Magnetic Element Core Segmentation for Coil Access
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Solution Overview
Problem
Conventional magnetic elements with a ring core structure around a drum core face difficulties in pulling out the coil ends for terminal connection due to the ring core's peripheral placement, leading to magnetic saturation and limitations in inductance value and wire thickness.
Innovation Solution
A magnetic element design featuring a wound coil with a center core and planar cores, where a side core forms an open area around the coil, allowing easy extraction of coil ends and preventing magnetic saturation by increasing the side core's cross-sectional area, thus enabling higher inductance values or reduced wire thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a ring core is disposed around the periphery of a drum core, then the magnetic element structure is compact, but the coil ends are difficult to pull out for terminal connection
Solution Approach 1:
The core is divided into a drum core and a ring core positioned at specific locations rather than completely surrounding the coil. This segmentation allows the coil ends to be accessible while maintaining a compact magnetic element structure.
Solution Approach 2:
The ring core is extracted from completely surrounding the coil and repositioned to specific locations. This extraction creates openings that allow easy access to coil ends for terminal connection while maintaining the benefits of the ring core structure.
2Reliability
If the side core cross-sectional area is increased to prevent magnetic saturation, then magnetic saturation is prevented, but the device size increases
Solution Approach 1:
The side core is positioned strategically to provide magnetic flux pathways only where needed. This local quality approach increases the cross-sectional area for magnetic flux in critical areas to prevent saturation, while keeping the overall device size compact by not increasing the core area everywhere.
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
The design allows for easy coil end extraction, prevents magnetic saturation, and increases the number of windings or reduces wire thickness, enhancing inductance value and direct current resistance.
Implementation Method 1
a wound coil (102), a core unit (101) having a center core (105) inserted into an inner periphery of the coil (102)
Data Source
Figure 1~2
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AI summary
To provide a magnetic element the ends of the coil of which can be drawn out from the core easily, is compact, and further, is one in which magnetic saturation does not arise easily. A magnetic element has a core unit provided with a wound coil, a center core 105 inserted into the interior of the inner periphery of the coil, planar cores disposed at both ends of the center core, and a side core disposed between the planar cores and on the outside periphery of the coil. The side core is disposed so as to form an open portion between the two planar cores around the coil, with a recessed portion formed in a surface of the side core facing the coil in which the coil is partially contained.