Tape-Wound Ring Core With Lateral Flux Guide for Air Gap Control
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Solution Overview
Problem
Existing ring core assemblies used in filter chokes, such as common-mode chokes and differential-mode chokes, exhibit unsatisfactory magnetic properties due to magnetic saturation issues and micro air gaps between tape layers, leading to degraded performance.
Innovation Solution
A ring core assembly design that incorporates a flux guide piece made of ferromagnetic material, arranged laterally on the tape-wound ring core to contact the narrow sides of multiple tape layers, thereby reducing magnetic resistance and preventing increased air gaps due to magnetic saturation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ferromagnetic crosspiece is inserted into the central opening of the ring core to guide magnetic flux, then magnetic flux guidance is improved, but magnetic saturation occurs leading to increased air gaps and degraded performance
Solution Approach 1:
The flux guide piece is positioned laterally on the outer circumference of the ring core rather than in the central opening, changing the spatial dimension of flux guidance from internal to external. This dimensional change allows the flux guide to contact narrow sides of multiple tape layers simultaneously, providing stable magnetic flux guidance without causing magnetic saturation in the same location as traditional designs.
2Loss of energy
If magnetic saturation occurs in the ring core, then magnetic resistance increases, but air gaps between tape layers expand leading to further increased magnetic resistance and performance degradation
Solution Approach 1:
The flux guide piece acts as an intermediary element that provides a dedicated magnetic flux path through its lateral contact with multiple tape layers. By introducing this intermediary structure, magnetic flux is guided through the flux guide piece rather than forcing saturation in the existing core structure, thereby preventing the expansion of air gaps and the associated increase in magnetic resistance.
3Reliability
If a traditional ferromagnetic crosspiece is used in the central opening, then magnetic flux guidance is provided, but the structure is complex and performance is unsatisfactory
Solution Approach 1:
The invention extracts the flux guidance function from the central opening location and relocates it to the outer circumference of the ring core. By taking out the flux guide piece from the traditional internal position and placing it laterally on the outer surface, the design simplifies the overall structure while maintaining effective magnetic flux guidance, thereby reducing device complexity without sacrificing magnetic properties.
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 proposed design enhances the magnetic properties of the ring core assembly by reducing eddy currents and maintaining magnetic flux, thereby improving the performance of filter chokes, especially in high-frequency interference scenarios.
Implementation Method 1
at least one flux guide piece made of ferromagnetic material... arranged laterally on the tape-wound ring core such that it (mechanically) contacts the narrow sides of a plurality of tape layers
Implementation Method 2
The proposed design enhances the magnetic properties of the ring core assembly by reducing eddy currents and maintaining magnetic flux
Data Source
AI summary
An embodiment relates to a ring core assembly. The ring core assembly includes a ring core wound from a ferromagnetic tape and at least one flux guide piece. The at least one flux guide piece is arranged laterally on the ring core so as to (mechanically) contact narrow sides of a plurality of tape layers of the ring core.