CN112489958A - Novel low-loss transformer - Google Patents
Novel low-loss transformer Download PDFInfo
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- CN112489958A CN112489958A CN202011296378.2A CN202011296378A CN112489958A CN 112489958 A CN112489958 A CN 112489958A CN 202011296378 A CN202011296378 A CN 202011296378A CN 112489958 A CN112489958 A CN 112489958A
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- 239000006247 magnetic powder Substances 0.000 claims abstract description 34
- 238000004804 winding Methods 0.000 claims abstract description 28
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 24
- 239000000956 alloy Substances 0.000 claims abstract description 24
- 239000002184 metal Substances 0.000 claims abstract description 15
- 229910052751 metal Inorganic materials 0.000 claims abstract description 15
- 239000002245 particle Substances 0.000 claims abstract description 14
- 239000011248 coating agent Substances 0.000 claims abstract description 8
- 238000000576 coating method Methods 0.000 claims abstract description 8
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 14
- KSIIOJIEFUOLDP-UHFFFAOYSA-N [Si].[Fe].[Ni] Chemical compound [Si].[Fe].[Ni] KSIIOJIEFUOLDP-UHFFFAOYSA-N 0.000 claims description 11
- 230000035699 permeability Effects 0.000 claims description 9
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 8
- 229910052759 nickel Inorganic materials 0.000 claims description 7
- 230000008859 change Effects 0.000 claims description 5
- 238000009413 insulation Methods 0.000 claims description 5
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 4
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 claims description 4
- 229910052802 copper Inorganic materials 0.000 claims description 4
- 239000010949 copper Substances 0.000 claims description 4
- 229910052742 iron Inorganic materials 0.000 claims description 4
- 239000000843 powder Substances 0.000 claims description 4
- 229910052710 silicon Inorganic materials 0.000 claims description 4
- 239000010703 silicon Substances 0.000 claims description 4
- 239000011810 insulating material Substances 0.000 claims description 3
- 229910000859 α-Fe Inorganic materials 0.000 abstract description 12
- 230000004907 flux Effects 0.000 abstract description 11
- 238000009792 diffusion process Methods 0.000 abstract description 8
- 238000006243 chemical reaction Methods 0.000 abstract description 5
- 239000011162 core material Substances 0.000 description 82
- 238000004088 simulation Methods 0.000 description 7
- 238000010586 diagram Methods 0.000 description 4
- 230000007547 defect Effects 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 229910000990 Ni alloy Inorganic materials 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000009713 electroplating Methods 0.000 description 1
- 238000004146 energy storage Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000017525 heat dissipation Effects 0.000 description 1
- 210000001503 joint Anatomy 0.000 description 1
- 239000006249 magnetic particle Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000021715 photosynthesis, light harvesting Effects 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/24—Magnetic cores
- H01F27/255—Magnetic cores made from particles
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/34—Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/34—Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
- H01F2027/348—Preventing eddy currents
Abstract
The invention provides a novel low-loss transformer which comprises two or more magnetic cores, a coil, a winding framework and a conductive metal terminal, wherein the coil is wound on the winding framework, and the magnetic cores are formed by insulating and coating one or more high-saturation low-loss alloy magnetic powder and an insulating medium, then pressing the magnetic cores through a die and then baking and curing the magnetic cores at a high temperature. The initial magnetic conductivity of the magnetic core is 10-250, and the magnetic conductivity can be adjusted by changing the proportion of the particle sizes of the magnetic powder, so that a closed magnetic circuit without air gaps is realized. The problems of increased eddy current loss and poor EMI performance caused by the diffusion of magnetic flux in the air gap of the traditional ferrite core structure in high-frequency application are solved. The transformer without air bubbles has the advantages of high reliability, high power density, high conversion efficiency, high saturation magnetic flux density, excellent heavy current resistance and EMI performance. Can completely replace the traditional transformer ferrite air gap core structure.
Description
Technical Field
The invention relates to a transformer, in particular to a novel low-loss transformer.
Background
In high-frequency transformer application, in order to achieve energy storage, prevent core saturation and obtain smaller inductance fluctuation under a large-current working state, an air gap design needs to be performed on a traditional ferrite core magnetic circuit to meet the performance requirement of a product, but the following defects exist: a large amount of diffusion magnetic flux can be generated at the air gap, high-frequency eddy current loss is generated in the coil winding cut by the diffusion magnetic flux, and the efficiency of the transformer is reduced. And the EMI performance of the transformer is deteriorated due to the influence of the air gap diffusing magnetic flux. As the switching frequency increases, the additional high frequency eddy current losses near the air gap increase significantly and the EMI performance deteriorates even more.
Disclosure of Invention
The invention aims to provide a novel low-loss transformer, which reduces the energy loss of the transformer and improves the conversion efficiency.
Aiming at the defects of the traditional ferrite technology, the invention provides a novel transformer without air gaps
The technical solution of the invention is as follows:
a novel low-loss transformer comprises a magnetic core main body, a coil, a winding framework and a conductive metal terminal, wherein the magnetic core main body comprises a magnetic core column and side columns, the magnetic core column and the side columns are connected through connecting end parts at two ends to form a magnetic conduction structure with a cross section in a shape of a Chinese character 'ri', the coil is wound on the magnetic core column, the magnetic core column penetrates through a central channel of the coil, and the tail ends of the end heads of the coil are respectively and electrically connected with the conductive metal terminal; the side columns are wrapped on the outer side of the winding framework, and the coil and the magnetic core main body form a closed magnetic circuit transformer structure without an air gap.
The novel low-loss transformer is characterized in that the magnetic core main body is of a two-part combined structure cut from the middle of the magnetic core column, and the cut surfaces of the magnetic core column and the side column are in close contact.
The novel low-loss transformer is characterized in that the magnetic core main body is made by insulating and coating one or more alloy magnetic powder and an insulating medium, then pressing the alloy magnetic powder and the insulating medium through a die, and then baking and curing at a high temperature.
The novel low-loss transformer is characterized in that the grain size of the alloy magnetic powder is 1-100 μm.
The novel low-loss transformer is characterized in that the alloy magnetic powder is made of alloy powder containing 85% of iron, 8.2% of silicon and 6.8% of nickel, the iron-silicon-nickel magnetic powder is insulated and coated with an insulating medium, then the iron-silicon-nickel magnetic powder is pressed by a die, and the iron-silicon-nickel magnetic powder is baked and solidified at the temperature of over 500 ℃.
The novel low-loss transformer is characterized in that the alloy magnetic powder has a particle size of 16 μm and a density of 6.8g/cm3The effective magnetic permeability of the magnetic core main body is 54 +/-8%; under the condition of 55A direct current bias, the inductance change is less than 20%.
The novel low-loss transformer comprises a magnetic core main body, wherein the magnetic core main body is of an air-gap-free structure, the magnetic conductivity is 10-250, and when the magnetic core main body is manufactured, the proportion and the particle size of the alloy magnetic powder are changed to obtain the magnetic core main body with different magnetic conductivities and an air-gap-free closed loop.
The novel low-loss transformer is characterized in that the coil is wound on the winding frame, the winding frame is installed in the magnetic core body and sleeved on the magnetic core column, and the winding frame is made of an insulating material and used for supporting the coil winding and insulating.
The novel low-loss transformer is characterized in that the conductive metal terminal is made of red copper C1100, and the outer layer of the conductive metal terminal is plated with nickel and tin.
The novel low-loss transformer comprises two or more windings, wherein the two or more windings are respectively wound on the bobbin, and the coil is formed by litz film-covered wires with the diameter of 0.05mm × 650 strands.
From the above description, it is clear that the present invention has the following advantages:
the invention provides a novel low-loss transformer which comprises two or more magnetic cores, a coil, a winding framework and a conductive metal terminal, wherein the coil is wound on the winding framework, and the magnetic cores are formed by insulating and coating one or more high-saturation low-loss alloy magnetic powder and an insulating medium, then pressing the magnetic cores through a die and then baking and curing the magnetic cores at a high temperature. The initial magnetic permeability of the magnetic core is 10-250, the magnetic permeability can be adjusted by changing the size proportion of the magnetic powder particle size (air gap adjustment is not needed), and therefore a closed magnetic circuit without air gaps is achieved. The problems of increased eddy current loss and poor EMI performance caused by air gap diffusion magnetic flux of a traditional ferrite core structure (needing an air gap) in high-frequency application are solved. The transformer without air bubbles has the advantages of high reliability, high power density, high conversion efficiency, high saturation magnetic flux density, excellent heavy current resistance and EMI performance. Can completely replace the traditional transformer ferrite air gap core structure.
Drawings
FIG. 1 is a schematic perspective view of a transformer according to an embodiment of the present invention;
FIG. 2 is a schematic bottom view of a transformer according to an embodiment of the present invention;
FIG. 3A is a first schematic diagram of a magnetic core body of a transformer according to an embodiment of the present invention;
FIG. 3B is a second schematic diagram of a magnetic core body of a transformer according to an embodiment of the invention;
FIG. 4 is a graph of eddy current losses due to air gap diffusion flux in a conventional ferrite core structure;
FIG. 5 is a simulation diagram of the magnetic flux without air gap diffusion of the transformer according to one embodiment of the present invention;
FIG. 6 is a simulation graph of loss increase temperature rise for a conventional ferrite core structure;
FIG. 7 is a temperature rise simulation diagram of a low loss transformer according to the present invention;
FIG. 8 is a graph illustrating EMI performance degradation caused by air gap diffusion flux of a conventional ferrite core junction structure;
fig. 9 is an EMI test chart of a low-loss transformer according to the present invention.
Main element number description:
the invention comprises the following steps:
1: magnetic core main body 11: the magnetic core column 12: side column
2: coil 3: and (4) winding the framework: conductive metal terminal
5: side column joint surface 6: core leg joint face
Detailed Description
In order to more clearly understand the technical features, objects, and effects of the present invention, embodiments of the present invention will now be described with reference to the accompanying drawings.
In a preferred embodiment of the present invention, please refer to fig. 1 to 3, the novel low-loss transformer includes a magnetic core main body 1, a coil 2, a bobbin 3, and a conductive metal terminal 4, the magnetic core main body 1 includes a magnetic core post 11 and a side post 12, the magnetic core post 11 and the side post 12 are connected via connecting ends at two ends to form a magnetic conductive structure with a cross section in a shape of a japanese letter, of course, only one magnetic core post 11 is taken as an example here, or two magnetic core posts 11 may form a magnetic conductive structure in a shape of a chinese character "mu", or more magnetic core posts 11 may be used. The coil 2 is wound on the core leg 11, the core leg 11 passes through the central passage of the coil 2, when more core legs 11 are provided, the coil can be wound in more winding forms, or a plurality of independent coils 2 can be directly wound, and the like. The tail ends of the coils 2 are respectively and electrically connected with a conductive metal terminal 4; the side column 12 is wrapped on the outer side of the winding frame 3, and the coil 2 and the magnetic core main body 1 form a closed magnetic circuit transformer structure without an air gap. As shown in the figure, the novel low-loss transformer of the present invention has a structure of a fully-conducting magnetic core column 11 and a side column 12, and particularly, adopts a magnetic core column structure which is not disconnected continuously and is not provided with an air gap, so that the magnetic core main body 1 of the present invention has a closed magnetic circuit which is continuously conducted, and the problems of increased eddy current loss and poor anti-electromagnetic and interference performance caused by air gap diffusion magnetic flux of the conventional ferrite magnetic core structure in high-frequency application of the transformer when the magnetic core main body 1 of the existing transformer adopts the air gap structure to adjust the magnetic permeability of the transformer are avoided. The invention has the advantages of low loss and high conversion efficiency, reduces the energy dissipation, reduces the heat dissipation pressure of the transformer and has better temperature characteristic.
In the preferred embodiment of the novel low-loss transformer of the present invention, the core body 1 is a two-part combination structure cut from the middle of the core leg 11, and the cut surfaces of the core leg 11 and the side legs 12 are in close contact. As shown in fig. 3, the magnetic core body 1 is composed of two parts, and by split combination of the two parts, the magnetic core body 1 can be processed more conveniently, the coil 2 can be wound and sleeved conveniently, meanwhile, the contact surface between the side columns 12 and the magnetic core columns 11 of the two parts is a smooth and close contact plane, and after the combination is completed, the magnetic core columns 11 and the side columns 12 on the two sides of the contact surface can form a good continuous magnetic conduction channel.
In the preferred embodiment of the novel low-loss transformer of the present invention, the magnetic core body 1 is made by insulating and coating one or more alloy magnetic powders and an insulating medium, pressing the coated alloy magnetic powders through a mold, and then baking and curing the pressed alloy magnetic powders at a high temperature. The magnetic core main body 1 does not adopt a traditional ferrite magnetic core structure, and adopts one or more high-saturation low-loss alloy magnetic powder and an insulating medium to carry out insulation coating and then baking pressing to form the magnetic core structure, so that the magnetic conductivity can be adjusted by changing the proportion of materials and the particle size, air gap adjustment is not needed, the magnetic conductivity and the large current magnetic saturation resistance are met, and the air gap-free closed loop of the transformer is realized.
In a preferred embodiment of the novel low-loss transformer of the present invention, the alloy magnetic powder has a particle size of 1 to 100 μm. When the magnetic core main body 1 is manufactured, the magnetic conductivity can be adjusted by changing the particle size, air gap adjustment is not needed, the magnetic conductivity and the large current magnetic saturation resistance are met, and therefore an air gap-free closed loop of the transformer is achieved.
In the preferred embodiment of the novel low-loss transformer of the present invention, the alloy magnetic powder is an iron-silicon-nickel magnetic powder composed of an alloy powder containing 85% of iron, 8.2% of silicon, and 6.8% of nickel, and is formed by performing insulation coating on the iron-silicon-nickel magnetic powder and an insulating medium, pressing the iron-silicon-nickel magnetic powder by a mold, and baking and curing the iron-silicon-nickel magnetic powder at a temperature of more than 500 ℃. When the magnetic core main body 1 is manufactured, the magnetic conductivity can be adjusted by changing the particle size, air gap adjustment is not needed, the magnetic conductivity and the large current magnetic saturation resistance are met, and therefore an air gap-free closed loop of the transformer is achieved.
In the preferred embodiment of the novel low-loss transformer of the present invention, the alloy magnetic powder has a particle size of 16 μm and a density of 6.8g/cm3The effective magnetic conductivity of the magnetic core main body 1 is 54 +/-8 percent(ii) a Under the condition of 55A direct current bias, the inductance change is less than 20%. The requirement of excellent effective magnetic conductivity of the transformer is met, the inductance change is small under the condition of high current, the running stability of the transformer is ensured, and the energy loss is reduced.
In the preferred embodiment of the novel low-loss transformer of the present invention, the magnetic core body 1 has an air-gap-free structure, and the magnetic permeability is between 10 and 250, and when the magnetic core body 1 is manufactured, the proportion and the particle size of the alloy magnetic powder are changed to obtain the magnetic core body 1 with an air-gap-free closed loop having different magnetic permeability. When the magnetic core main body 1 is manufactured, the magnetic conductivity can be adjusted by changing the particle size, air gap adjustment is not needed, the magnetic conductivity and the large current magnetic saturation resistance are met, and therefore an air gap-free closed loop of the transformer is achieved.
In the preferred embodiment of the novel low-loss transformer of the present invention, the coil 2 is wound on the bobbin 3, the bobbin 3 is mounted in the magnetic core body 1 and is sleeved on the magnetic core column 11, and the bobbin 3 is made of an insulating material and is used for supporting the coil winding and insulating. As shown in the figure, the coil 2 can be wound on the bobbin 3 and then sleeved in the magnetic core body 1, so that the insulation between the coil winding and the magnetic core body 1 is better, and the assembly is more convenient. Of course, in the novel low loss transformer of the present invention, when the insulation between the winding of the coil 2 and the magnetic core body 1 is good, the bobbin 3 may not be added.
In the preferred embodiment of the novel low-loss transformer of the present invention, the conductive metal terminals 4 are made of red copper C1100, and the outer layer thereof is plated with nickel and tin. The conductive terminals are mounted on the part of the winding frame 3 protruding out of the magnetic core main body 1 and are used for being connected with the outside of the transformer.
In the preferred embodiment of the novel low-loss transformer of the present invention, the coil 2 comprises two or more windings respectively wound on the bobbin 3, and the coil 2 is formed by litz film-covered wires with a diameter of 0.05mm × 650 strands. The insulating property of the coil is improved.
Hereinafter, one embodiment of the present invention will be described in detail, which is exemplified by a high frequency transformer of one PQ structure, but the present invention includes but is not limited to such a structure.
With reference to fig. 1, 2 and 3, the embodiment of the present invention employs a novel low-loss transformer, which comprises a two-part magnetic core body, a coil 2, a bobbin 3 and four conductive metal terminals 4; the magnetic core main body is of a PQ structure and comprises two side column joint surfaces 5 and a magnetic core column joint surface 6, the coil 2 is wound on the winding framework 3, the magnetic core column 11 penetrates through a center hole of the winding framework 3, and three joint surfaces of the two parts of the magnetic core main body are tightly jointed with each other to form a closed magnetic circuit without air gaps; the magnetic core material is prepared by insulating and coating iron-silicon-nickel magnetic powder consisting of 85.5% of iron, 8.2% of silicon and 6.8% of nickel alloy powder and an insulating medium, pressing the coated iron-silicon-nickel magnetic powder by a die, and baking and curing the coated iron-silicon-nickel magnetic powder at a high temperature of over 500 ℃. Wherein, magnetic particle size D50 ═ 16um, density is: 6.8g/cm 3. Wherein, the effective magnetic conductivity of the magnetic core main body is 54 +/-8%; the inductance change under 55A dc bias is less than 20%. Wherein, the terminal material is red copper C1100, and outer electroplating nickel and tin, and fix in winding skeleton 3 bottom both sides.
In addition, the coil has two coils wound on the bobbin 3, the coil is formed by litz film-covered wires with the diameter of 0.05mm × 650 strands, and 4 outgoing line connectors are respectively led out by welding on 4 conductive metal terminals 4.
By comparing the magnetic circuit simulation and the temperature simulation of the present embodiment with the conventional ferrite air gap structure, the magnetic circuit simulation of fig. 4 to 5, the temperature simulation results of fig. 6 and 7, and the EMI test results of fig. 8 and 9 are obtained correspondingly. Has low loss, high conversion efficiency and excellent temperature characteristics.
The above description is only an exemplary embodiment of the present invention, and is not intended to limit the scope of the present invention. Any equivalent changes and modifications that can be made by one skilled in the art without departing from the spirit and principles of the invention should fall within the protection scope of the invention.
Claims (10)
1. A novel low-loss transformer is characterized by comprising a magnetic core main body, a coil, a winding framework and a conductive metal terminal, wherein the magnetic core main body comprises a magnetic core column and side columns, the magnetic core column and the side columns are connected through connecting end parts at two ends to form a magnetic conduction structure with a cross section in a shape of a Chinese character 'ri', the coil is wound on the magnetic core column, the magnetic core column penetrates through a central channel of the coil, and the tail ends of the coil are respectively and electrically connected with the conductive metal terminal; the side columns are wrapped on the outer side of the winding framework, and the coil and the magnetic core main body form a closed magnetic circuit transformer structure without an air gap.
2. The novel low loss transformer of claim 1, wherein said core body is a two-part assembly structure cut from the middle of said core leg, said core leg being in intimate contact with said cut surface of said side leg.
3. The novel low-loss transformer according to claim 1 or 2, wherein the magnetic core body is made by insulating and coating one or more alloy magnetic powder and insulating medium, pressing the coated magnetic core body by a die, and then curing the coated magnetic core body by high-temperature baking.
4. The novel low-loss transformer according to claim 3, wherein the alloy magnetic powder has a particle size of 1 to 100 μm.
5. A novel low-loss transformer according to claim 4, characterized in that said alloy magnetic powder is made of iron-silicon-nickel magnetic powder composed of alloy powder containing 85% of iron, 8.2% of silicon and 6.8% of nickel, which is insulated and coated with insulating medium, pressed by a mold, and baked and solidified at 500 ℃ or higher.
6. The novel low-loss transformer according to claim 5, wherein the alloy magnetic powder has a particle size of 16 μm and a density of 6.8g/cm3The effective magnetic permeability of the magnetic core main body is 54 +/-8%; under the condition of 55A direct current bias, the inductance change is less than 20%.
7. The novel low-loss transformer of claim 3, wherein the magnetic core main body is of an air-gap-free structure, the magnetic permeability is 10-250, and when the magnetic core main body is manufactured, the proportion and the particle size of the alloy magnetic powder are changed to obtain the magnetic core main body with the air-gap-free closed loop and different magnetic permeability.
8. The new low loss transformer as claimed in claim 6 or 7, wherein said coil is wound on a bobbin, said bobbin is mounted inside said core body and fitted over said core leg, said bobbin is made of insulating material for supporting the coil winding and insulation.
9. The novel low loss transformer of claim 8, wherein said conductive metal terminals are made of red copper C1100, and their outer layers are plated with nickel and tin.
10. The novel low loss transformer of claim 9, wherein said coil comprises two or more windings wound on said bobbin, said coil being formed of litz film-covered wire having a diameter of 0.05mm x 650 strands.
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CN202011296378.2A CN112489958A (en) | 2020-11-18 | 2020-11-18 | Novel low-loss transformer |
PCT/CN2020/132591 WO2022104897A1 (en) | 2020-11-18 | 2020-11-30 | Novel low-loss transformer |
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Cited By (1)
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CN114199991A (en) * | 2021-12-14 | 2022-03-18 | 河北工业大学 | Device for measuring high-frequency magnetic characteristics of bar-shaped magnetostrictive material |
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Application publication date: 20210312 |