Octagonal Magnetic Core Structure for Reliable Coil Winding
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Solution Overview
Problem
Traditional rectangular magnetic cores lead to high stress on copper wires, poor winding consistency, and increased risk of misalignment and short circuits due to lack of positioning features, resulting in inadequate withstand voltage and product defects.
Innovation Solution
The magnetic core is redesigned with an octagonal winding core and flange portions, featuring inclined surfaces and bosses/concave faces to reduce mechanical stress, improve winding consistency, and prevent misalignment, along with terminal electrodes for precise assembly and physical isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a rectangular magnetic core is used, then the structure is simple and easy to manufacture, but the copper wire experiences high stress at right-angle corners causing insulating layer damage and poor withstand voltage
Solution Approach 1:
The patent applies curvature by replacing the rectangular cross-section with an octagonal cross-section. This introduces rounded corners and inclined surfaces that eliminate the sharp right-angle corners, thereby reducing stress concentration on the copper wire insulating layer while maintaining manufacturing feasibility through standard molding processes.
2Ease of manufacture
If a rectangular magnetic core is used, then the structure is simple, but the copper wire cannot fully fit the magnetic core resulting in large air gaps and poor winding consistency
Solution Approach 1:
The octagonal cross-section with curved transitions allows the copper wire to follow the contour more closely, eliminating large air gaps between the wire and magnetic core that occur with rectangular corners, thereby improving winding consistency and electrical performance.
Solution Approach 2:
The patent applies different surface characteristics to different regions of the magnetic core. The inclined surfaces and rounded corners provide localized geometric features that optimize wire contact and fit, while the overall octagonal structure maintains simplicity for manufacturing.
3Ease of manufacture
If metal terminals are assembled to the magnetic core without positioning features, then the assembly process is simple, but misalignment occurs during transportation and assembly leading to soldering defects and short circuits
Solution Approach 1:
The positioning protrusions and positioning grooves are pre-formed on the magnetic core during manufacturing. This preliminary action establishes precise reference features before the terminal assembly process, enabling accurate positioning and preventing misalignment during subsequent transportation and soldering operations.
Solution Approach 2:
The positioning protrusions and grooves act as intermediary features that mediate between the magnetic core and metal terminals. These features provide mechanical guidance and constraint, ensuring accurate alignment without requiring complex assembly procedures or additional positioning devices.
4Strength
If adhesive agent is used to fix metal terminals on the magnetic core, then the terminals are securely fixed, but the adhesive agent overflows to undesired positions causing defects
Solution Approach 1:
The positioning protrusions and positioning grooves are pre-formed to establish precise boundaries before adhesive application. This preliminary geometric constraint limits the spread of adhesive agent to only the intended bonding areas, preventing overflow to undesired positions while maintaining secure fixation strength.
Data Source
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.