T-Shaped Magnetic Core Packaging for Low-Loss High-Saturation Chokes
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Solution Overview
Problem
Traditional chokes with toroidal or ferrite cores face challenges in reducing manufacturing costs and minimizing size while maintaining high saturation current and low core loss, especially when shrinking in size, and iron-powder cores have high core loss due to inability to perform annealing post-molding.
Innovation Solution
A magnetic device featuring a T-shaped magnetic core made of annealed soft magnetic metal with specific core loss and permeability characteristics, surrounded by a wire coil and a magnetic body, which allows for efficient energy storage and release with reduced core loss and increased saturation current.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If the size of traditional choke with toroidal core is reduced, then the manufacturing cost is reduced, but it becomes difficult to manually wind the wire coil and the choke cannot produce desired output at high saturation current
Solution Approach 1:
The patent replaces the manual mechanical winding process with an automated wire winding machine. This substitution resolves the contradiction by enabling efficient winding of wire coils on small-sized toroidal cores, making the manufacturing process feasible and cost-effective while maintaining high saturation current capability.
Solution Approach 2:
The patent changes the manufacturing parameters by using automated winding machines with precise control over wire placement, tension, and winding patterns. This allows for consistent quality in miniaturized chokes, overcoming the limitations of manual winding while maintaining electrical performance at high saturation currents.
2Ease of manufacture
If iron-powder core is used in molding process, then the manufacturing cost is reduced, but the core loss is relatively high due to inability to perform annealing
Solution Approach 1:
The patent applies preliminary annealing treatment to the iron-powder core before the molding process. This preliminary action reduces the core loss by optimizing the magnetic properties of the iron powder particles, allowing the molded core to achieve lower core loss while maintaining the cost advantages of iron-powder construction.
Solution Approach 2:
The patent uses composite iron-powder materials with specific compositions and treatments that reduce core loss. By carefully selecting and treating the iron powder particles, the core achieves improved magnetic properties with lower hysteresis and eddy current losses, resolving the contradiction between cost and energy efficiency.
3Volume of stationary object
If sealed choke with ferrite core is used, then the structure is compact, but it cannot produce desired output at high saturation current and becomes difficult to wind wire coil when size shrinks
Solution Approach 1:
The patent designs a multi-functional manufacturing system that combines automated wire winding capability with precise positioning systems. This universal approach enables the same equipment to handle various core sizes and types, producing reliable chokes at high saturation currents while maintaining compact dimensions through optimized winding patterns and core geometries.
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 provides a low-cost, compact choke with high saturation current at heavy loads and low core loss at light loads, outperforming conventional chokes in efficiency and performance.
Implementation Method 1
the choke stores the same by a magnetic field
Implementation Method 2
the T-shaped magnetic core being made of an annealed soft magnetic metal material
Data Source
AI summary
An inductor is disclosed, the inductor comprising: a T-shaped magnetic core, being made of a material comprising an annealed soft magnetic metal material and having a base and a pillar integrally formed with the base, wherein μC×Hsat≥1800, where μC is a permeability of the T-shaped magnetic core, and Hsat (Oe) is a strength of the magnetic field at 80% of μC0, where μC0 is the permeability of the T-shaped magnetic core when the strength of the magnetic field is 0.