Transformer Coil Filling Layer for Magnetic Flux Conduction
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Solution Overview
Problem
Transformers with air-filled gaps between the magnetic core and coils inefficiently conduct magnetic flux, leading to unnecessary material and cost expenditure on electrical steel and support structures.
Innovation Solution
Incorporating a magnetizable filling layer made of paramagnetic or soft-magnetic materials between the magnetic core and coil to enhance magnetic flux conduction, reducing the required electrical steel and support structures by increasing the cross-sectional area filled with magnetizable material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If air-filled gaps are left between the magnetic core and coil, then the transformer structure is simple and easy to manufacture, but the magnetic flux conduction is inefficient
Solution Approach 1:
A filling layer made of magnetizable material (such as soft magnetic composite or iron powder) is introduced as an intermediary substance between the magnetic core and the coil. This filling layer mediates the magnetic flux transmission, providing a continuous magnetic path that bridges the air gaps created by the laminated electrical steel layers, thereby improving magnetic flux conduction efficiency without complicating the manufacturing process
2Loss of energy
If more electrical steel is used to compensate for air gaps, then the magnetic flux conduction is improved, but the material cost and manufacturing cost increase
Solution Approach 1:
The patent employs composite materials, specifically soft magnetic composite (SMC) or iron powder mixed with binder material, to create the filling layer. These composite materials provide high magnetic permeability and effective magnetic flux conduction, serving as a cost-effective alternative to using additional electrical steel, thereby reducing both material quantity and manufacturing costs while improving magnetic flux efficiency
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 filling layer optimizes magnetic flux conduction, reduces the need for electrical steel, and decreases the magnetic core's electromagnetic induction, thereby saving material and manufacturing costs while maintaining effective performance.
Implementation Method 1
The filling layer supports the conduction of a magnetic flux of the magnetic core of the transformer by increasing the cross-sectional area enclosed by the coil, which is filled with magnetizable material
Implementation Method 2
the filling layer is made from a paramagnetic material. Through the use of a paramagnetic material, the magnetization of the filling layer follows the magnetic field generated by the coil and thus advantageously increases the magnetic flux conducted by the magnetic core
Implementation Method 3
the filling layer is produced by pressing and sintering a soft magnetic powder composite material
Data Source
AI summary
A transformer has a magnetic core, a coil which runs around a core section of the magnetic core, and a filling layer which is arranged between the core section and the coil. The filling layer, which may fill a gap formed between the core and the coil completely, is produced from a magnetizable material.