Octagonal Magnetic Core Structure for Wire Stress and Terminal Alignment
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Solution Overview
Problem
Traditional rectangular magnetic cores cause stress on copper wires, leading to poor withstand voltage and electrical performance due to bending issues, misalignment of metal terminals, and a risk of short circuits, exacerbated by the lack of positioning features and physical barriers to prevent adhesive overflow.
Innovation Solution
An octagonal magnetic core with flange portions and inclined surfaces reduces mechanical stress on copper wires, improves winding consistency, and incorporates bosses and concave faces to assist terminal electrode alignment and prevent short circuits, while the design of the flange portions aids in maintaining proper positioning and preventing adhesive overflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a rectangular magnetic core is used, then the manufacturing is simple, but the copper wire experiences large stress at right-angle corners causing poor withstand voltage
Solution Approach 1:
The patent applies curvature by transitioning from rectangular corners to rounded corners with a specified radius (R1). This curvature eliminates the sharp right-angle corners that cause stress concentration, allowing copper wire to bend smoothly without insulating layer damage, thereby improving withstand voltage performance while maintaining manufacturing feasibility
2Device complexity
If a rectangular magnetic core is used, then the structure is simple, but the copper wire cannot fully fit the core causing poor winding consistency
Solution Approach 1:
The rounded corners with radius R1 enable the copper wire to conform to the magnetic core surface without air gaps. The curved transition allows uniform wire wrapping around corners, eliminating the fitting problems associated with sharp rectangular corners and improving winding consistency
3Ease of manufacture
If metal terminals are assembled using adhesive agents, then the assembly process is simple, but the adhesive may overflow to undesired positions
Solution Approach 1:
The patent incorporates positioning protrusions and positioning grooves before the adhesive application step. These pre-designed mechanical positioning features constrain the metal terminals to correct positions, preventing adhesive overflow by ensuring proper alignment before the adhesive is applied and cured
4Stability of the object's composition
If clamps are used to hold metal terminals during assembly, then the terminals are fixed, but misalignment risk remains due to dimensional errors and vibration
Solution Approach 1:
The patent implements self-positioning through the interaction between positioning protrusions on the magnetic core and positioning grooves on the metal terminals. This self-aligning mechanism eliminates reliance on external clamps and their associated dimensional errors, allowing the components to automatically find their correct relative positions and preventing misalignment even during vibration and transportation
5Device complexity
If the magnetic core has no positioning features, then the structure is simple, but the metal terminals cannot be accurately positioned
Solution Approach 1:
The patent divides the magnetic core structure into functional segments: the positioning protrusions are distinct geometric features integrated into the core body. These segmented positioning features provide precise location references for metal terminals without requiring complex external positioning systems, achieving accurate positioning through simple geometric elements
Data Source
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AI summary
A magnetic core includes a winding core portion and two flange portions. The winding core portion is an octagonal cylinder. Two flange portions are respectively provided to two ends of the octagonal cylinder. Each of two flange portions has a top surface. One end of each of plural winding wires is connected to the top surface of one of two flange portions, and the other end of each of the winding wires is connected to the top surface of the other one of two flange portions. The octagonal cylinder has a first lateral surface and a second lateral surface adjacent to each other. The first lateral surface of the octagonal cylinder is parallel to the top surface of each of two flange portions. The area of the first lateral surface of the octagonal cylinder is less than the area of the second lateral surface of the octagonal cylinder.