Segmented Core Coil Structure for Leakage Flux Suppression
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Solution Overview
Problem
Conventional coil apparatuses with limited gaps in magnetic paths fail to adequately suppress leakage flux, leading to increased loss in the coil due to eddy currents.
Innovation Solution
A coil apparatus with a first core component and a second core component comprising a plurality of core segments arranged in a row with gaps, forming a magnetic path to reduce leakage flux and enhance inductance accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a limited number of gaps (up to two) are provided in the magnetic path using conventional techniques, then the device complexity is reduced and ease of manufacture is improved, but leakage flux is insufficiently suppressed resulting in increased coil loss
Solution Approach 1:
The second core component is divided into multiple core segments (three or more) arranged in a row with gaps between them. This segmentation allows the magnetic path to include multiple gaps that distribute and suppress leakage flux, thereby reducing coil loss while maintaining manageable device complexity through modular construction
2Measurement precision
If gap length is adjusted by fixing cores with a gap sheet, then gap length adjustment is achieved, but variations in gap sheet dimensions or polishing precision result in variations in inductance value
Solution Approach 1:
The desired gap length is predetermined during the design and manufacturing of the core segments themselves, rather than being adjusted later using gap sheets. The core segments are manufactured with precise dimensions that inherently provide the required gap spacing when assembled, eliminating the need for post-manufacturing adjustment and avoiding inductance variations caused by gap sheet tolerance accumulation
3Measurement precision
If the gap length is increased to adjust inductance, then inductance value is adjusted, but leakage flux increases causing larger eddy currents and increased loss in the coil
Solution Approach 1:
Instead of using a single large gap to adjust inductance, the magnetic path is segmented into multiple smaller gaps distributed across several core segments. This segmentation maintains the required total gap length for inductance adjustment while distributing the magnetic flux across multiple smaller discontinuities, thereby suppressing leakage flux and reducing eddy current losses in the coil
Solution Approach 2:
The core segments are strategically positioned to create localized gaps at specific positions along the magnetic path. This local placement of gaps optimizes the distribution of magnetic flux and minimizes leakage effects at critical locations, allowing inductance adjustment without proportionally increasing overall coil loss
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 solution effectively reduces coil loss by distributing leakage flux and improving inductance accuracy, enhancing the performance and efficiency of the coil apparatus.
Implementation Method 1
a second core component that includes a plurality of core segments arranged in a row with gaps between the core segments, and is connected to the leg to form a magnetic path together with the first core component
Implementation Method 2
a coil; a first core component including a leg around which the coil is wound
Implementation Method 3
When the leakage flux becomes larger, the magnetic flux causes eddy currents to flow in a coil constituting the coil apparatus, increasing loss in the coil
Data Source
AI summary
A coil apparatus includes a coil unit including a coil, a base core that is a first core component, and a core module that is a second core component. The first core component includes a center leg that is a leg around which the coil is wound. The second core component includes a plurality of core segments arranged in a row with gaps between them. The second core component is connected to the leg to form a magnetic path together with the first core component.