Multi-Segment Ferrite Antenna With Interlocking Cores
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Solution Overview
Problem
Current ferrite antennas face challenges in achieving optimal length and thickness due to difficulties in producing small, long ferrite cores and the need for sophisticated winding machines, leading to high labor and manufacturing costs, as well as fragility and torsion issues with monolith ferrite cores.
Innovation Solution
A multi-segment antenna design comprising interlocking antenna segments with a ferrite magnetic core and coil carrier, where the magnetic core and coil carrier extend beyond the wire coil at one end and the coil carrier and wire coil extend beyond the magnetic core at the other, allowing for efficient assembly and reduced manufacturing costs, using ferrite materials for enhanced electromagnetic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a monolith ferrite core is used for long antennas, then antenna length can be increased, but the core becomes fragile and prone to torsion and damage during handling and coil winding
Solution Approach 1:
The ferrite core is divided into multiple separate core segments that can be handled and assembled individually. Each segment is shorter and more robust, avoiding the fragility issues of long monolith cores. The segments are arranged in sequence to form the complete antenna core structure, with coils wound around each segment separately.
2Reliability
If direct coil winding on the ferrite core is performed, then antenna efficiency is improved, but sophisticated winding machines with synchronized drivers are required, increasing manufacturing complexity and cost
Solution Approach 1:
The antenna is divided into multiple segments, each with its own coil wound around individual core segments. This allows each coil to be wound separately using simpler, more robust winding machines without requiring synchronized multi-axis control. The segments are then assembled in sequence to form the complete antenna.
Solution Approach 2:
A coil carrier structure is introduced as an intermediary component that holds the coil in the correct position relative to the core segments. The coil carrier simplifies the winding process by providing a stable support structure, eliminating the need for complex synchronized winding machines while maintaining proper coil positioning for efficient electromagnetic coupling.
3Ease of manufacture
If multiple core segments are used, then handling and coil winding become easier, but the assembly process becomes more complex requiring precise alignment of segments
Solution Approach 1:
The core segments are designed with asymmetric features including protrusions and recesses that provide self-aligning capabilities during assembly. The protrusion on one segment fits into the recess of the adjacent segment, ensuring precise alignment without requiring complex alignment procedures or specialized assembly equipment.
Solution Approach 2:
The core segments are designed to nest together in sequence, with each segment fitting into the structure formed by the previous segment. This nested arrangement simplifies assembly by providing natural alignment paths and reducing the need for complex positioning mechanisms.
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 design enables cost-effective production of long ferrite antennas with improved efficiency and reduced risk of core damage, allowing for reliable connection of segments into a single, efficient antenna, utilizing ferrite materials for better electromagnetic performance.
Implementation Method 1
inductive assembly components and, especially, ferrite antennas
Data Source
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AI summary
The antenna segment (10, 10') comprises a coil carrier (14, 14') with a first end section (18, 18') and a second end section (20, 20'). Furthermore the antenna segment (10, 10') comprises a wire coil (16, 16') which is arranged around the coil carrier (14, 14') and a magnetic core (12, 12') arranged in the coil carrier (14, 14'), wherein the magnetic core (12, 12') and the wire coil (16, 16') are arranged such that in the first end section (18, 18') the magnetic core (12, 12') and the coil carrier (14, 14') extend beyond the wire coil (16, 16') and in the second end section (20, 20') the coil carrier (14, 14') and the wire coil (16, 16') extend beyond the magnetic core (12, 12'). The multi-segment antenna (100) comprises at least two antenna segments (10, 10'), wherein the at least two antenna segments (10, 10') are arranged in a row such that the first end section (18, 18') of a respective subsequent antenna segment (10') and the second end section (20, 20') of a respective previous antenna segment (10) of joining antenna segments (10, 10') mechanically interlock.