Magnetic Element Combining Compression and Injection Molded Bodies
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Solution Overview
Problem
Magnetic elements used in high-frequency, high-current applications face issues with heat generation due to iron loss and poor heat dissipation, particularly in large or complex configurations, where compression molded magnetic bodies excel in thermal conductivity but are costly and difficult to produce, while injection molded bodies are inferior in thermal conductivity and specific heat.
Innovation Solution
A magnetic element combining compression molded and injection molded magnetic bodies, where the compression molded body is split into two halves with a void portion to enhance heat dissipation and is positioned at the inside diameter side of the coil, allowing for improved thermal conductivity and reduced production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If compression molded magnetic body is used, then thermal conductivity and heat dissipation performance are improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The magnetic body is divided into two distinct parts: a compression molded magnetic body (excellent in heat dissipation) and an injection molded magnetic body (good in moldability). This segmentation allows each part to be manufactured using the most suitable method for its specific requirements, reducing overall manufacturing complexity and cost while maintaining superior thermal performance where needed.
Solution Approach 2:
The compression molded magnetic body is strategically positioned at the inside diameter side of the coil where heat generation is most intense and heat dissipation is most difficult. This local quality approach ensures that the superior thermal conductivity is applied precisely where needed, rather than throughout the entire magnetic body, optimizing both thermal performance and manufacturing efficiency.
2Adaptability or versatility
If injection molded magnetic body is used, then moldability and configuration flexibility are improved, but thermal conductivity and heat dissipation performance deteriorate
Solution Approach 1:
The magnetic body is divided into two distinct parts: a compression molded magnetic body (excellent in heat dissipation) and an injection molded magnetic body (good in moldability). This segmentation allows each part to be manufactured using the most suitable method for its specific requirements, reducing overall manufacturing complexity and cost while maintaining superior thermal performance where needed.
Solution Approach 2:
The compression molded magnetic body is strategically positioned at the inside diameter side of the coil where heat generation is most intense and heat dissipation is most difficult. This local quality approach ensures that the superior thermal conductivity is applied precisely where needed, rather than throughout the entire magnetic body, optimizing both thermal performance and manufacturing efficiency.
3Temperature
If compression molded magnetic body is used for large current applications, then heat dissipation is improved, but production equipment size and production cost increase
Solution Approach 1:
The magnetic body is divided into two distinct parts: a compression molded magnetic body (excellent in heat dissipation) and an injection molded magnetic body (good in moldability). This segmentation allows each part to be manufactured using the most suitable method for its specific requirements, reducing overall manufacturing complexity and cost while maintaining superior thermal performance where needed.
Solution Approach 2:
The compression molded magnetic body is strategically positioned at the inside diameter side of the coil where heat generation is most intense and heat dissipation is most difficult. This local quality approach ensures that the superior thermal conductivity is applied precisely where needed, rather than throughout the entire magnetic body, optimizing both thermal performance and manufacturing efficiency.
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 effectively reduces heat generation and improves heat dissipation performance, allowing for more efficient operation of magnetic elements in high-current applications while maintaining cost-effectiveness and design flexibility.
Implementation Method 1
the compression molded magnetic body is disposed at the inside diameter side of the coil in a state of being in contact with the coil, thereby the magnetic element is effective in restraining heat generation
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(b)
Figure 3(a)~3(b)
AI summary
The present invention provides a magnetic element in which iron loss-caused heat generation is restrained and which can be produced with a high productivity. The magnetic element has a magnetic body which allows a magnetic flux generated by a coil (4) to pass therethrough. The magnetic body is a combined body formed by combining two halves, of the magnetic body composed of the compression molded and injection molded bodies, obtained by bisection made in an axial direction of the coil with each other. A compression molded magnetic body (2) is disposed at a portion generating iron loss-caused heat to a high extent or a portion inferior in heat dissipation performance. An injection molded magnetic body (3) is disposed at a portion other than the portion where the compression molded magnetic body is disposed. The compression molded and injection molded magnetic bodies are combined with each other. The compression molded magnetic body is exposed to a surface of the magnetic body composed of the compression molded and injection molded bodies.