Toroidal Magnetic Core Housing for Brittle Strip Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for producing wound magnetic cores using amorphous and nanocrystalline alloys face challenges due to the brittleness of the material after heat treatment, which makes handling and assembly difficult, and the need for additional housing post-treatment, which increases costs and reduces efficiency.
Innovation Solution
A method where a soft magnetic strip is wound directly onto a carrier that serves as part of the housing, eliminating the need for post-treatment assembly gaps and allowing for the use of brittle materials, with the carrier forming a closed or open housing depending on the application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heat treatment is performed after core winding to achieve desired magnetic properties, then magnetic properties are improved, but the strip material becomes brittle and breaks easily during handling
Solution Approach 1:
The heat treatment is performed on the strip material before winding it into the core configuration. This preliminary action allows the material to achieve its desired magnetic properties and nanocrystalline structure while still maintaining ductility, preventing brittleness that would occur if heat treatment were performed after winding.
Solution Approach 2:
The patent changes the temporal parameter of the heat treatment process, performing it at an earlier stage (before winding) rather than after winding. This parameter change in process sequencing allows the material to develop optimal magnetic properties while avoiding the brittleness issue that arises from post-winding heat treatment.
2Reliability
If plastic housing is used to protect the core, then protection is provided, but the plastic cannot withstand the high temperatures required for heat treatment
Solution Approach 1:
The core is wound and heat-treated first, achieving optimal magnetic properties before any protective housing is applied. The protective housing is then added in a subsequent step after the heat treatment is complete, eliminating the temperature resistance conflict.
Solution Approach 2:
The manufacturing process is segmented into distinct stages: strip preparation, heat treatment, winding into core configuration, and finally housing application. This segmentation allows each component to be optimized independently - the core receives high-temperature treatment while the housing is added later for protection without temperature constraints.
3Reliability
If additional housing assembly steps are required after core production, then protection is provided, but assembly complexity and costs increase
Solution Approach 1:
The protective housing is integrated into the core structure itself, with the housing forming an integral part of the core assembly. This merging eliminates the need for separate housing assembly steps, reducing complexity while maintaining protection.
Solution Approach 2:
The housing structure serves multiple functions: it provides mechanical protection for the core, maintains structural integrity, and is formed as part of the core manufacturing process itself. This multi-functionality eliminates the need for separate protective components and assembly steps.
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 approach simplifies assembly, reduces costs, and allows for more efficient use of space while maintaining magnetic properties, making it suitable for brittle materials like nanocrystalline strips, and enables safer handling during further processing steps.
Implementation Method 1
cores made of crystalline iron-based alloys such as silicon-iron, often also amorphous and nanocrystalline alloys are used. Selection criteria for the material of the magnetic core are high permeability, low coercivity (Hc), low losses and high linearity of the hysteresis loop
Data Source
AI summary
A device is described, which, according to one exemplary embodiment, includes a carrier which has a through opening along a longitudinal axis, and at least one soft magnetic strip wound around the carrier to form a toroidal strip core. The strip is wound directly onto the carrier so that there is no play between the toroidal strip core and the carrier. The carrier can thus serve as part of the housing of the toroidal strip core.