiency.
Solution Approach 2:
By adding lateral posts with air gaps, the invention expands the air gap distribution into additional spatial dimensions. This three-dimensional arrangement increases the effective distance between adjacent air gaps compared to a single central post configuration, thereby improving working efficiency while continuing to reduce magnetic leakage loss.
3Ease of operation
If winding frame is used to fix winding between magnetic cores, then winding is secured, but space is occupied and total number of windings is reduced
Solution Approach 1:
The invention removes the winding frame from the magnetic core structure, extracting this non-essential component. The winding is then directly secured to the magnetic cores through alternative fixation methods, eliminating the space occupation by the winding frame and increasing the available space for additional windings, thereby improving winding utilization ratio.
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 method effectively reduces magnetic leakage and saturation, enhances winding utilization, and improves the overall efficiency of magnetic elements by distributing air gaps across the entire magnetic path and using an external isolating member to manage flux.
Implementation Method 1
forming a block including a central post and two lateral posts with magneto-conductive materials
Implementation Method 2
a plurality of air gaps are formed in the central post and the lateral post... prevents magnetic saturation and controls magnetic leakage loss
Data Source
AI summary
A manufacturing method of a magnetic element includes the following steps: forming a block including a central post and at least one lateral post with magneto-conductive materials; cutting the block along a first plane passing through the central and lateral posts to form a first half body and a second half body; combining the first half body with the second half body to form a first air gap between the central post of the first half body and the central post of the second half body and a second air gap between the lateral post of the first half body and the lateral post of the second half body; and cutting or grinding the combined first half body and second half body along a second plane passing through the central post and the lateral post to form a third half body including the first and second air gaps.