Split-Core Coil Structure for Lower AC Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing coil components experience significant power loss due to alternating-current resistance and fail to achieve sufficient quality factors, particularly at high frequencies and with large electric power applications.
Innovation Solution
A coil component structure featuring a core composed of linearly arranged split cores with non-magnetic intervening layers to reduce leakage magnetic flux, combined with a hollow cylindrical design and insulating coatings to minimize skin effect and core loss, allowing for reduced alternating-current resistance and enhanced quality factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a traditional solid core structure is used, then the magnetic flux path is continuous, but the alternating-current resistance increases and quality factor decreases due to skin effect and core loss
Solution Approach 1:
The core is divided into multiple split cores (first split core, second split core, third split core, fourth split core) arranged linearly with non-magnetic intervening layers between them. This segmentation breaks the continuous magnetic flux path into discrete segments, reducing the skin effect and core loss that occur in traditional solid core structures, thereby reducing alternating-current resistance and improving quality factor.
Solution Approach 2:
Non-magnetic intervening layers are strategically placed between adjacent split cores at specific locations where magnetic flux leakage occurs. These intervening layers have different magnetic properties (non-magnetic) compared to the split cores, creating local variations in magnetic flux distribution that reduce leakage and improve overall efficiency.
2Loss of energy
If split cores with non-magnetic intervening layers are used, then leakage magnetic flux is reduced and alternating-current resistance decreases, but the core structure becomes more complex
Solution Approach 1:
The core is divided into multiple split cores (first split core, second split core, third split core, fourth split core) arranged linearly with non-magnetic intervening layers between them. This segmentation breaks the continuous magnetic flux path into discrete segments, reducing the skin effect and core loss that occur in traditional solid core structures, thereby reducing alternating-current resistance and improving quality factor.
Solution Approach 2:
Multiple split cores are combined in a linear arrangement to form a unified core structure that functions as a single magnetic circuit element. The individual split cores are positioned and connected through the bobbin structure to create an integrated assembly that achieves the desired magnetic flux control while maintaining structural coherence.
3Reliability
If a hollow cylindrical core design with insulating coatings is used, then skin effect and core loss are minimized, but manufacturing complexity increases
Solution Approach 1:
Insulating coatings are applied to the hollow cylindrical core structure at specific locations to provide electrical isolation where needed. This localized application of insulating properties allows the core to maintain its hollow cylindrical geometry while providing necessary electrical insulation to reduce skin effect and core loss, balancing performance requirements with manufacturing feasibility.
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 coil component design effectively reduces alternating-current resistance and achieves high-quality factors, making it suitable for high-frequency, high-power applications like field coupling non-contact power supply systems with low loss and excellent resonance performance.
Implementation Method 1
An intervening layer made out of a non-magnetic material is disposed between split cores adjacent to each other of the plurality of split cores. This structure reduces leakage magnetic flux and hence makes it possible to reduce alternating-current resistance.
Implementation Method 2
insulating coatings to minimize skin effect and core loss, allowing for reduced alternating-current resistance and enhanced quality factors
Implementation Method 3
a coil wound around the core 30. The coil component according to the present invention can be used, for example, as a resonance coil for a field coupling non-contact power supply system
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A coil component includes a core (30); and a coil wound around the core (30), in which the core (30) is configured to include plural split cores (31) arranged linearly alongside each other in an axial-center direction of the coil, and an intervening layer made out of a non-magnetic material (for example, comprised of an insulating coating (35)) is disposed between split cores (31) adjacent to each other of the plural split cores (31).