MAGNETIC CORE WITH FLEXIBLE PACKAGING

Abstract

The disclosure provides a core, comprising a body formed from a winding of tape shaped material, and a package encasing the body. A single gap is formed in the body and the package. A clamp is connected to the package to flex a flexible section of the package to reduce the gap.

Claims

1. A magnetic core, comprising: a core body formed from a winding of material; a package that receives the core body, the package including at least a partially flexible portion, an outer surface, and an inner surface defining a central opening of the core; a gap formed though the core body and the package between the outer surface of the package and the inner surface of the package; and a clamp having a first position in which the clamp secures the core in a closed position wherein the gap is decreased and a second position in which the clamp permits the core to move to an opened position wherein the gap is increased to permit passage of a wire into the central opening.

2. The core of claim 1, wherein the core body is formed in the shape of a toroid.

3. The core of claim 1, wherein the material is a flexible magnetic material.

4. The core of claim 1, wherein the package is formed of at least one of rubber or plastic.

5. The core of claim 1, further comprising a sealing material disposed in the gap to protect the core body from environmental conditions.

6. The core of claim 1, wherein the core body has a first end defining one side of the gap, a second end defining another side of the gap, and a continuous section extending between the first end and the second end.

7. The core of claim 1, further comprising a movable member coupled to the package to permit passage of a wire through the gap and into the central opening and to inhibit passage of the wire out of the central opening.

8. The core of claim 7, wherein the movable member is a biased hinge having one end attached to the inner surface of the package on one side of the gap and a flexible body extending across the gap.

9. A core, comprising: a body formed from a winding of tape shaped material; a package encasing the body, the package having an outer surface and an inner surface defining a central opening, the outer surface being radially outward of the outer surface of the body and the inner surface being radially inward of the inner surface of the body, the package including a flexible section; a single gap formed in the body and the package that extends between the outer surface of the package and the inner surface of the package through the body; and a clamp connected to the package, the clamp having a first end connected to the package on a first side of the gap and a second end connected to the package on a second side of the gap, the clamp being movable to a closed position thereby flexing the flexible section of the package such that the first side of the gap is moved toward the second side of the gap to reduce the gap.

10. The core of claim 9, wherein the clamp is movable to an opened position thereby permitting the flexible section of the package to return to an unflexed state such that the gap is increased to permit passage of a wire into the central opening.

11. The core of claim 9, wherein the body is formed of magnetic material wound into the shape of a toroid.

12. The core of claim 11, wherein the magnetic material is a flexible magnetic material.

13. The core of claim 9, wherein the package is formed of at least one of rubber or plastic.

14. The core of claim 9, further comprising a sealing material disposed in the gap to protect the body from environmental conditions.

15. The core of claim 9, wherein the body has a first end defining one side of the gap, a second end defining another side of the gap, and a continuous section extending between the first end and the second end.

16. The core of claim 9, further comprising a movable member coupled to the package to permit passage of a wire through the gap and into the central opening and to inhibit passage of the wire out of the central opening.

17. A method of forming a magnetic core, comprising: winding material into a core body; enclosing the body in a package having a partially flexible portion, an outer surface, and an inner surface defining a central opening of the core; forming a gap through the body and the package between the outer surface of the package and the inner surface of the package; and installing a sealing material in the gap to protect the body from environmental conditions.

18. The method of claim 17, further comprising attaching a clamp to the package, the clamp having a first position in which the clamp secures the core in a closed position wherein the gap is decreased and a second position in which the clamp permits the core to move to an opened position wherein the gap is increased to permit passage of a wire into the central opening.

19. The method of claim 17, further comprising coupling a movable member to the package to permit passage of a wire through the gap and into the central opening and to inhibit passage of the wire out of the central opening.

20. The method of claim 19, wherein the movable member is a biased hinge having one end attached to the inner surface of the package on one side of the gap and a flexible body extending across the gap.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Embodiments of the present disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0012] FIG. 1 is a perspective view of a prior art tape wound core body;

[0013] FIG. 2 is an exploded, perspective view of a prior art tape wound core;

[0014] FIG. 3 is a conceptual view of a twisted pair wire application using the core depicted in FIG. 1;

[0015] FIG. 4 is a perspective view of another prior art tape wound core;

[0016] FIG. 5(A) is a top view of a package according to one embodiment of the present disclosure;

[0017] FIG. 5(B) is a top view of a core according to one embodiment of the present disclosure prior to formation of a gap in the core;

[0018] FIG. 5(C) is a top view of the core of FIG. 5(B) with a gap;

[0019] FIG. 5(D) is a top view of the core of FIG. 5(C) with a clamp;

[0020] FIG. 6(A) is a top view of a package according to one embodiment of the present disclosure;

[0021] FIG. 6(B) is a top view of a core according to one embodiment of the present disclosure prior to formation of a gap in the core;

[0022] FIG. 6(C) is a top view of the core of FIG. 6(B) with a gap; and

[0023] FIG. 6(D) is a top view of the core of FIG. 6(C) with a clamp.

[0024] While the disclosure is amenable to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and are described in detail below. The disclosure, however, is not to limit the invention to the particular embodiments described. On the contrary, the invention is intended to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE DISCLOSURE

[0025] FIGS. 5(A)-(D) depict a first embodiment of a core according to the principles of the present disclosure. Core 150 includes a body 152 (FIG. 5(B)), which may be formed in the shape of a toroid or cylinder, made by winding material, for example, of the type and in the manner described above with reference to FIGS. 1-3. In certain embodiments, the material is vitreous material or a flexible magnetic material. Body 152 includes an outer surface 154, an inner surface 156, a first side surface 158 and a second side surface 160 (not shown). Body 152 is encased within a package 162 (FIG. 5(A)), which may be formed of rubber, plastic or other suitable flexible material. Package 162 includes an outer surface 164, an inner surface 166, a first side surface 168 and a second side surface 170 (not shown). Inner surface 166 of package 162 defines a central opening 172 for receiving a wire or wires such as in the twisted pair application described above.

[0026] As shown in FIG. 5(C), in one embodiment after body 152 is installed in package 162, a narrow slit or gap 174 is formed through package 162 and body 152 between outer surface 164 of package 162 and inner surface 166. After gap 174 is formed, the free ends of body 152 and package 162 are sealed, for example, using epoxy or other sealing material to protect body 152 from environmental conditions and chemical conditions which often exist in automotive applications. Also, sealing the ends helps to protect against environment induced degradation of the material or its properties. Because body 152 and package 162 are flexible, exerting pressure in the direction of arrows A will cause gap 174 to close. Depending upon the size of core 150, the pressure to close gap 174 may be applied with one hand. Releasing such force permits core 150 to return to its uncompressed state such that gap 174 is again opened. It should also be understood that gap 174 may be expanded by applying pressure in a direction opposite arrows A from within central opening 172. This may be desirable to accommodate passage of a thick wire or bundle of wires through gap 174.

[0027] It should be understood that in a variation of this embodiment, gap 174 may be pre-formed in package 162. In this variation, only core body 152 is cut to form gap 174. After gap 174 is formed in body 152, body 152 is placed in package 162 such that body 152, including the free ends of body 152 formed upon creation of gap 174, is completely enclosed within package 162. In either variation of this embodiment, package 162 is constructed of material that permits deformation of body 152 (i.e., to close gap 174) but inhibits excessive deformation that may cause body 152 to break.

[0028] As shown in FIG. 5(D), gap 174 may be retained in a closed position by using a clamp 176 or other suitable device. Clamp 176 may be constructed in a variety of ways with the function of closing gap 176, retaining it in a closed position and aligning the free ends of core 150. Thus, clamp 176 may be constructed as a spring latch, a slam latch, a cam lock, a Norfolk latch, a Suffolk latch, a crossbar, a cabin hook, or any other suitable clamping means. Clamp 176 may also include a movable member 177 which is constructed to permit a wire or wires to pass through gap 174 into central opening 172 but inhibit such wire or wires from passing the other direction out of opening 172. In this regard, movable member 177 be a biased hinge having one on one end attached to the inner surface of package 162 on one side of gap 174 and a flexible body extending across gap 174 that permits the other end of movable member 177 to pivot into opening 172 as a wire is passed into opening 172 and snap back to cover gap 174 after the wire has passed. Alternatively, movable member 177 may include one or more flexible elements that flex in one direction to permit passage of a wire and return to an un-flexed position (perhaps overlapping) to prevent movement of the wire in the opposite direction. Other suitable movable members 177 will be apparent to those skilled in the art.

[0029] It is desirable to maintain gap 174 in the closed position during operation of core 150 to obtain the desired performance characteristics from core 150. As the configuration of core 150 permits gap 174 to be opened and closed, when core 150 fails in a twisted pair application such as that described above with reference to FIG. 3, clamp 176 may simply be removed to permit gap 174 to move to the opened position, and core 150 may be removed from the wire or wires that extend through central opening 172. The wire or wires may then be passed through gap 174 of a new core 150 into central opening 172, and gap 174 of the new core 150 may be closed using clamp 176. In this manner, none of the other components of the application need to be disturbed in the process of replacing core 150.

[0030] As will be understood by one of skill in the art, gap 174 is defined on one side by a free end 171 of coil body 152 and on another side by a free end 173 of coil body 152. A continuous section 175 of coil body 152 extends between end 171 and end 173. Gap 174 is formed such that there is a very small distance between the free ends 171, 173 of coil body 152. Forming gap 174 through body 152 results in some losses in coil performance. However, the single, narrow gap 174 formed through body 152 according to the embodiments of the present disclosure is far more desirable (i.e., causes much less loss) than the configuration of core 40 of FIG. 4 which includes two gaps.

[0031] Referring now to FIGS. 6(A)-(D), a second embodiment of a core according to the principles of the present disclosure is shown. Core 250 (FIG. 6(B)) includes a body 252 made by winding material, for example, of the type and in the manner described above with reference to FIG. 3. Body 252 includes an outer surface 254, an inner surface 256, a first side surface 258 and a second side surface 260 (not shown). Body 252 is encased within a partially rubber based package 262 (FIG. 6(A)). Package 262 includes flexible portion 253 (which in one embodiment is rubber based) and an epoxy or plastic portion 255 which adds to the strength of core 250. Flexible portion 253 acts as a hinge as is described below. Package 262 further includes an outer surface 264, an inner surface 266, a first side surface 268 and a second side surface 270 (not shown). Inner surface 266 of package 262 defines a central opening 272 for receiving a wire or wires such as in the twisted pair application described above.

[0032] As shown in FIG. 6(C), after body 252 is installed in package 262, a narrow slit or gap 274 is formed through package 262 and body 252 between outer surface 264 of package 262 and inner surface 266. After gap 274 is formed, the free ends of core 250 are sealed using epoxy or other suitable material to protect them from the application environment. Because body 252 and flexible portion 253 of package 262 are flexible, exerting pressure in the direction of arrows A will cause gap 274 to close. Releasing such force permits core 250 to return to its uncompressed state such that gap 274 is again opened.

[0033] As shown in FIG. 6(D), gap 274 may be retained in a closed position by using a clamp 276 or other suitable device. It is desirable to maintain gap 276 in the closed position during operation of core 250 to obtain the desired performance characteristics of core 250. As the configuration of core 250 permits gap 274 to be opened and closed, when core 250 fails in a twisted pair application such as that described above with reference to FIG. 3, clamp 276 may simply be removed to permit gap 274 to move to the opened position, and core 250 may be removed from the wire or wires that extend through central opening 272. The wire or wires may then be passed through a gap 274 of a new core 250 into central opening 272, and gap 274 of the new core 250 may be closed using clamp 276. In this manner, none of the other components of the application need to be disturbed in the process of replacing core 250.

[0034] As is the case with the embodiment of FIGS. 5(A)-(D), gap 274 is formed such that there is a very small distance between the free ends 271, 273 of coil body 252. Forming gap 274 through body 252 results in some losses in coil performance. However, the single, narrow gap 274 formed through body 252 according to the embodiments of the present disclosure is far more desirable (i.e., causes much less loss) than the configuration of core 40 of FIG. 4 which includes two gaps.

[0035] Various modifications and additions can be made to the exemplary embodiments discussed without departing from the scope of the present invention. For example, while the embodiments described above refer to particular features, the scope of this invention also includes embodiments having different combinations of features and embodiments that do not include all of the described features. Accordingly, the scope of the present invention is intended to embrace all such alternatives, modifications, and variations as fall within the scope of the claims, together with all equivalents thereof.