Segmented Magnetic Core Mounting for Thermal Strain Relief
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Solution Overview
Problem
Devices with rotating components, such as gyroscopic sensing modules or LIDAR devices, face issues with power and data transmission due to the use of brittle magnetic cores that can break or chip under thermal strain caused by differences in thermal expansion properties between the core and the mounting structure.
Innovation Solution
A magnetic core is split into sections separated by spaces, allowing each section to move relative to the mounting structure as it expands or contracts, reducing strain and maintaining alignment and functionality across changing thermal conditions, while an intermediate film contains any broken pieces to prevent obstruction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the magnetic core is made as a single solid piece, then the electrical component can be manufactured with simple structure, but the magnetic core is prone to breaking or chipping under thermal strain
Solution Approach 1:
The magnetic core is divided into multiple segments separated by gaps, allowing each segment to expand and contract independently during thermal cycling. This segmentation prevents the buildup of thermal stress that would otherwise cause the solid magnetic core to break or chip, while still maintaining the electrical component's functionality.
2Stability of the object's composition
If the magnetic core is rigidly coupled to the mounting structure, then the assembly is structurally stable, but the magnetic core experiences strain during thermal expansion
Solution Approach 1:
By segmenting the magnetic core and introducing gaps between segments, the structure allows for differential thermal expansion between the magnetic core and mounting structure without transmitting excessive stress to the magnetic core material.
Solution Approach 2:
The design accommodates thermal strain by allowing physical parameters (position of magnetic core segments) to change during thermal cycling, rather than maintaining rigid fixed positions that would generate stress.
3Ease of manufacture
If the magnetic core is made from brittle ferrite material, then the electrical component can be manufactured with simple materials, but the magnetic core is prone to breaking under applied strain
Solution Approach 1:
Segmenting the brittle ferrite magnetic core into multiple pieces prevents crack propagation through the entire component. When thermal or mechanical stress is applied, the gaps between segments stop crack progression, preventing complete failure even though the material itself remains brittle.
Solution Approach 2:
The gaps between magnetic core segments act as pre-designed stress relief zones that cushion against thermal and mechanical strains before they can cause damage to the brittle ferrite material.
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 solution reduces mechanical stress on the magnetic core, preventing breakage and ensuring continuous power and data transmission across thermal changes, maintaining device operation and movement.
Implementation Method 1
Differences in thermal expansion properties between the transformer and a surface on which it is mounted may be a source of such strain experienced by the transformer when the device encounters a change in thermal conditions
Data Source
AI summary
An example device includes a mounting structure including a first material having a first coefficient of thermal expansion (CTE). The mounting structure includes a center portion and an outer portion. The device further includes a magnetic core for an electrical component that is coupled to the outer portion of the mounting structure. The magnetic core includes a second material having a second CTE. The magnetic core is split into a plurality of sections separated by spaces extending from the center portion to an outer edge of the outer portion. Each of the plurality of sections is separately coupled to the mounting structure, and each of the plurality of sections is connected to the electrical component.