Magnetic Element with Intermediate Core for High-Density Mounting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge is to reduce the layout area of magnetic elements on a mounting substrate for high-density mounting while ensuring secure connection and efficient manufacturing, as existing configurations require significant space and intervals between elements.
Innovation Solution
A magnetic element configuration using a first and second core with flange portions and an intermediate core, forming a closed magnetic circuit, where the cross-sectional areas of the winding cores and intermediate core are optimized to reduce layout area and facilitate high-density mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple inductance elements are disposed on a mounting substrate, then the functional requirements are met, but the mounting substrate becomes large due to the layout area requirement
Solution Approach 1:
The patent combines multiple inductance elements into a single integrated magnetic element structure. The first and second inductance elements share common magnetic paths through the first and second common magnetic paths, allowing multiple functional units to occupy a reduced layout area while maintaining individual electrical characteristics.
Solution Approach 2:
The magnetic element structure serves multiple functions simultaneously: it provides separate inductance paths for multiple elements while sharing common magnetic flux paths, achieves high-density mounting capability, and maintains electrical isolation between elements through the insulating layer while reducing the overall footprint on the mounting substrate.
2Reliability
If mounting elements are kept at appropriate intervals to prevent damages during mounting work, then element reliability is maintained, but the layout area of inductance elements needs to be further reduced for high density mounting
Solution Approach 1:
The patent merges multiple inductance elements into a single integrated structure where the first and second inductance elements share common magnetic paths and are mounted together as one unit. This eliminates the need for spacing intervals between separate elements while maintaining their individual functionality and reliability.
Solution Approach 2:
The structure nests the first and second inductance elements within a shared magnetic circuit framework. The inductance elements are positioned adjacent to each other with their winding cores aligned, sharing common magnetic paths, which allows them to be mounted in close proximity without requiring protective spacing intervals.
3Area of stationary object
If a common core is used to flow magnetic fluxes from multiple magnetic elements, then layout area is reduced, but the connection security between cores must be ensured
Solution Approach 1:
The patent merges multiple magnetic elements into a unified magnetic circuit where the first and second inductance elements share common magnetic paths. The winding cores of both elements are integrally connected to the first and second common magnetic paths, ensuring secure magnetic flux flow while reducing layout area.
Solution Approach 2:
The patent employs curved or rounded corner designs in the magnetic core structure, particularly at the interfaces between winding cores and common magnetic paths. This curvature design ensures smooth magnetic flux transitions and secure mechanical connections, preventing flux leakage and maintaining connection integrity.
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 reduces the layout area of magnetic elements, enables secure connection, and lowers manufacturing costs by using a common core to manage magnetic flux, allowing for efficient high-density mounting without increasing the size of the inductance element.
Implementation Method 1
an intermediate core to form a closed magnetic circuit which is disposed between the first core and the second core in a manner being integrally connected with the first core and the second core
Implementation Method 2
a first core and a second core each of which has a winding core provided with a flange portion
Data Source
AI summary
A magnetic element including a first core and a second core each of which has a winding core provided with a flange portion having a flange surface at least at one end thereof; and an intermediate core to form a closed magnetic circuit which is disposed between said first core and said second core in a manner being integrally connected with said first core and said second core.