Wound Core End-Face Offset Structure for Lower Core Loss
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Solution Overview
Problem
Existing magnetic core designs face challenges in maintaining precise alignment of end faces during assembly, leading to increased lacing load, deformation, and higher core loss due to positional offsets and strain-induced heat generation, while also failing to effectively combine cooling and noise suppression.
Innovation Solution
The magnetic core design features a configuration where the end faces of bent soft magnetic sheets are arranged to periodically offset in the circumferential direction, with a third part positioned to prevent sheet interlocking and maintain alignment, reducing core loss and heat generation, and incorporating a band for secure fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the end faces of soft magnetic sheets are made to abut at multiple locations to reduce lacing load, then the lacing load is reduced, but the magnetic core is liable to deform and core loss increases
Solution Approach 1:
The magnetic core is divided into multiple sections along the circumferential direction, with joined parts distributed at different positions. This segmentation allows the lacing load to be distributed across multiple points while maintaining precise alignment through the periodic offset pattern, preventing both excessive load concentration and deformation.
Solution Approach 2:
The end faces of soft magnetic sheets are designed with periodic offset in the circumferential direction, creating an asymmetric pattern rather than perfect symmetry. This asymmetric arrangement allows multiple joined parts to coexist without causing deformation, as the offset pattern prevents sheets from entering between other sheets during assembly.
2Manufacturing precision
If positioning precision is improved to prevent offset, then alignment is maintained, but the assembly process becomes more difficult
Solution Approach 1:
The periodic offset pattern is predetermined and built into the design of the soft magnetic sheets before assembly. By pre-establishing the offset pattern, the sheets naturally guide themselves into correct positions during assembly, reducing the need for high-precision positioning operations and making the assembly process easier.
Solution Approach 2:
The periodic offset structure enables the soft magnetic sheets to self-align during assembly. The offset pattern creates natural positioning features that guide the sheets into correct relative positions without requiring complex external positioning mechanisms, thereby maintaining precision while simplifying assembly.
3Volume of moving object
If bent parts with small radii of curvature are used, then the core structure is more compact, but heat generation increases due to strain
Solution Approach 1:
Instead of reducing the radius of curvature in the bent parts, the invention distributes the joining locations along the circumferential direction. This dimensional redistribution allows the use of larger radius bent parts that generate less heat, while still achieving a compact overall core structure through the periodic offset arrangement of multiple joined parts.
4Volume of moving object
If gaps at coil openings are narrowed to improve compactness, then the core is more compact, but insertion work increases and deformation occurs
Solution Approach 1:
The magnetic core is segmented into multiple sections with joined parts distributed along the circumferential direction. This segmentation creates multiple access points and distributes the structural support, allowing for easier insertion of soft magnetic sheets even with narrower gaps at coil openings, while maintaining compactness through the periodic offset pattern.
Data Source
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AI summary
When joining end faces of a plurality of soft magnetic sheets which are superposed in the sheet thickness direction and which are bent at parts forming corner areas of a core, offset of positions of the end faces from the desired positions is suppressed. In a region of a window part comprised of a region inside of a first part 110 and second part 120, a third part 130 with a length in a longitudinal direction (X-axial direction) the same as a length in the X-axial direction of the window part at the position where the third part 130 is arranged is arranged so as to contact the region of the inner circumferential surface between the first corner area 101 and third corner area 103.