CN111009392A - Toroidal core, toroidal transformer and inductor and automated manufacturing method thereof - Google Patents

Abstract

The invention discloses a ring-shaped magnetic core, a ring-shaped transformer, an inductor and an automatic manufacturing method thereof, wherein the ring-shaped magnetic core comprises a first magnetic core and a second magnetic core, the first magnetic core is staggered by a certain angle through the end parts of a first magnetic block and a second magnetic block to form a step, the second magnetic core is staggered by a certain angle through the end parts of a third magnetic block and a fourth magnetic block to form a step, two end parts of the first magnetic core and two end parts of the second magnetic core are respectively butted through glue dispensing in the horizontal direction of the step to form the ring-shaped magnetic core, and the glue dispensing position is not on the magnetic path of the ring-shaped magnetic core, so that the electrical parameters of the ring-shaped magnetic core are not influenced, and the ring-shaped magnetic core.

Description

Toroidal core, toroidal transformer and inductor and automated manufacturing method thereof

Technical Field

The invention relates to the technical field of electronic information, in particular to a toroidal magnetic core, a toroidal transformer, an inductor and an automatic manufacturing method thereof.

Background

The toroidal magnetic core is widely applied to power grids, high-power supplies, photovoltaic inverters, UPS, vehicles or large-scale charging equipment, such as flat vertical winding toroidal inductors and transformers, and has the advantages of simple and firm structure, simplicity and convenience in production, uniform magnetic field distribution, small magnetic flux leakage and the like.

For a flat vertical winding annular inductor or a flat vertical winding annular transformer, the power of the device is improved, the working current is larger, and the heat dissipation performance is more excellent, however, when a coil is assembled on an annular magnetic core, the coil can be installed only by cutting an opening on the annular magnetic core, the opening is supplemented by adhesive glue on the end face of the opening after the coil is assembled, so that the air gap on the end face is increased, the electrical parameters of the inductor or the flat vertical winding annular transformer are changed, for example, the inductance is reduced, meanwhile, the electrical parameters are unstable due to the fact that the glue is not easy to control, and in addition, the material density and the hardness of the magnetic core are higher, so that the magnetic core is difficult to cut, the cutting efficiency is.

Disclosure of Invention

The invention mainly solves the technical problem of providing a toroidal magnetic core, a toroidal transformer and an inductor which generate stable electrical parameters and an automatic manufacturing method thereof.

According to a first aspect, an embodiment provides a toroidal core comprising a first core and a second core;

the first magnetic core comprises a first magnetic block and a second magnetic block which are overlapped together from the height direction or the thickness direction, at least part of the surface of the first magnetic block and at least part of the surface of the second magnetic block are attached together, and the end parts of the first magnetic block and the second magnetic block are staggered by a certain angle to form a step;

the second magnetic core comprises a third magnetic block and a fourth magnetic block which are overlapped together from the height direction or the thickness direction, at least partial surfaces of the third magnetic block and at least partial surfaces of the fourth magnetic block are attached together, and the end parts of the third magnetic block and the fourth magnetic block are staggered by a certain angle to form a step and are matched with the step formed by the end part of the first magnetic core;

and two end parts of the first magnetic core and two end parts of the second magnetic core are respectively butted to form an annular magnetic core.

Further, the annular magnetic core is formed by fixedly butting two end parts of the first magnetic core and two end parts of the second magnetic core in a horizontal direction of the step by means of glue dispensing.

Further, the first magnetic block and the second magnetic block have the same geometric center of gravity, and the third magnetic block and the fourth magnetic block have the same geometric center of gravity.

Further, all the outer surfaces of the first magnetic core and the second magnetic core except the joint surface are attached with insulating layers.

Furthermore, the edges of the first magnetic core and the second magnetic core are provided with chamfers.

Further, the annular magnetic core can be in a circular ring shape or a square-shaped structure.

According to a second aspect, an embodiment provides a toroidal inductor comprising a toroidal core and a coil wound on the toroidal core.

According to a third aspect, an embodiment provides a toroidal transformer comprising a toroidal core, and a primary coil and a secondary coil; the primary coil and the secondary coil are wound on the annular magnetic core, and the number of winding turns of the primary coil and the number of winding turns of the secondary coil are different.

According to a fourth aspect, an embodiment provides an automated manufacturing method of a toroidal inductor, comprising the steps of:

obtaining a first magnetic core, wherein the first magnetic core comprises a first magnetic block and a second magnetic block which are overlapped together from the height direction or the thickness direction, at least part of the surface of the first magnetic block and at least part of the surface of the second magnetic block are attached together, and the end parts of the first magnetic block and the second magnetic block are staggered by a certain angle to form a step;

obtaining a second magnetic core, wherein the second magnetic core comprises a third magnetic block and a fourth magnetic block which are overlapped together from the height direction or the thickness direction, at least partial surfaces of the third magnetic block and at least partial surfaces of the fourth magnetic block are attached together, and the end parts of the third magnetic block and the fourth magnetic block are staggered by a certain angle to form a step and are matched with the step formed by the end part of the first magnetic core;

winding a winding coil on the first magnetic core and/or the second magnetic core respectively;

and respectively dispensing, butting and fixing two end parts of the first magnetic core and two end parts of the second magnetic core to form the annular inductor.

According to the toroidal core, the toroidal transformer and the inductor of the above embodiments and the automated manufacturing method thereof, the steps are formed at the two ends of the first magnetic core and the second magnetic core respectively, and since the two ends of the first magnetic core and the two ends of the second magnetic core are respectively connected to form the toroidal core by dispensing glue in the horizontal direction of the steps, the dispensing position is not on the magnetic path of the toroidal core, thereby not affecting the electrical parameters of the toroidal core, the toroidal inductor or the transformer has stable electrical parameters.

Drawings

FIG. 1 is a schematic diagram of an inductor with a magnetic core having a circular ring structure according to an embodiment;

FIG. 2 is a schematic diagram of a specific structure of the first magnetic core or the second magnetic core according to an embodiment;

FIG. 3 is a schematic diagram of a specific structure of a first magnetic core or a second magnetic core according to another embodiment;

FIG. 4 is a schematic diagram of a specific structure of a winding coil wound by a first magnetic core or a second magnetic core;

FIG. 5 is a schematic view of the first or second magnetic core being painted with an insulating paint;

fig. 6(a) is a detailed structural view of a first and/or a second core of a toroidal core having a square-shaped structure according to an embodiment, and fig. 6(b) is a structural view of a toroidal core having a square-shaped structure according to an embodiment;

fig. 7(a) is a detailed structural view of a first and/or a second core of a toroidal core having a square-shaped structure according to another embodiment, and fig. 7(b) is a structural view of a toroidal core having a square-shaped structure according to another embodiment;

FIG. 8 is a flow chart of an automated method of manufacturing a toroidal inductor;

fig. 9(a) is a structural view of a toroidal core with an opening, fig. 9(b) is a structural view of a coil, and fig. 9(c) is a structural view after the coil is assembled to the toroidal core.

Detailed Description

The present invention will be described in further detail with reference to the following detailed description and accompanying drawings. Wherein like elements in different embodiments are numbered with like associated elements. In the following description, numerous details are set forth in order to provide a better understanding of the present application. However, those skilled in the art will readily recognize that some of the features may be omitted or replaced with other elements, materials, methods in different instances. In some instances, certain operations related to the present application have not been shown or described in detail in order to avoid obscuring the core of the present application from excessive description, and it is not necessary for those skilled in the art to describe these operations in detail, so that they may be fully understood from the description in the specification and the general knowledge in the art.

Furthermore, the features, operations, or characteristics described in the specification may be combined in any suitable manner to form various embodiments. Also, the various steps or actions in the method descriptions may be transposed or transposed in order, as will be apparent to one of ordinary skill in the art. Thus, the various sequences in the specification and drawings are for the purpose of describing certain embodiments only and are not intended to imply a required sequence unless otherwise indicated where such sequence must be followed.

The numbering of the components as such, e.g., "first", "second", etc., is used herein only to distinguish the objects as described, and does not have any sequential or technical meaning. The term "connected" and "coupled" when used in this application, unless otherwise indicated, includes both direct and indirect connections (couplings).

Referring to fig. 9, fig. 9 is a structural diagram of a conventional toroidal core, where fig. 9(a) is a toroidal core with an opening, fig. 9(b) is a coil, and fig. 9(c) is a structural diagram of a coil assembled on a toroidal core, when assembling the coil, the toroidal coil is cut into an opening by a cutting machine, then the coil is assembled on the toroidal core with an opening through the opening, and after assembling the coil, the cut-off core is bonded to the opening by adhesive on an end surface of the opening to obtain a complete toroidal core. Because the glue is adhered to the end face of the opening and is positioned on the magnetic circuit of the magnetic core, after the coil is assembled, the inductance is reduced because the air gap in the glue is larger than that of the magnetic core, and the inductance is unstable due to the difference of the glue amount. In addition, the magnetic core is mainly made of ferrite, alloy powder, amorphous and silicon steel, and the density and hardness of the magnetic core are high, so that the cutting opening is very difficult, the cutting efficiency is low, the cost is high, and the requirement on cutting equipment is high.

In the embodiment of the invention, the annular magnetic core is formed by respectively butting the two end parts of the first magnetic core and the two end parts of the second magnetic core, the two end parts of the first magnetic core and/or the second magnetic core are provided with matched steps, after the coil is assembled on the first magnetic core and/or the second magnetic core, the two end parts of the first magnetic core and the two end parts of the second magnetic core are fixedly butted together by dispensing glue in the horizontal direction of the steps, so that the dispensing glue is not positioned on a magnetic path of the magnetic core, the electric parameters of the dispensing glue are not influenced, and the electric parameters of the annular magnetic core are stabilized.

For convenience of description, the present embodiment is described by taking an inductor with a magnetic core having a circular ring structure as an example.

The first embodiment is as follows:

referring to fig. 1, fig. 1 is a schematic structural diagram of an inductor with a magnetic core having a circular ring structure according to an embodiment, which includes: annular magnetic core 2 and coil 1, coil 1 twines on annular magnetic core 2.

The annular magnetic core comprises a first magnetic core and a second magnetic core, as shown in fig. 2 and 5, the first magnetic core comprises a first magnetic block 201 and a second magnetic block 203 which are stacked together from a height direction or a thickness direction, at least part of the surface of the first magnetic block 201 and at least part of the surface of the second magnetic block 203 are bonded together, wherein fig. 2 shows the first magnetic block 201 and the second magnetic block 203 which are stacked together from the height direction, the height direction in the embodiment refers to a direction from top to bottom or from bottom to top in fig. 2, fig. 3 shows the first magnetic block 201 and the second magnetic block 203 which are stacked together from the thickness direction, and the end portions of the first magnetic block 201 and the second magnetic block 203 are staggered to form steps, the thickness direction in the embodiment refers to a direction from left to right or from right to left in fig. 3, and in the embodiment, the first magnetic block 201 and the second magnetic block 203 are stacked and bonded together by dispensing; similarly, the second magnetic core comprises a third magnetic block and a fourth magnetic block which are overlapped together from the height direction or the thickness direction, at least part of surfaces of the third magnetic block and at least part of surfaces of the fourth magnetic block are attached together, the end parts of the third magnetic block and the fourth magnetic block are staggered to form a step and matched with the step formed at the end part of the first magnetic core, and the third magnetic block and the fourth magnetic block are overlapped and adhered together through glue dispensing.

Before the two ends of the first magnetic core and the second magnetic core are respectively butted, the winding coil 1 needs to be wound on the first magnetic core and/or the second magnetic core, as shown in fig. 4, if the annular inductor is an annular filter inductor, an annular boost inductor and the like, the winding coil 1 only needs to be wound on any one of the first magnetic core and the second magnetic core; if the annular inductor is a common-mode inductor, two groups of winding coils 1 with the same number of turns need to be wound on the first magnetic core and the second magnetic core respectively, and the winding directions are opposite; if the toroidal core is used in a toroidal transformer, two sets of winding coils 1 with different turns need to be wound around the first and second magnetic cores, respectively.

The first and second magnetic cores in this embodiment are symmetrically matched in structure, and when the magnetic cores are butted, the annular magnetic core 2 is formed by glue dispensing and fixed butting in the horizontal direction of the step 202, specifically, in the first and/or second magnetic cores of the structure shown in fig. 2, glue dispensing and fixed butting is performed on the upper surface and the lower surface of the step 202, in the first and/or second magnetic cores of the structure shown in fig. 3, glue dispensing and fixed butting is performed on the inner side surface and the outer side surface of the step 202, and since the magnetic path of the annular magnetic core 2 is in the circumferential direction, the position where the glue dispensing and butting is performed in this embodiment is not on the magnetic path of the annular magnetic core, and the inductance of the inductor is not affected.

In order to facilitate the bonding of the first magnetic core and the second magnetic core, the surfaces used for butt joint in the steps at the two ends of the first magnetic core and/or the second magnetic core are polished to form a polished surface, so that no gap exists at the joint of the first magnetic core and the second magnetic core, the connection is tighter, and the inductance is improved.

Be equipped with the chamfer on the whole edges of first magnetic core and second magnetic core, the ring limit on the ring shape structure magnetic core has all carried out the chamfer promptly and has handled, and it can be for straight chamfer or round chamfer to prevent that the magnetic core edge is too sharp and will assemble the winding coil damage on the magnetic core.

All surfaces of the first magnetic core and the second magnetic core except the joint surface are respectively attached with an insulating layer, and a layer of insulating paint 3 can be sprayed on the insulating layers. Specifically, when the insulating paint 3 is sprayed on the outer surfaces of the first and/or second magnetic cores except for the joint surface, the first and second magnetic blocks 201 and 203 may be sprayed respectively before being overlapped and bonded, as shown in fig. 5, all the surfaces of the first and second magnetic blocks 201 and 203 except for the joint surface are sprayed with the insulating paint 3, after the first and second magnetic blocks 201 and 203 are separately sprayed, the insulating paint 3 is dried and then fixed by dispensing, the outer surfaces of the first and/or second magnetic cores obtained after the dispensing and fixing are sprayed with the insulating paint 3, and when the insulating paint 3 is sprayed on the first and second magnetic blocks 201 and 203, one surface (joint surface) of each of the first and second magnetic blocks 201 and 203 is not sprayed, so that when the insulating paint is sprayed, the surface which is not sprayed is in contact with the bearing object, the other surfaces are sprayed, and no secondary spraying is needed, the spraying process is simplified.

The arc length of first magnetic core and/or second magnetic core in this embodiment is half of annular magnetic core girth, and first magnetic core and second magnetic core are half circle ring structure promptly, only need a mould can produce first magnetic core and second magnetic core simultaneously when producing like this, and is with low costs, production efficiency is high, easily realizes automated production.

In this embodiment, the first magnetic block and the second magnetic block have the same geometric gravity center, and the third magnetic block and the fourth magnetic block have the same geometric gravity center.

In another specific embodiment, the annular magnetic core 2 may also have a square-shaped structure, please refer to fig. 6, where fig. 6(a) is a specific structural diagram of a first and/or a second magnetic core of the square-shaped annular magnetic core according to an embodiment, and fig. 6(b) is a structural diagram of the square-shaped annular magnetic core according to an embodiment; fig. 7 is a schematic structural diagram of a toroidal core with a square-shaped structure according to another embodiment, where fig. 7(a) is a schematic structural diagram of a first and/or a second core of a toroidal core with a square-shaped structure according to another embodiment, and fig. 7(b) is a schematic structural diagram of a toroidal core with a square-shaped structure according to another embodiment. The specific embodiments of the first and/or second magnetic cores have been described in detail in the magnetic core with a circular ring structure, and are not described herein in detail.

Referring to fig. 8, fig. 8 shows an automated manufacturing method of a toroidal inductor according to an embodiment, including the following steps:

and S1, obtaining a first magnetic core, wherein the first magnetic core comprises a first magnetic block and a second magnetic block which are overlapped together from the height direction or the thickness direction, at least part of the surface of the first magnetic block and at least part of the surface of the second magnetic block are attached together, and the end parts of the first magnetic block and the second magnetic block are staggered by a certain angle to form a step. In the circular magnetic core in this embodiment, in order to facilitate generation, the first magnetic block and the second magnetic block may be both configured as magnetic blocks having the same shape and size and having a semicircular annular structure, and if the first magnetic block and the second magnetic block are semicircular, the end portions of the first magnetic block and the second magnetic block are staggered by 15 ° to 45 ° according to the size of the circular magnetic core to form a step.

S2, obtaining a second magnetic core, wherein the second magnetic core comprises a third magnetic block and a fourth magnetic block which are overlapped together from the height direction or the thickness direction, at least part of the surface of the third magnetic block and at least part of the surface of the fourth magnetic block are attached together, and the end parts of the third magnetic block and the fourth magnetic block are staggered by a certain angle to form a step and are matched with the step formed by the end part of the first magnetic core; similarly, the molds of the third magnetic block and the fourth magnetic block can be set to be semi-circular structures with the same size and shape.

S3, winding a winding coil on the first magnetic core and/or the second magnetic core respectively; for toroidal inductors of different applications, the number of turns of winding coils is different, and the winding manner is also different, for example, in a common mode toroidal inductor, winding coils of the same number of turns and opposite directions are required to be wound on the first magnetic core and the second magnetic core respectively.

And S4, after the winding coil is wound on the first magnetic core and/or the second magnetic core, respectively butting two end parts of the first magnetic core and two end parts of the second magnetic core to form a ring-shaped inductor.

In the embodiment, a test is performed on a ring-shaped magnetic core with a circular ring structure, the ring-shaped magnetic core is manufactured by taking the conventional FeSi system magnetic powder core PF158060 as a sample plate, the external dimension is phi 40 phi 22 phi 17 (external diameter and internal diameter and height), opening a die and pressing the sample plate into a semicircular ring (a first magnetic core and/or a second magnetic core), in order to reduce the die, the first magnetic block and the second magnetic block of the embodiment are equal in height and all have the external dimension of phi 40 phi 22 phi 8.5, after insulating paint is sprayed on the first magnetic block and the second magnetic block respectively, the first magnetic block and the second magnetic block are overlapped and bonded, the angle is staggered by 30 degrees, a coil is formed by adopting a 0.8 phi 6mm F-level flat wire through a vertical winding machine, the number of turns of the magnetic core is 24, the formed flat vertical winding coil is sleeved outside the first magnetic core or the second magnetic core in a rotating mode, or the first magnetic core or the second magnetic core is rotated into an internal cavity of the flat winding coil, and the upper surface or the lower surface, and then assembling the other half of the bonded first magnetic core or second magnetic core in a combined manner to form a ring-shaped magnetic core with a complete magnetic circuit structure, and finally curing the bonding glue to process the pin outlet position of the coil. After the inductors were assembled as described above, the inductors were tested and the test structures are shown in table 1.

TABLE 1 test results

As can be seen from the test results in table 1, the inductance of the inductor is higher than that of the prior art, and is only 5.7% lower than the theoretical value of 70uH, and other electrical parameters and tensile strength are the same as those of the inductor in the prior art.

Example two:

the embodiment provides a toroidal transformer, which comprises a toroidal magnetic core, a primary coil and a secondary coil; the annular magnetic core is any one of the annular magnetic cores provided in the first embodiment, and the specific implementation of the annular magnetic core has been described in detail in the first embodiment, and is not described herein again.

The number of turns of the primary coil and the secondary coil is different; and the primary coil and the secondary coil are wound on the annular magnetic core and form a primary winding and a secondary winding respectively. The number of turns of the primary winding and the number of turns of the secondary winding are set according to the application of the toroidal transformer, and generally, in the case of a step-up transformer, the number of turns of the primary winding is smaller than the number of turns of the secondary winding, and in the case of a step-down transformer, the number of turns of the primary winding is larger than the number of turns of the secondary winding.

The present invention has been described in terms of specific examples, which are provided to aid understanding of the invention and are not intended to be limiting. For a person skilled in the art to which the invention pertains, several simple deductions, modifications or substitutions may be made according to the idea of the invention.

Claims (9)

1. A ring-shaped magnetic core is characterized by comprising a first magnetic core and a second magnetic core;

the first magnetic core comprises a first magnetic block and a second magnetic block which are overlapped together from the height direction or the thickness direction, at least part of the surface of the first magnetic block and at least part of the surface of the second magnetic block are attached together, and the end parts of the first magnetic block and the second magnetic block are staggered by a certain angle to form a step;

the second magnetic core comprises a third magnetic block and a fourth magnetic block which are overlapped together from the height direction or the thickness direction, at least partial surfaces of the third magnetic block and at least partial surfaces of the fourth magnetic block are attached together, and the end parts of the third magnetic block and the fourth magnetic block are staggered by a certain angle to form a step and are matched with the step formed by the end part of the first magnetic core;

and two end parts of the first magnetic core and two end parts of the second magnetic core are respectively butted to form an annular magnetic core.

2. The toroidal core according to claim 1, wherein said toroidal core is constituted by fixedly butting both end portions of the first core and both end portions of the second core by dispensing in a horizontal direction of the step, respectively.

3. The toroidal core according to claim 1 or 2, wherein said first and second magnetic blocks have the same geometric center of gravity and said third and fourth magnetic blocks have the same geometric center of gravity.

4. A toroidal magnetic core as claimed in claim 1 or 2, wherein said first and second magnetic cores are provided with insulating layers on all outer surfaces except for the joint surfaces.

5. An annular magnetic core according to claim 1 or 2, wherein the edges of the first and second magnetic cores are chamfered.

6. A toroidal core as claimed in claim 1 or 2, wherein said toroidal core is of circular or square configuration.

7. A toroidal inductor comprising a toroidal core according to any of claims 1 to 6 and a coil wound around said toroidal core.

8. A toroidal transformer comprising a toroidal core according to any of claims 1 to 6, and a primary coil and a secondary coil; the primary coil and the secondary coil are wound on the annular magnetic core, and the number of winding turns of the primary coil and the number of winding turns of the secondary coil are different.

9. An automated manufacturing method of a toroidal inductor, comprising the steps of:

obtaining a first magnetic core, wherein the first magnetic core comprises a first magnetic block and a second magnetic block which are overlapped together from the height direction or the thickness direction, at least part of the surface of the first magnetic block and at least part of the surface of the second magnetic block are attached together, and the end parts of the first magnetic block and the second magnetic block are staggered by a certain angle to form a step;

obtaining a second magnetic core, wherein the second magnetic core comprises a third magnetic block and a fourth magnetic block which are overlapped together from the height direction or the thickness direction, at least partial surfaces of the third magnetic block and at least partial surfaces of the fourth magnetic block are attached together, and the end parts of the third magnetic block and the fourth magnetic block are staggered by a certain angle to form a step and are matched with the step formed by the end part of the first magnetic core;

winding a winding coil on the first magnetic core and/or the second magnetic core respectively;

and respectively dispensing, butting and fixing two end parts of the first magnetic core and two end parts of the second magnetic core to form the annular inductor.

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