Toroidal Converter Coils with Nanocrystalline Core
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing converter devices with toroidal coil arrangements face challenges in reducing coil volume and material usage while maintaining performance, as they often require multiple materials with different permeabilities, increasing production costs.
Innovation Solution
The coupling of at least two coils via a coupling toroid, where the windings are controlled to balance direct current components, allowing for a soft-magnetic core free of DC components and maximizing material savings, with the coils being wound through toroidal cores made of nanocrystalline Fe-Cu-Si-B-Nb alloy for efficient frequency range usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple materials with different permeabilities are used in toroidal cores, then coil performance is improved, but production costs increase
Solution Approach 1:
The patent applies local quality by creating different permeability zones within a single toroidal core material. The core is designed with a first region having higher permeability and a second region having lower permeability, allowing optimal magnetic flux distribution without requiring multiple materials. This resolves the contradiction by achieving improved coil performance through localized property variation while maintaining production cost efficiency through single-material construction.
2Device complexity
If DC components are present in toroidal cores, then simple coil construction is achieved, but power losses increase
Solution Approach 1:
The patent segments the toroidal core into distinct functional regions: a first region for carrying AC flux and a second region for carrying DC flux. This segmentation allows the AC and DC components to be separated spatially, preventing DC saturation in the AC flux path while maintaining simple coil construction. The multi-region core structure resolves the contradiction by eliminating power losses without increasing device complexity.
Solution Approach 2:
The patent introduces an intermediary structure - the second region of the toroidal core with lower permeability - that acts as a dedicated DC flux path. This intermediary region mediates between the AC and DC components, allowing DC current to flow through the core without causing saturation or excessive losses in the AC flux path. This resolves the contradiction by reducing power losses while maintaining simple coil construction.
3Volume of stationary object
If coil volume is reduced, then material usage decreases, but performance may be compromised
Solution Approach 1:
The patent uses local quality optimization within the toroidal core to maintain high performance in a reduced volume. By creating regions with different permeabilities within the compact core structure, the patent achieves optimal magnetic flux distribution that maximizes performance per unit volume. This resolves the contradiction by maintaining reliability through localized property optimization while achieving volume reduction.
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 achieves significant material savings, improved power efficiency, and a wide frequency range capability, reducing power losses by over 60% of core material usage for DC components and enhancing the coil's performance in high-DC circuits.
Implementation Method 1
The coupling of at least two different coils or windings, which are coupled to one another via a coupling toroid
Implementation Method 2
toroidal cores made of nanocrystalline Fe-Cu-Si-B-Nb alloy
Implementation Method 3
a toroidal tape core made of a soft-magnetic nanocrystalline material
Data Source
Figure 1~2
Figure 3~5
Figure 6
AI summary
The invention relates to a converter device comprising a converter and a coil arrangement that contains a number of coils, wherein the coil arrangement has a plurality of interconnected coils, and toroidal cores consisting of a soft magnetic nanocrystalline material are associated with each of said coils, a coupling toroidal core (11) being provided with a core opening (12) through which at least two windings (8, 9) of different coils can be guided and mounted, at least the winding of one coil being guided and mounted through a core opening of an individual toroidal core (13, 14), and an open/closed-loop control device being provided with a current controller that acts on the coils such that direct current components are compensated by currents flowing through the windings of the coils.