Nested Magnetic Element Structure for Insulation and Surge Stability
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Solution Overview
Problem
Magnetic elements, such as transformers, face challenges in miniaturization due to the need for horizontal spacing of coils to maintain insulation distances, which increases their planar area and makes them vulnerable to surges when resin injection ports are positioned in critical areas.
Innovation Solution
A magnetic element design with a core unit, first and second coil units, and molding parts on the outer surface of the second coil unit, featuring recesses and resin injection ports strategically placed in non-core areas to enhance insulation and reduce surge vulnerability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coils are disposed horizontally to maintain insulation distance, then insulation is improved, but planar area increases
Solution Approach 1:
The patent transitions from horizontal coil arrangement to vertical stacking arrangement, utilizing the vertical dimension to achieve insulation while maintaining compact planar footprint. Multiple coil units are stacked vertically with insulation structures between them, converting a 2D horizontal layout into a 3D vertical structure.
Solution Approach 2:
The patent employs nested bobbins where inner bobbins are placed within outer bobbins, creating a compact vertical stack. The first bobbin is nested within the second bobbin, and third and fourth bobbins are nested within the fifth bobbin, allowing multiple coils to occupy minimal planar space while maintaining insulation distances.
2Reliability
If molding part is formed with injection port in critical area, then insulation is improved, but surge vulnerability increases
Solution Approach 1:
The patent applies different structural characteristics to different regions of the molding part. Critical areas where surges may occur are designed with recesses to prevent resin injection ports from being positioned there, while non-critical areas contain the injection ports. This localized differentiation of structural quality resolves the contradiction between insulation and surge resistance.
Solution Approach 2:
The patent extracts the injection port positioning from critical surge-prone areas by creating recesses in those regions. The injection ports are taken out and relocated to safe zones on the outer surfaces of bobbins, separating the insulation function from surge vulnerability.
3Area of stationary object
If multiple coils are stacked vertically to reduce planar area, then miniaturization is improved, but insulation distance may be compromised
Solution Approach 1:
The patent introduces insulation structures as intermediary elements between vertically stacked coil units. These insulation structures include insulation sheets or insulating fillers positioned between adjacent bobbins, acting as mediators that maintain required insulation distances while allowing vertical stacking for miniaturization.
Solution Approach 2:
The patent uses composite construction with different materials for different functions: conductive materials for coils, insulating materials for bobbin bodies, and specialized insulation fillers or sheets between coils. The molding part combines resin material with embedded insulation structures, creating a composite structure that achieves both compact size and adequate insulation.
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 achieves robustness against surges while allowing for miniaturization by optimizing insulation and reducing planar area, improving efficiency and surge stability.
Implementation Method 1
a core unit including an upper core and a lower core, a first coil unit and a second coil unit, each being at least partially accommodated between the upper core and the lower core
Implementation Method 2
a molding part disposed on an outer surface of the second coil unit
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
Abstract: A magnetic element according to an embodiment comprises: a core part comprising an upper core and a lower core; a first coil part and a second coil part; and a molding part disposed on the outer surface of the second coil part. The first coil part comprises: a first bobbin having a first hollow portion through which the central leg of the core part passes, the first bobbin being at least partially accommodated in the core part; a first coil disposed in a first accommodation space of the first bobbin; and a first pin connected to the first coil. The second coil part comprises: a second bobbin having a second hollow portion in which the first bobbin is at least partially accommodated, the second bobbin being disposed outside the first bobbin; a second coil disposed in a second accommodation space of the second bobbin; and a second pin connected to the second coil. The second bobbin comprises: a core region that overlaps the core part in the vertical direction; a non-core region that does not overlap the core part in the vertical direction; and a groove formed in the non-core region.