Choke With Variable Cross-Section Coil For Low Resistance
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Solution Overview
Problem
Existing chokes face high resistance losses due to their coil design, which limits space utilization and makes it difficult to increase the cross-section, especially in confined spaces.
Innovation Solution
A choke with a closed loop magnetic core and a coil having a varying cross-section along its length, featuring narrow inner and wide outer portions, which reduces resistance and allows for better space utilization, enabling a larger magnetic core volume and improved cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the coil cross-section is enlarged to reduce resistance, then coil resistance decreases, but available space is insufficient in confined areas
Solution Approach 1:
The coil cross-section is designed with non-uniform dimensions, featuring a larger cross-sectional area at the outer portion and a smaller cross-sectional area at the inner portion. This local variation in quality allows the coil to have sufficient conductive material for low resistance where space permits (outer portion), while adapting to spatial constraints near the magnetic core (inner portion), thereby resolving the contradiction between reducing resistance and maintaining compact dimensions.
2Loss of energy
If the coil cross-section is uniform and large, then resistance is low, but the choke volume increases reducing space utilization
Solution Approach 1:
Instead of using a uniformly large coil cross-section throughout, the invention applies local quality variation where the coil has larger cross-section at the outer portion and smaller cross-section at the inner portion. This allows the coil to achieve low resistance through sufficient conductor material in critical areas while minimizing overall volume by reducing material in less critical inner regions, thus resolving the contradiction between low resistance and compact volume.
Solution Approach 2:
The invention transitions from a uniform one-dimensional coil design to a two-dimensional variable cross-section design, where the cross-sectional dimensions vary along the length of the coil. This dimensional change enables optimization of both resistance (through sufficient conductor area) and volume (through reduced material in inner portions) simultaneously, resolving the contradiction between these two parameters.
3Reliability
If the magnetic core volume is increased to improve performance, then choke performance improves, but the overall choke size increases
Solution Approach 1:
The variable cross-section coil design with larger outer portion and smaller inner portion enables more efficient space utilization around the magnetic core. This allows the magnetic core to be sized optimally for performance without unnecessarily increasing overall choke dimensions, as the coil adapts its cross-section to fit the available space efficiently, resolving the contradiction between performance and size.
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 results in lower coil resistance, enabling a smaller choke design with the same resistance as existing chokes, improved space utilization, and enhanced cooling capabilities.
Implementation Method 1
The magnetic core 2 comprises magnetic material with a high magnetic permeability. The magnetic core 2 is adapted to confine and guide magnetic field of the choke.
Implementation Method 2
a coil 6 wound around the magnetic core 2... adapted to block high frequency alternating current in an electrical circuit, while passing low frequency or direct current
Data Source
AI summary
A choke comprising a magnetic core having a centre line that forms a closed loop, the choke has a choke axis around which the magnetic core is located, and a coil wound around the magnetic core, the coil has a plurality of turns, each of the turns has a width perpendicular to lengthwise direction of the turn, and a thickness perpendicular to both lengthwise direction of the turn and the width. The coil has a cross-section whose shape varies along lengthwise direction of the coil, such that each turn has an inner portion and an outer portion whose width is substantially greater than width of the inner portion, the outer portion is located further from the choke axis than the inner portion.