CN101110292A - Filter element and method for manufacturing the same - Google Patents

Filter element and method for manufacturing the same Download PDF

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Publication number
CN101110292A
CN101110292A CNA2006101061563A CN200610106156A CN101110292A CN 101110292 A CN101110292 A CN 101110292A CN A2006101061563 A CNA2006101061563 A CN A2006101061563A CN 200610106156 A CN200610106156 A CN 200610106156A CN 101110292 A CN101110292 A CN 101110292A
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China
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iron core
filter element
magnetic
manufacture method
outside
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CNA2006101061563A
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Chinese (zh)
Inventor
李政鸿
薛煜霖
黄逸鸿
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Delta Electronics Inc
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Delta Electronics Inc
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Abstract

The invention discloses a filter element and a manufacturing method thereof, the filter element can simultaneously have the function of filtering common mode noise and differential mode noise, and the filter element comprises a common mode filter, a second iron core and a container for forming. The common mode filter comprises a first iron core and at least one winding, and the winding surrounds the outside of the first iron core. The second iron core is completely coated outside the common-mode filtering piece. The common mode filter and the second iron core are both arranged in the container for molding, and the first iron core and the second iron core respectively have different initial magnetic permeability values .

Description

Filter element and manufacture method thereof
Technical field
The present invention relates to a kind of filter element and manufacture method thereof, particularly relate to a kind of filter element and manufacture method thereof that can have filtering common-mode noise and differential mode noise simultaneously.
Background technology
People make electrical appliance very frequent now, and utilization electrical equipment can use power supply unavoidably, just can make its electrical equipment normal operation.But; because electrical equipment is when using AC power, may be because of the running of the parasitic capacitance or the stray capacitance of power supply supply, high frequency transformer or other element, make in the electric current of supplying by AC power; regular meeting is carrying noise current secretly, and this promptly is the electromagnetic interference phenomenon.
Generally speaking, the noise that uses AC power to produce comprises differential mode noise (differential modenoise) and common-mode noise (common mode noise), and the EMI filter circuit can be used as the first line of defence of power supply anti-electromagnetic-radiation, mainly be made up of choking-winding (choke coil) and capacitor (capacitor), the inhibition noise that act as of choking-winding produces or enters in electronic instrument or the equipment.Please refer to Figure 1A, it is the schematic diagram of the iron core of the 4th, 587, No. 507 patents of invention of U.S.'s notification number.In Figure 1A, the iron core 1 of existing choking-winding is made of metal amorphous (amorphous metallic alloy) strip.Because metal amorphous frequency of utilization is usually less than 100 KHz (kHz), and its anti-DC-bias characteristic is also relatively poor, thereby designs an air gap (air gap) 2 in iron core 1, improve the relatively poor shortcoming of anti-DC-bias characteristic with attempt.But this way can reduce the initial permeability (initial permeability) of choking-winding significantly.
Please refer to Figure 1B, it is the schematic diagram of the iron core of the 6th, 456, No. 182 patents of invention of U.S.'s notification number.In order to eliminate common-mode noise, in the 6th, 456, No. 182 patents of invention of U.S.'s notification number disclosed mode be utilize three independently iron core 11a, 11b, 11c combination to become a choking-winding that is used for eliminating common-mode noise.The material of iron core 11a, 11b, 11c is the oxidation magnetisable material, in the middle of iron core and iron core, separate with insulating material or viscose, utilize three independently dimensional resonance phenomenons of iron core 11a, 11b, 11c, can make its frequency of operation extend to 10MHz, make noise all can effectively be subdued to 10MHz at 10kHz.Yet this kind uses three modes that iron core is stacked, and with making the whole height of choking-winding increase, is unfavorable for the trend of microminiaturization.In addition, this kind choking-winding can only be used for eliminating common-mode noise, and can't eliminate differential mode noise.
Please refer to Fig. 1 C, it is the schematic diagram of the iron core of the 5th, 581, No. 224 patents of invention of U.S.'s notification number.Eliminate common-mode noise and differential mode noise simultaneously, U.S.'s notification number the 5th, 581 in order to have, disclose a kind of choking-winding in No. 224 patents of invention, it mainly is by two iron cores independently, is respectively to be positioned at peripheral iron core 111 and to be positioned at inner iron core 114 and to form, and forms after twining coiling 18.The material of iron core 111 is magnetic ferrites (ferrite) or noncrystalline material, and iron core 114 is the powder core (dust core) of a low permeability, separates with the insulation material in the middle of iron core 111 and 114.Utilize the characteristic of the high permeability of iron core 111 to come the filtering common-mode noise, and the characteristic of utilizing the low permeability of iron core 114 comes the differential mode noise of filtering part, yet, the mode of this kind ornaments two independent iron cores, to make that the shared area of whole choking-winding is quite big, and be unfavorable for microminiaturization.And both separate with it owing to must be coated with an insulation material between two independent iron cores, not only increase material cost, and this kind structure need artificial assembling, lost time.Moreover, owing to iron core very easily produces the element of leakage inductance arround influencing, and iron core itself also be easy to be subjected to arround the influence in magnetic field, make the element characteristic instability.
Therefore, how to make to be used for effectively eliminating simultaneously the choking-winding of common-mode noise and differential mode noise, and can meet the trend of overall volume microminiaturization under the consideration of Financial cost, this field personage needs the direction of research badly just.
Summary of the invention
Therefore, for addressing the above problem, the present invention proposes a kind of filter element and manufacture method thereof, can effectively eliminate common-mode noise and differential mode noise simultaneously, and effectively improve filter effect.In addition, owing to can in same filter element, just can possess the noise of eliminating differential mode and common mode, and then can effectively reduce cost and shared volume.
According to purpose of the present invention, a kind of filter element is proposed, comprise a common mode filtering part, one second iron core and a moulding container.Common mode filtering part comprises one first iron core and at least one coiling, and wire winding ring is around in the first iron core outside.The second iron core complete packet is overlying on outside the common mode filtering part.Wherein the common mode filtering part and second iron core all are arranged in the moulding container, and first iron core and second iron core have different initial permeability value (μ) respectively.
According to another object of the present invention, other proposes a kind of manufacture method of filter element, comprising: a common mode filtering part is provided, comprises one first iron core and at least one coiling, and wire winding ring is around in the first iron core outside; Common mode filtering part is inserted a moulding with in the container; Pour into a magnetic slurry in moulding with container in and fill up the moulding container; And carry out one and solidify (curing) program; Wherein, the magnetic slurry promptly forms one second iron core and complete packet is overlying on outside the common mode filtering part behind program curing, and first iron core and second iron core have different initial permeability value (μ) respectively.
As above-mentioned filter element and manufacture method thereof, the material of its first iron core comprises magnetic ferrites (ferrite), and the material of second iron core is a magnetic slurry.Wherein the magnetic slurry comprises a magnetic filler and a resin, and resin is a thermosetting resin (thermosetting resin) or a ray hardening resin.The magnetic filler comprises a pure iron, contains the Magnaglo of ferromagnetic metal alloy, manganese-zinc ferrite or nickel-Zn ferrite, and contains the ferromagnetic metal alloy and comprise ferro-silicium, ferrocobalt, sendust or iron-nickel alloy.The magnetic filler percentage by weight that accounts for the magnetic slurry is about more than 0% and below 95% again.In addition, outside first iron core, more comprise an insulation crust, and coiling is surrounded on the outside of first iron core and insulation crust respectively.First iron core utilizes ejection formation or powder extrusion forming to form again, and second iron core forms after utilizing slurry molding and curing.Above-mentioned filter element can be applicable to the electronic installation of a choking-winding, a power supply unit, an inductor or a generation noise, can eliminate a common-mode noise and a differential mode noise.
For above and other objects of the present invention, feature and advantage can be become apparent, a preferred embodiment cited below particularly, and cooperate appended graphicly, be described in detail below:
Description of drawings
Figure 1A is the schematic diagram of the iron core of the 4th, 587, No. 507 patents of invention of existing U.S. notification number;
Figure 1B is the schematic diagram of the iron core of the 6th, 456, No. 182 patents of invention of existing U.S. notification number;
Fig. 1 C is the schematic diagram of the iron core of the 5th, 581, No. 224 patents of invention of existing U.S. notification number;
Each schematic diagram when Fig. 2 A to Fig. 2 C makes for the filter element of preferred embodiment of the present invention;
Fig. 3 is the schematic diagram of the common mode filtering part in the filter element of preferred embodiment of the present invention.
The main element symbol description:
1,11a, 11b, 11c, 111,114: iron core
18: coiling
2: air gap
20: filter element
22: the second iron cores
24: the moulding container
30: common mode filtering part
32: the first iron cores
34: shell
36: coiling
38a, 38b, 38c, 38d: outlet
Embodiment
Please be simultaneously with reference to Fig. 2 A, Fig. 2 B, Fig. 2 C and Fig. 3, each schematic diagram when Fig. 2 A to Fig. 2 C makes according to the filter element of preferred embodiment of the present invention, and Fig. 3 is the schematic diagram of the common mode filtering part in the filter element of preferred embodiment of the present invention.The disclosed filter element 20 of preferred embodiment of the present invention can be applicable to a choking-winding, uses as power supply unit, inductor or other filtering that may produce the electronic installation of noise.Perhaps, also above-mentioned filter element can be used in the making inductor, also can reach the function that makes the inductor microminiaturization.Filter element 20 mainly comprises a common mode filtering part 30, one second iron core 22 and moulding container 24.Common mode filtering part 30 comprises one first iron core 32, an insulation crust 34 and two groups of coilings 36.First iron core 32 utilizes ejection formation or powder extrusion forming to form, and insulation crust 34 is coated on outside first iron core 32, in order to the increase insulating properties, and avoids first iron core 32 to contact and be short-circuited with first iron core 22, and can promote the characteristic of proof voltage.
Two groups of coilings 36 are surrounded on the outside of first iron core 32 and insulation crust 34 respectively, and and have four outlet 38a, 38b, 38c, a 38d.Second iron core 22 forms after utilizing slurry molding and curing, and second iron core, 22 complete packet are overlying on outside the common mode filtering part 30.Wherein the common mode filtering part 30 and second iron core 22 all are arranged in moulding container 24.
In addition, preferred embodiment of the present invention proposes the manufacture method of a filter element 20 in addition, comprising: a common mode filtering part 30 is provided, comprise one first iron core 32 and two groups of coilings 36, and two groups of coilings 36 is surrounded on first iron core, 32 outsides respectively; Common mode filtering part 30 is inserted a moulding with in the container 24, and moulding is the container that central authorities have a predetermined space with container 24, and the size in its space corresponds to the follow-up size that will make second iron core 22 of formation; Pour into a magnetic slurry in moulding with container 24 in and fill up moulding with container 24; And carry out one and solidify (curing) program; Wherein, the magnetic slurry promptly forms one second iron core 22 and complete packet is overlying on outside the common mode filtering part 30 behind program curing, only stays four outlet 38a, 38b, 38c, 38d to pass second iron core 22, as the usefulness that is electrically connected with outer member.
First iron core 32 of common mode filtering part 30 and the different initial permeability value (μ) of second iron core, 22 difference tools that coats outside it, and because the permeability of second iron core 22 is come lowly than the permeability of first iron core 32, can be used to the filtering differential mode noise, and for for first iron core 32 that magnetic ferrites constituted, the characteristic of its high permeability can be used to the filtering common-mode noise, thus, can reach the effect that only just can possess the noise of eliminating differential mode and common mode, and then can effectively reduce cost with single filter element 20.Moreover, owing to be embedded in second iron core 22 in the common mode filtering part 30, make the volume of filter element 20 integral body to reach and meet trend compact, microminiaturization because of the design of built-in type.
As above-mentioned filter element 20 and manufacture method thereof, the material of its first iron core 32 comprises magnetic ferrites (ferrite), and the material of second iron core 22 is a magnetic slurry.Wherein the magnetic slurry comprises a magnetic filler and a resin, and resin is a thermosetting resin (thermosetting resin) or a ray hardening resin.The magnetic filler comprises a pure iron, contains the Magnaglo of ferromagnetic metal alloy, manganese-zinc ferrite or nickel-Zn ferrite, and contains the ferromagnetic metal alloy and comprise ferro-silicium, ferrocobalt, sendust or iron-nickel alloy.The percentage by weight that this magnetic filler accounts for the magnetic slurry is about more than 10% and below 98%.
Below will propose various experimental data, and relatively do one relatively with the existing choking-winding that only can eliminate common-mode noise at second iron core 22 that uses different magnetic slurry mades.
First kind magnetic filler (ferromagnetic metal alloy)
Utilize above-mentioned production method, use the various Magnaglo that contains the ferromagnetic metal alloy, the collocation resin formulated magnetic slurry, its concentration is 85% percentage by weight.The various experimental data of its gained is as shown in the table.
DM inserts loss (dB) DM resonance frequency (MHz) DM inductance value (μ H) @10KHz
Existing 20.1@30MHz Greater than 30 6.38
3 valency ferro-siliciums 40 18.9 12.23
6 valency ferro-siliciums 41.1 18.6 12.17
Ferrocobalt 40.2 21.3 10.68
Iron-nickel alloy 40.5 17.5 12.73
As seen from the above table, according to the filter element of preferred embodiment of the present invention, on the characteristic of the inductance value of differential mode noise (Differential mode noise, DM noise), increased about one times than the existing choking-winding that only can eliminate common-mode noise, so its effect is very obvious.In addition, aspect differential mode noise (DM) insertion loss,, also increased about one times than the existing choking-winding that only can eliminate common-mode noise according to the filter element of preferred embodiment of the present invention.
The second class magnetic filler (manganese-zinc ferrite)
Utilize above-mentioned production method, use the Magnaglo of manganese-zinc ferrite with different initial permeability values (μ), the collocation resin formulated magnetic slurry, its concentration is about 80%~85% percentage by weight.The various experimental data of its gained is as shown in the table.
DM inserts loss (dB) DM resonance frequency (MHz) DM inductance value (μ H) @10KHz
Existing 20.1@30MHz Greater than 30 6.38
Manganese-zinc ferrite-A10 37.5 19.3 14.06
Manganese-zinc ferrite-A05 38.9 18.6 14.53
Wherein, A10 represents that its initial permeability value (μ) is 10000, and A05 represents that its initial permeability value (μ) is 5000.As seen from the above table, according to the filter element of preferred embodiment of the present invention, on the characteristic of the inductance value of differential mode noise (Differential mode noise, DM noise), the existing choking-winding that only can eliminate common-mode noise of ratio is greater than more than two times, so its effect is very obvious.In addition, aspect differential mode noise (DM) insertion loss, filter element according to preferred embodiment of the present invention, also increased nearly about one times than the existing choking-winding that only can eliminate common-mode noise, and, show good differential mode filtering characteristic owing to insert loss nearly 40 decibels (dB) according to the DM that filter element showed of preferred embodiment of the present invention.
The 3rd class magnetic filler (nickel-Zn ferrite)
Utilize above-mentioned production method, use the Magnaglo of nickel-Zn ferrite with different initial permeability values (μ), the collocation resin formulated magnetic slurry, its concentration is about 85% percentage by weight.The various experimental data of its gained is as shown in the table.
DM inserts loss (dB) DM resonance frequency (MHz) DM inductance value (μ H) @10KHz
Existing 20.1@30MHz Greater than 30 6.38
Nickel-Zn ferrite-R7 38.7 28.8 10.5
Nickel-Zn ferrite-K22 28.9@30MHz Greater than 30 7.37
Wherein, R7 represents that its initial permeability value (μ) is 1500, and K22 represents that its initial permeability value (μ) is 350.As seen from the above table, according to the filter element of preferred embodiment of the present invention, on the characteristic of the inductance value of differential mode noise (Differential mode noise, DM noise), than the existing effect that only can eliminate the choking-winding of common-mode noise come good.In addition, aspect differential mode noise (DM) insertion loss, filter element according to preferred embodiment of the present invention, also increased nearly about one times than the existing choking-winding that only can eliminate common-mode noise, and owing to insert loss nearly 40 decibels (dB) according to the DM that filter element showed of preferred embodiment of the present invention, and then near 30MHz, show good differential mode filtering characteristic in the higher-frequency position.。
In sum, the filter element of preferred embodiment of the present invention can effectively be eliminated common-mode noise and differential mode noise simultaneously, and effectively improve filter effect.In addition, owing to can in same filter element, just can possess the noise of eliminating differential mode and common mode, and then can effectively reduce cost and shared volume, meet trend compact, microminiaturization.Moreover, can avoid existing because of iron core produce leakage inductance influence arround the problem of element, and can avoid the influence of existing iron core itself because of magnetic field arround being subjected to, cause the element characteristic problem of unstable.
Though disclosed the present invention in conjunction with an above preferred embodiment; yet it is not in order to limiting the present invention, anyly is familiar with this operator, without departing from the spirit and scope of the present invention; when can being used for a variety of modifications and variations, so protection scope of the present invention should be with being as the criterion that claim was defined.

Claims (19)

1. filter element comprises:
One common mode filtering part comprises one first iron core and at least one coiling, and this wire winding ring is around in this first iron core outside; And
One second iron core, complete packet are overlying on outside this common mode filtering part;
Wherein this first iron core and this second iron core are distinguished the different initial permeability value (μ) of tool.
2. filter element as claimed in claim 1, wherein the material of this first iron core comprises magnetic ferrites, and the material of this second iron core is a magnetic slurry.
3. filter element as claimed in claim 2, wherein this magnetic slurry comprises a magnetic filler and a resin.
4. filter element as claimed in claim 3, wherein this resin is a thermosetting resin or a ray hardening resin.
5. filter element as claimed in claim 3, wherein this magnetic filler Magnaglo that contains ferromagnetic metal alloy, manganese-zinc ferrite or nickel-Zn ferrite of comprising a pure iron, forming by ferro-silicium, ferrocobalt, sendust or iron-nickel alloy.
6. filter element as claimed in claim 3, wherein this magnetic filler percentage by weight of accounting for this magnetic slurry is about more than 10% and below 98%.
7. filter element as claimed in claim 1, wherein this first iron core utilizes ejection formation or powder extrusion forming to form, and this second iron core utilizes slurry molding also to form after the curing.
8. filter element as claimed in claim 1 more comprises an insulation crust, and it is positioned at outside this first iron core, and this wire winding ring is around in the outside of this first iron core and this insulation crust.
9. filter element as claimed in claim 1 more comprises a moulding container, and this common mode filtering part and this second iron core all are arranged in this moulding container.
10. the manufacture method of a filter element comprises:
One common mode filtering part is provided, comprises one first iron core and at least one coiling, and this wire winding ring is around in this first iron core outside;
This common mode filtering part is inserted a moulding with in the container;
Pouring a magnetic slurry into uses in the container in this moulding; And
Carry out a program curing;
Wherein, this magnetic slurry promptly forms one second iron core and complete packet is overlying on outside this common mode filtering part behind this program curing, and this first iron core and this second iron core have different initial permeability value (μ) respectively.
11. manufacture method as claimed in claim 10, wherein the material of this first iron core comprises magnetic ferrites, and the material of this second iron core is this magnetic slurry.
12. manufacture method as claimed in claim 10, wherein this magnetic slurry comprises a magnetic filler and a resin.
13. manufacture method as claimed in claim 12, wherein this resin is a thermosetting resin or a ray hardening resin.
14. manufacture method as claimed in claim 12, wherein this magnetic filler Magnaglo that contains ferromagnetic metal alloy, manganese-zinc ferrite or nickel-Zn ferrite of comprising a pure iron, forming by ferro-silicium, ferrocobalt, sendust or iron-nickel alloy.
15. manufacture method as claimed in claim 12, wherein this magnetic filler percentage by weight of accounting for this magnetic slurry is about more than 10% and below 98%.
16. manufacture method as claimed in claim 10, wherein this first iron core utilizes ejection formation or powder extrusion forming to form, and this second iron core utilizes slurry molding also to form after the curing.
17. manufacture method as claimed in claim 10 more comprise forming an insulation crust outside this first iron core, and this wire winding ring is around in the outside of this first iron core and this insulation crust.
18. manufacture method as claimed in claim 10, wherein this filter element can be eliminated a common-mode noise and a differential mode noise.
19. manufacture method as claimed in claim 10, wherein this filter element is applied to the electronic installation of a choking-winding, a power supply unit, an inductor or a generation noise.
CNA2006101061563A 2006-07-20 2006-07-20 Filter element and method for manufacturing the same Pending CN101110292A (en)

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Application Number Priority Date Filing Date Title
CNA2006101061563A CN101110292A (en) 2006-07-20 2006-07-20 Filter element and method for manufacturing the same

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CN101110292A true CN101110292A (en) 2008-01-23

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103065784A (en) * 2011-10-24 2013-04-24 西北台庆科技股份有限公司 Inductor packaging method capable of stabilizing shape
CN106887299A (en) * 2015-12-16 2017-06-23 莱尔德电子材料(深圳)有限公司 Common mode choke including manganese-zinc ferrite and nickel-zinc ferrite
CN106920628A (en) * 2017-04-20 2017-07-04 马焰琳 A kind of liquid metal filters the manufacture craft of RT coils

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103065784A (en) * 2011-10-24 2013-04-24 西北台庆科技股份有限公司 Inductor packaging method capable of stabilizing shape
CN106887299A (en) * 2015-12-16 2017-06-23 莱尔德电子材料(深圳)有限公司 Common mode choke including manganese-zinc ferrite and nickel-zinc ferrite
CN106920628A (en) * 2017-04-20 2017-07-04 马焰琳 A kind of liquid metal filters the manufacture craft of RT coils
CN106920628B (en) * 2017-04-20 2019-05-14 马焰琳 A kind of manufacture craft of liquid metal filter coil

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Open date: 20080123