Segmented Charging Coil Core for Hand Tool Energy Transmission
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Solution Overview
Problem
Existing hand tool devices with charging coils lack protection against mechanical stress, such as impacts, and face inefficiencies in energy transmission due to material limitations and design constraints.
Innovation Solution
The hand tool device incorporates a movable coil core with multiple segments made of ferromagnetic or ceramic materials, separated by a separating element to minimize magnetic flux influence and enhance protection, along with a conductor holding unit for stable fixing and efficient energy transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a one-piece coil core is used, then the structural integrity is high, but the device is vulnerable to mechanical damage from impacts
Solution Approach 1:
The coil core is divided into multiple segments that can move relative to each other during impacts. This segmentation allows the core to absorb mechanical stress through relative movement between segments, preventing the catastrophic failure that would occur in a rigid one-piece core while maintaining structural integrity during normal operation.
2Use of energy by moving object
If the coil core is made of ferromagnetic material, then the magnetic field conduction is improved, but the energy losses due to eddy currents increase
Solution Approach 1:
The ferromagnetic coil core is segmented into multiple electrically isolated sections. This segmentation interrupts the paths for eddy currents while maintaining the magnetic field conduction capability of the ferromagnetic material, thereby reducing energy losses due to eddy currents while preserving magnetic efficiency.
Solution Approach 2:
The invention uses composite construction where ferromagnetic segments are combined with electrically insulating materials at the segment interfaces. This composite approach maintains the beneficial magnetic properties of ferromagnetic materials while preventing eddy current losses through the insulating barriers between segments.
3Reliability
If the coil core segments are separated by a large distance, then the protection against mechanical damage is improved, but the magnetic flux influence between segments increases
Solution Approach 1:
The core segments are designed with controlled spacing that allows sufficient movement range for impact protection while maintaining close enough proximity to minimize magnetic flux disruption. The segmentation enables dynamic adjustment of segment positions to balance mechanical protection needs with magnetic field continuity.
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 provides a robust and efficient energy transmission system that is protected against mechanical damage, reduces energy losses, and allows for easier assembly and manufacturing of the coil core segments.
Implementation Method 1
A 'coil core' is understood to be, in particular, an element which is provided for conducting a magnetic field of a coil loop of the charging coil to another charging coil
Implementation Method 2
a charging coil which transmits and/or preferably receives energy for charging and/or discharging, in particular, a hand tool battery
Implementation Method 3
The coil core is preferably made of a ferromagnetic material. The coil core is preferably made of a soft magnetic material. In particular, the coil core has a relative permeability greater than 100, preferably greater than 1,000
Implementation Method 4
In particular, the coil core has a relative permeability greater than 100, preferably greater than 1,000, particularly preferably greater than 5,000
Implementation Method 5
In particular, losses due to eddy currents may be minimized
Implementation Method 6
the coil core is made of a ceramic, in particular ferromagnetic, material, which makes it possible to advantageously achieve a particularly high efficiency during energy transmission
Data Source
AI summary
In a hand tool device having at least one charging coil provided for transmitting energy, the charging coil includes a coil core having at least two core segments which are movable relative to each other.