Wire-Frame Magnetic Assembly for Uniform Air Gaps
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Solution Overview
Problem
Existing magnetic assemblies with multi-air-gap magnetic cores bonded using epoxy resin suffer from uneven gaps and skewing, leading to increased magnetic loss due to dimensional tolerance and thickness differences.
Innovation Solution
A magnetic assembly design featuring a wire frame with evenly spaced accommodating spaces and block magnetic cores fixed in a drawer-like manner, surrounded by a wire wrap, ensures consistent gaps and prevents shifting, thereby reducing magnetic loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If multi-air-gap magnetic cores are bonded together with epoxy resin, then the magnetic cores are fixed in the wire frame, but the gap between the magnetic cores becomes uneven and there is skewed deviation in the assembly, leading to larger magnetic loss
Solution Approach 1:
The patent introduces a wire frame as an intermediary structure with pre-formed accommodating spaces to hold the block magnetic cores. This wire frame mediator ensures uniform gaps between cores without relying on epoxy resin thickness, resolving the contradiction between assembly stability and gap uniformity by providing a rigid structural framework that maintains precise spacing.
Solution Approach 2:
The wire frame is segmented into multiple accommodating spaces that are separated from each other and arranged at equal intervals. This segmentation allows each block magnetic core to be independently positioned in its own compartment, ensuring uniform gaps and preventing skewed deviation while maintaining overall assembly stability.
2Strength
If epoxy resin is used to bond magnetic cores, then the cores are fixed together, but dimensional tolerance and thickness difference of epoxy resin cause uneven gaps and skewing
Solution Approach 1:
The wire frame serves as an intermediary structure that replaces epoxy resin as the primary positioning element. The accommodating spaces in the wire frame provide mechanical constraints that ensure consistent gaps between magnetic cores, eliminating the precision problems associated with epoxy resin thickness variations while maintaining bonding strength through the wire frame's structural integrity.
Solution Approach 2:
The patent replaces the chemical bonding mechanism (epoxy resin) with a mechanical positioning system (wire frame with accommodating spaces). This substitution eliminates the dependency on resin thickness for gap control, as the mechanical structure of the wire frame inherently maintains uniform spacing through its pre-formed compartments.
3Manufacturing precision
If block magnetic cores are placed in accommodating spaces of the wire frame in a drawer-like manner, then the gaps between cores become consistent and shifting is prevented, but the wire frame structure becomes more complex
Solution Approach 1:
The wire frame is divided into multiple separated accommodating spaces arranged at equal intervals. This segmentation provides precise positioning for each block magnetic core, ensuring uniform gaps without requiring complex additional components. The segmented structure achieves high manufacturing precision through its modular compartment design.
Solution Approach 2:
The wire frame structure serves multiple functions simultaneously: it provides mechanical support, defines precise gap dimensions through its accommodating spaces, prevents core shifting, and enables easy assembly through the drawer-like placement method. This multi-functionality reduces the need for additional components, offsetting the perceived structural complexity with functional integration.
Data Source
AI summary
A magnetic assembly including a first magnetic core, a second magnetic core, a wire frame, multiple block magnetic cores, and a wire wrap is provided. The second magnetic core is assembled with the first magnetic core. The wire frame is disposed between the first magnetic core and the second magnetic core. The wire frame includes multiple accommodating spaces that are separated from each other, arranged at equal intervals, and have the same size. The block magnetic cores are respectively placed and fixed in the accommodating spaces of the wire frame in a drawer-like manner. The wire wrap is disposed around the wire frame, so as to wrap a part of the wire frame and the block magnetic cores in the wire wrap.