CN116612967A - Magnetic core and common mode choke coil using the same - Google Patents
Magnetic core and common mode choke coil using the same Download PDFInfo
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- CN116612967A CN116612967A CN202211091192.2A CN202211091192A CN116612967A CN 116612967 A CN116612967 A CN 116612967A CN 202211091192 A CN202211091192 A CN 202211091192A CN 116612967 A CN116612967 A CN 116612967A
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- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 48
- 239000000696 magnetic material Substances 0.000 claims abstract description 8
- 238000004804 winding Methods 0.000 claims description 16
- 229910052802 copper Inorganic materials 0.000 claims description 5
- 239000010949 copper Substances 0.000 claims description 5
- 238000004519 manufacturing process Methods 0.000 claims description 5
- 229910045601 alloy Inorganic materials 0.000 claims description 4
- 239000000956 alloy Substances 0.000 claims description 4
- 239000011888 foil Substances 0.000 claims description 2
- 238000010030 laminating Methods 0.000 claims description 2
- 229910000859 α-Fe Inorganic materials 0.000 description 18
- 230000035699 permeability Effects 0.000 description 14
- 230000004907 flux Effects 0.000 description 7
- 238000000034 method Methods 0.000 description 5
- 230000007547 defect Effects 0.000 description 2
- 239000010410 layer Substances 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 239000002159 nanocrystal Substances 0.000 description 2
- 230000002950 deficient Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000011229 interlayer Substances 0.000 description 1
- 229910001004 magnetic alloy Inorganic materials 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Classifications
-
- 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
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/04—Fixed inductances of the signal type with magnetic core
- H01F17/06—Fixed inductances of the signal type with magnetic core with core substantially closed in itself, e.g. toroid
-
- 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
- H01F27/245—Magnetic cores made from sheets, e.g. grain-oriented
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F2017/0093—Common mode choke coil
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/04—Fixed inductances of the signal type with magnetic core
- H01F17/06—Fixed inductances of the signal type with magnetic core with core substantially closed in itself, e.g. toroid
- H01F2017/065—Core mounted around conductor to absorb noise, e.g. EMI filter
Abstract
The invention provides a magnetic core for a common mode choke coil and a toroidal coil using the same. The magnetic core is formed of a nanocrystalline magnetic material, and when the width of the cross-sectional shape of the magnetic core is a, the height is b, the inner diameter of the magnetic core is ID, and the effective cross-sectional area of the magnetic core is Ae, the conditions b/a=1.0 to 1.3 are satisfied=4.0 to 5.3. According to the present invention, the core can be miniaturized, and the characteristics can be sufficiently ensured even if the amount of copper wire used is reduced.
Description
Technical Field
The present invention relates to a magnetic core and a common mode choke coil using the same, and more particularly, to a magnetic core capable of maintaining performance even if a winding length is reduced, and a common mode choke coil using the same.
Background
Conventionally, common mode choke coils have been widely used as noise preventing members in power supply devices such as AC adapters and home appliances. A toroidal ferrite core is often used in such a common mode choke because of its excellent balance of cost and performance. However, when the inductance value of the ferrite core is large and magnetic saturation is required not to occur even when a direct current is superimposed, the core must be enlarged to meet the requirement.
Accordingly, patent document 1 proposes a small toroidal coil using a small toroidal core by changing the material of a magnetic material. That is, this document proposes a method for manufacturing a toroidal coil as follows: a split toroidal core is inserted one by one into a cylindrical coil hollow portion while a cylindrical coil formed by winding a wire in advance is bent into a ring shape, and split surfaces are joined to form the toroidal core. In particular, this document discloses that the tubular coil is a square tubular coil around which a flat wire is wound.
In addition, defects of the wire when winding on the core have been studied in the prior art. For example, patent document 2 has proposed a case in which, focusing on the fact that a conventional case for a magnetic core has a square cross-sectional shape, when a wire is wound around its outer peripheral surface, the wire is subjected to excessive tension at the corners of the square, and thus a problem of a defective portion such as a pinhole or a crack is likely to occur.
In addition, a core using a nanocrystalline core having excellent characteristics has been developed in recent years and put into practical use. The nanocrystalline magnetic core has the characteristics of high magnetic permeability, high saturation magnetic flux density, excellent temperature characteristics, light weight and the like. Due to these features, the use of the nanocrystalline core can achieve high performance and miniaturization of the common mode choke coil. For example, patent document 3 proposes a coil component including a coil and a magnetic core having a laminate in which a plurality of soft magnetic layers having a thickness of 10 μm or more and 30 μm or less are laminated, and a structure composed of Fe-based nanocrystals is observed in the soft magnetic layers.
Prior art literature
Patent literature
Patent document 1: japanese patent laid-open No. 2001-68364
Patent document 2: japanese laid-open patent publication No. 1-153606
Patent document 3: japanese patent laid-open No. 2020-141041
Disclosure of Invention
Problems to be solved by the invention
As described above, patent document 1 proposes a technique of changing the material constituting the magnetic core to reduce the size of the toroidal coil. However, this document solves the above problems by improving the manufacturing method, and does not consider the shape of the core itself. Accordingly, one of the problems of the present invention is to provide a magnetic core capable of realizing miniaturization of a toroidal coil by reconsidering the shape of the magnetic core and also capable of reducing the amount of copper wire wound, and a toroidal coil using the magnetic core.
Further, although the above patent document 2 has studied defects in winding a wire (copper wire or the like) around a magnetic core, the characteristics such as inductance have not been studied sufficiently. Accordingly, another object of the present invention is to provide a magnetic core which can be miniaturized and can sufficiently secure characteristics even when the amount of copper wire used is reduced, and a toroidal coil using the magnetic core.
In addition, patent document 3 proposes a coil component composed of nanocrystals, but the nanocrystalline core has excellent characteristics, but its cost is high due to manufacturing processes and the like, so the adoption in general-purpose equipment remains in a small scale. Accordingly, another object of the present invention is to provide a common mode choke coil which is low in cost even if a nanocrystalline core is used as a core for a common mode choke coil, and which can be miniaturized even if it has the same performance as a common mode choke coil using a ferrite core, and a core for the common mode choke coil.
Means for solving the problems
The present inventors have made intensive studies to solve the above problems, and have focused on the magnetic saturation characteristics, the volume of the core, the inductance, and the copper wire amount, thereby solving the above problems.
That is, the present invention provides a magnetic core for a common mode choke coil, the magnetic core being formed of a nanocrystalline magnetic material, and having an effective cross-sectional area of a cross-section of the magnetic core as Ae, a width of a cross-sectional shape as a, a height as b, and an inner diameter of the magnetic core as ID, a/a=1.0 to 1.3 being a/a=1.0 to 1.3, and ID beingThe ratio is->
The present invention also provides a common mode choke coil including a magnetic core and copper wires wound around the magnetic core. The copper wire wound around the core may be a round wire or a flat wire, and particularly in the case of using a flat wire, may be a common mode choke coil wound around the core in an edgewise (edgewise) direction.
The present invention also provides a method for manufacturing the common mode choke coil of the present invention, wherein the copper wire is wound around a magnetic core formed of a laminated core formed by laminating nanocrystalline alloy foils into a ring-shaped body by an automatic winding machine.
Effects of the invention
The magnetic core for a common mode choke coil of the present invention is formed of a nanocrystalline magnetic material, and satisfies the conditions b/a=1.0 to 1.3, when the width of the cross-sectional shape of the magnetic core is a, the height is b, the inner diameter of the magnetic core is ID, and the effective cross-sectional area of the magnetic core is Ae,Thus, a magnetic core which can be miniaturized and which can be sufficiently ensured even when the amount of copper wire used is reduced, and a common mode choke coil using the same can be providedPreserving its characteristics. In particular, it is possible to provide a common mode choke coil which can be miniaturized even if a nanocrystalline magnetic core is used, and which can be miniaturized even if the same performance as a common mode choke coil using a ferrite magnetic core is provided, and a magnetic core used for the common mode choke coil.
Drawings
Fig. 1 is a perspective view (a), a front view (B), and a cross-sectional view (C) C-C of the magnetic core according to the present embodiment.
Fig. 2 is a perspective view of a common mode choke coil formed by winding (a) a flat wire and (B) a round wire using the magnetic core of fig. 1.
FIG. 3 is a schematic diagram of example 2Is a graph of (2).
FIG. 4 is a graph showing the results of example 3.
Symbol description: 10. a magnetic core; 20. and a common mode choke.
Detailed Description
The magnetic core of the present embodiment and the common mode choke coil formed using the same will be described in detail below with reference to the drawings. In particular, in the present embodiment, the core is formed of a nanocrystalline magnetic material.
Fig. 1 is a front view (a), a perspective view (B), and a cross-sectional view (C) C-C of a magnetic core 10 according to the present embodiment. In particular, the magnetic core 10 of the present embodiment is formed in a ring shape, and its cross-sectional shape (c—c cross-sectional shape) is formed in a substantially square shape. When the thickness of the core 10 is a and the radial direction of the annular shape is a height b, the ratio (b/a) of the thickness a to the height b may be 1.0 to 1.3.
The nanocrystalline magnetic material constituting the magnetic core is also called nanocrystalline, supermicrocrystalline alloy, supermicrocrystalline soft magnetic alloy, or the like, and is provided as a soft magnetic material having nanocrystalline in an amorphous (noncrystalline) alloy.
By winding copper wires around the nanocrystalline core 10, the common mode choke coil 20 shown in fig. 2 can be formed. The copper wire may be used in various cross-sectional shapes, but a flat copper wire formed in a rectangular cross section is preferably used. This is because the duty factor of the copper wire can be increased by using the flat copper wire, and miniaturization and large current can be achieved for the common mode choke coil 20.
The copper wire is preferably wound in a flat wire vertical winding manner using an automatic winding machine. This is because, by winding the flat wire vertically, the short side of the copper wire cross section can be brought into contact with the core, and therefore the number of copper wires that can be wound, that is, the number of turns of the coil can be increased. Further, by automatically winding the coil by using a winding machine, the coil can have excellent high-frequency characteristics, and can realize high quality while suppressing occurrence of interlayer short-circuit failure unlike a structure in which round wires are stacked and wound.
Example 1
In this example, experiments were conducted focusing on the magnetic saturation characteristics that are practical as common mode chokes. That is, experiments were conducted to confirm that the nanocrystalline core can obtain the same performance as the ferrite core even if the effective cross-sectional area Ae of the core is about 1/5.
If the formulae of b=μ H, H =ni/Le, al=μae/Le are substituted into l=al·n 2 And the following formula can be obtained by finishing. N represents the number of turns (turns) of the coil, and Le represents the magnetic path length of the core.
I=B·Ae·N/L
When the magnetic flux density at the time of magnetic saturation is Bm and the current at that time is Im, the above expression is given as follows.
Im=Bm·Ae·N/Lleak
In the formula, ileak represents the inductance at the time of magnetic saturation, that is, leakage inductance.
From the formula ae=im·ileak/bm·n obtained by deforming the above formula, the required core cross-sectional area Ae can be calculated, and it can be confirmed that the higher the saturation magnetic flux density Bm, the smaller the effective cross-sectional area Ae of the core can be made when the same magnetic saturation current Im is desired.
Therefore, when the saturation magnetic flux density Bm of the ferrite core (magnetic permeability: μ7000, outer diameter: 47mm, inner diameter: 27mm, thickness: 15 mm) and the nanocrystalline core (magnetic permeability: μ36000, outer diameter: 40mm, inner diameter: 28mm, thickness: 6 mm) were actually measured, the results shown in Table 1 were obtained. The saturation magnetic flux density Bm is a value at 100 ℃.
TABLE 1
From the results of table 1, when the same magnetic saturation current Im is desired, if the number of turns N of the coil is the same as the inductance ileak at the time of magnetic saturation, the sectional area of the nanocrystalline core is about 1/5 of that of the ferrite core. If the diameters of the cores are the same, the core volume becomes 1/5 because the sectional area becomes 1/5, so that the core cost can be reduced, and the price difference between the ferrite core and the nanocrystalline core can be reduced or the price can be made equal. That is, in this example, even if the price per unit volume of the nanocrystalline core is about 5 times the price per unit volume of the ferrite core, the volume thereof can be reduced, and as a result, the same price can be achieved.
Example 2
In this embodiment, a shape of a core through which a saturation current can flow while reducing the core volume and the amount of copper wire used as compared with a ferrite core has been studied.
Hereinafter, S denotes a geometric cross-sectional area (=vertical a×horizontal b), ae denotes an effective cross-sectional area (=s×duty δ), the duty δ of the ferrite core is 0.97, and the duty δ of the nanocrystalline core is 0.79.
In order to determine the core inner diameter ID, a relationship between the core cross-sectional area Ae and the inner diameter window area Sid was studied.
Window area (space area) of N copper wires passing through inner diameter of magnetic core sid=pi (ID/2) 2 The sectional area s of each 1 copper wire is shown below.
s=n·Sid/N=π·n·(ID/2) 2 /N
Where N represents an area filling ratio when a circle of a window area Sid of the core inner diameter is filled with a round copper wire of a cross-sectional area s (n≡0.75 in a range where the number of turns n=7 or more).
If a copper wire is used, the allowable current density J (typically set to J=10A/mm 2 ) The upper limit I of the current that can flow through 1 copper wire can be determined by the following formula.
I=J·s=π·J·n·(ID/2) 2 /N
On the other hand, as described above, the magnetic saturation current Im is given by im=bm·ae·n/ileak. In order to cause the magnetic saturation current to flow, since "im.ltoreq.i" is required, the following relationship needs to be satisfied.
Bm·Ae·N/Lleak≤π·J·n·(ID/2) 2 /N
{4·Bm·N 2 /(n·π·J·Lleak)}·Ae≤ID 2
In the method, in the process of the invention,
the above equation shows the relationship between the core cross-sectional area Ae and the core inner diameter ID from the viewpoint of saturation current, and shows that the larger the core cross-sectional area Ae is, the larger the magnetic saturation current Im is, and therefore, the copper wire is wound by an amount equivalent to the amount through which the magnetic saturation current Im can flow, and therefore, the core inner diameter ID also becomes large.
And, ifIt means that exactly the magnetic saturation current Im can be made to flow. Let the horizontal axis +.>The slope k of the curve of the vertical axis ID is small and +.>The magnetic saturation current Im can flow with room, but even if a current larger than the saturation current flows, the characteristics of the magnetic core are saturated, thus causing waste. Assuming that the above-mentioned slope k is large and +.>The current that can flow through the core cannot flow completely. Therefore, the slope k has an upper limit and a lower limit to some extent.
Therefore, in order to confirm the appropriate range of the slope k, calculation was performed from the actual measurement value using the actual common mode choke.
The names of the samples shown in tables 2 and 3 below mean "core type-turns-copper wire diameter (example:) The cores used in each sample are shown below.
Nanocrystalline magnetic core
NCS40-12-240: magnetic core (relative permeability: mu 36000, outer diameter: 40mm, inner diameter 28mm, thickness: 6 mm)
NCS40-19-150: magnetic core (relative permeability: mu 36000, outer diameter: 40mm, inner diameter 28mm, thickness: 6 mm)
NCS32-07-200: magnetic core (relative permeability: mu 36000, outer diameter: 32mm, inner diameter 21mm, thickness: 5.5 mm)
NCS32-13-150: magnetic core (relative permeability: mu 36000, outer diameter: 32mm, inner diameter 21mm, thickness: 5.5 mm)
NC29-10-180: magnetic core (relative permeability: mu 36000, outer diameter: 29mm, inner diameter 20mm, thickness: 4.5 mm)
Q26-10-150: magnetic core (relative permeability: mu 36000, outer diameter: 26mm, inner diameter 18mm, thickness: 4 mm)
Ferrite core
ADR47M-12-240: magnetic core (magnetic permeability: mu 7000, outer diameter: 47mm, inner diameter 27mm, thickness: 15 mm)
ADR-47-12-240: magnetic core (magnetic permeability: mu 5500, outer diameter: 47mm, inner diameter 27mm, thickness: 15 mm)
ADR38M-07-200: magnetic core (magnetic permeability: mu 7000, outer diameter: 38.1mm, inner diameter 19mm, thickness: 12.7 mm)
ADR31M-11-180: magnetic core (magnetic permeability: mu 7000, outer diameter: 31mm, inner diameter 20mm, thickness: 15 mm)
ADR25M-09-150: magnetic core (magnetic permeability: mu 7000, outer diameter: 25mm, inner diameter 15mm, thickness: 12 mm)
TABLE 2
Nanocrystalline magnetic core
In table 2, bm: saturation magnetic flux density (T), N: turns of copper wire, J: maximum current density (A/mm) of copper wire 2 ) Lleak: leakage inductance (μh), n: duty factor of copper wire, k: the value of k obtained by the above formula 1, ae: magnetic core cross-sectional area (mm) 2 ) ID: magnetic core inner diameter (mm).
TABLE 3 Table 3
Ferrite core
In table 3, bm: saturation magnetic flux density (T), N: turns of copper wire, J: maximum current density (A/mm) of copper wire 2 ) Lleak: leakage inductance (μh), n: duty factor of copper wire, k: the value of k obtained by the above formula 1, ae: magnetic core cross-sectional area (mm) 2 ) ID: magnetic core inner diameter (mm).
As shown in tables 2 and 3, any one of the cores satisfies the following conditionIs a necessary condition of (2). Furthermore, other cores are also included to draw +.>And find the slope +.>The slope of the ferrite coreThe above slope of the nano-core (NC series)>(see FIG. 3).
Example 3
Next, studies were made on the core size, inductance, and cost (copper wire usage). As a result, it was found that the copper wire cost was minimized in the vicinity of the aspect ratio of the core cross section of 1.0 to 1.3.
The more the core with high inductance can be obtained, the more the number of turns required to obtain the same inductance L can be reduced, and as a result, the amount of copper wire used as a winding wire can be reduced. The necessary number of turns N can be expressed by the following formula, assuming that the inductance of the core is AL.
L=AL·N 2 =(μAe/Le)·N 2
The length Ls of the copper wire around the circumference of the core cross section can be obtained from the cross section S of the core and the aspect ratio b/a of the core cross section by the following equation.
Ls=2(a+b)
The copper wire length L required for the core can be obtained by "l=ls·n".
In practice, the minimum value is obtained by establishing the copper wire length calculation formula and differentiating the copper wire length calculation formula, and the aspect ratio b/a of the core cross section at which the required copper wire length L is minimum is obtained by numerical calculation.
That is, the result of "the minimum copper wire length when r=b/a=1.3 is obtained when the sectional area S and the inner diameter ID are predetermined" is obtained from the above formula "l=ls·n", and the result of "the minimum copper wire length when r=b/a=1.0 is obtained when the sectional area S and the magnetic path length Le are predetermined is obtained from the same formula. In addition, r=1.0 (square) is preferable in view of automatic winding, and thus, a range of r=b/a=1 to 1.3 is obtained. The results are shown in FIG. 4.
In addition, the above formula is a case where a copper wire is wound along the case, and is a case where the copper wire is wound into a round shape by automatic windingHowever, the aspect ratio b/a at which the copper wire length becomes minimum is r=1.2.
From the above results, the results of examining the shape of the magnetic core that can reduce the volume of the magnetic core, reduce the amount of copper wire used, and allow the saturation current to flow are shown below.
The cross-sectional area Ae of the core is 1/5 of that of ferrite having the same saturation characteristics.
From the aspect ratio r=b/a=1.0 to 1.3, s=ab, of the cross section, it follows that,
thus, it was confirmed that the shape of the nanocrystalline core, which can reduce the core volume and the amount of copper wire used and can allow the same saturation current as that of the ferrite core to flow, is required to satisfy 1/5, b/a=1.0 to 1.3, of the ferrite core having the same core cross-sectional area and performance
INDUSTRIAL APPLICABILITY
The nanocrystalline core of the present invention satisfies b/a=1.0 to 1.3 by assuming that the width of the cross-sectional shape is a, the height is b, the core inner diameter is ID, and the effective cross-sectional area of the core is Ae,Can be used as a magnetic core having a core shape which can reduce the volume of the magnetic core, can reduce the amount of copper wire used, and can allow a saturation current to flow.
As a result, it is possible to provide a common mode choke coil which can reduce the cost even when a nanocrystalline magnetic core is used as a magnetic core for the common mode choke coil and which can be miniaturized even when the ferrite magnetic core has the same performance as the common mode choke coil, and a magnetic core for the common mode choke coil.
Claims (3)
1. A magnetic core for a common mode choke is characterized in that,
the magnetic core is formed of nanocrystalline magnetic material, and
when the width of the cross-sectional shape of the core is a, the height is b, the inner diameter of the core is ID, and the effective cross-sectional area of the core is Ae, the conditions b/a=1.0 to 1.3 are satisfied=4.0~5.3。
2. A common mode choke is characterized in that,
the common mode choke coil is constituted by the magnetic core according to claim 1 and a copper wire wound around the magnetic core.
3. A method of manufacturing a common mode choke as set forth in claim 2, characterized in that,
copper wires are wound around a magnetic core formed of a laminated core formed by laminating nanocrystalline alloy foils into a ring-shaped body by an automatic winding machine.
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JP2022018906A JP7116517B1 (en) | 2022-02-09 | 2022-02-09 | Magnetic core and common mode choke coil using this |
JP2022-018906 | 2022-02-09 |
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JPS5982709A (en) * | 1982-11-04 | 1984-05-12 | Mitsui Petrochem Ind Ltd | Core for inverter transformer |
JP2918255B2 (en) * | 1989-10-09 | 1999-07-12 | 日本ケミコン株式会社 | Manufacturing method of magnetic core |
JP2001135533A (en) * | 1999-11-10 | 2001-05-18 | Concorde Denshi Kogyo:Kk | Semi-closed magnetic domain inductor and producing method therefor |
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