Planar Magnetic Assembly With Segmented Air Gaps
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Solution Overview
Problem
Current magnetic assemblies with a single air gap suffer from high magnetic loss and increased energy loss due to excessive spacing, making them inefficient and bulky, which is a challenge in developing thin-type magnetic elements for light electrical equipment.
Innovation Solution
A magnetic assembly design featuring multiple pillars with controlled air gaps between the pillars and magnetic cores, allowing for efficient magnetic flux distribution and reduced leakage inductance, achieved by stacking circuit boards with through holes and corresponding pillars to create internal spaces with uniform or varied air gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single air gap is formed between the central pillars of two magnetic cores to prevent magnetic saturation, then magnetic saturation is prevented, but the spacing becomes too large causing higher magnetic loss and increased energy loss
Solution Approach 1:
The patent divides the single air gap into multiple air gaps by introducing intermediate pillars between the central pillars of the two magnetic cores. This segmentation reduces the spacing of each individual air gap while maintaining the overall gap structure, thereby preventing magnetic saturation and reducing magnetic loss simultaneously
Solution Approach 2:
The patent introduces intermediate pillars as mediators between the two magnetic cores. These intermediate pillars create multiple smaller air gaps that distribute the magnetic flux more evenly, preventing magnetic saturation while reducing the spacing-related magnetic loss
2Power
If a winding set with coil wound on winding frame is used in magnetic element, then electromagnetic induction function is achieved, but the device becomes bulky and cannot achieve light and thin type
Solution Approach 1:
The patent merges the magnetic core structure with the winding support function by integrating the winding frame into the magnetic core assembly. The circuit board is directly mounted on the magnetic core, eliminating the need for separate winding frames and reducing overall device volume
Solution Approach 2:
The patent transitions from traditional three-dimensional winding structures to a planar circuit board configuration. The windings are arranged on a two-dimensional circuit board that is mounted on the magnetic core, reducing the vertical height and achieving a thin-type magnetic element
3Reliability
If the spacing of air gap is increased to prevent magnetic saturation, then magnetic saturation is prevented, but leakage inductance increases and efficiency decreases
Solution Approach 1:
The patent segments the air gap into multiple smaller gaps using intermediate pillars. This segmentation maintains adequate spacing for magnetic saturation prevention while reducing the overall leakage inductance by distributing the magnetic flux across multiple smaller gaps, thereby improving efficiency
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 enhances efficiency, reduces magnetic loss, and achieves a thin-type magnetic assembly with low leakage inductance, addressing the need for compact and high-performance magnetic components.
Implementation Method 1
Today's electronic products often use various magnetic assemblies, such as transformers, inductance elements, etc., to meet the required circuit design by the principle of electromagnetic induction
Implementation Method 2
An existing magnetic element uses a single air gap formed between the central pillars of two magnetic cores to prevent magnetic saturation
Implementation Method 3
However, if the spacing of the single air gap is too large, it will cause higher magnetic loss, resulting in increased energy loss
Data Source
AI summary
A magnetic assembly includes a first magnetic core, a second magnetic core, at least one circuit board, and multiple pillars. The second magnetic core and the first magnetic core are assembled with each other to define an internal space. The circuit board is disposed in the internal space. The circuit board has multiple through holes separated from each other. The pillars are located in the internal space and respectively correspond to the through holes passing through the circuit board, and multiple air gaps are formed between the pillars or between the pillars and at least one of the first magnetic core and the second magnetic core.