CN210378730U - Magnetic element - Google Patents
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- CN210378730U CN210378730U CN201920383332.0U CN201920383332U CN210378730U CN 210378730 U CN210378730 U CN 210378730U CN 201920383332 U CN201920383332 U CN 201920383332U CN 210378730 U CN210378730 U CN 210378730U
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Abstract
The magnetic element of the utility model comprises a soft magnetic shell which is a hollow structure; the coil is arranged in the soft magnetic shell, and the end part of the coil extends out of the soft magnetic shell or is connected with an external terminal; the mixture is filled in the shell, and the coil is immersed in the mixture. Compared with the prior art, the utility model discloses magnetic element has following advantage: through the design of the mixed magnetic circuit consisting of the soft magnetic shell and the mixture consisting of the magnetic powder and the resin, the magnetic permeability of the mixture can be controlled in a reasonable range easy to produce, and meanwhile, the space utilization rate of the magnetic element almost reaches 100 percent, which is beneficial to realizing large current. And the magnetic shielding high-current magnetic element easy to automatically produce is further realized, the saturation current of the magnetic element is far larger than that of a common ferrite assembly magnetic element and is equivalent to that of an integrally formed magnetic element, but the reliability of the magnetic element is far superior to that of the ferrite assembly magnetic element, and the magnetic element is more suitable for batch automatic production.
Description
Technical Field
The utility model relates to a magnetic element especially relates to a magnetic screen component of high reliability, heavy current, and the application is magnetic element such as power inductance, coupling inductance, common mode inductance, transformer, reactor.
Background
There are two main ways of magnetic element products currently used in industry: a traditional ferrite assembly mode is used, the product has a wide sensing value range, and the defects that the borne current is generally small and the process is difficult to be completely automatic; another type of magnetic element is an integrally formed magnetic element which has been successful in the market for consumer electronics in recent ten years, and is formed by integrally pressing a coil with a mixture of alloy iron powder and resin having a higher saturation magnetic flux density. The magnetic shielding structure is characterized by large current bearing capacity and full magnetic shielding structure; the disadvantage is that the mixture of alloy iron powder and resin has a risk of thermal aging at high temperature, and in addition, the coil is subjected to a higher pressure during the production of the structure, which also brings a risk of damage. In recent years, automobile electronic requirements are vigorous year by year, and reliability is the highest threshold of the automobile electronic industry. For the above reasons, the integrally formed magnetic element is related in the field of automotive electronics, but cannot become the mainstream, but the automotive electronics industry has been expected to have a large current characteristic, because compared with the conventional ferrite assembled magnetic element, the integrally formed magnetic element occupies a volume more than half smaller than that of the former under the condition of meeting the same circuit parameter requirement, which becomes very attractive in the present and future of the full-scale electronization of automobiles. There have been proposed prior art solutions for potting magnetic elements using a mixture of magnetic powder and resin.
In prior art 1, the chinese invention patent "chip inductor with preformed shell and manufacturing method thereof" (application publication No. CN102867614A) proposes a chip inductor with preformed shell, which includes a preformed shell formed with a chamber, a coil accommodated in the chamber and having two ends, a set of electrodes electrically connecting the two ends to the outside of the shell, and a ferromagnetic colloid filled in the chamber of the shell. The preformed shell provides a container of ferromagnetic colloid, can be realized by plastic injection molding, ceramic co-firing, photoetching development and other modes, and is beneficial to realizing simple structure of elements, but the preformed shell cannot shield a magnetic field and is not beneficial to realizing large current.
In prior art 4, the chinese invention patent "inductor" (application publication No. CN103208347A) discloses an inductor, which includes an outer frame with an opening, a magnetic core accommodated in the outer frame, and a coil wound around the magnetic core, and further includes a magnetic glue sealed at the opening of the outer frame, wherein the magnetic glue is mainly used to increase inductance value on the basis of the existing assembled inductor, and the saturation current is decreased on the original basis.
Therefore, how to realize a magnetic shielding large-current magnetic element easy for automatic production, especially how to simultaneously realize high reliability of a coil, a magnetic material and an element under long-term high-temperature operation is a very critical development direction in the magnetic element industry, especially in automobile electronic application at present.
SUMMERY OF THE UTILITY MODEL
To the defect among the prior art, the utility model aims to provide a realize magnetic element of high reliability.
In order to solve the technical problem, the magnetic element of the utility model comprises a soft magnetic shell which is a hollow structure;
the coil is arranged in the soft magnetic shell, and the end part of the coil extends out of the soft magnetic shell or is connected with an external terminal;
the mixture is filled in the shell, and the coil is immersed in the mixture.
Preferably, the soft magnetic shell is a hollow structure with an opening at one end, the soft magnetic shell comprises a bottom plate and a side wall connected to the bottom plate and extending along the edge of the bottom plate and towards the vertical direction of the bottom plate, the side wall and the bottom plate form an accommodating space, and the free end of the side wall forms an opening part;
a magnetic member is provided in an opening of the soft magnetic housing.
Preferably, a recess is provided on an inner wall surface of the soft magnetic casing perpendicular to the spiral axis of the coil.
Preferably, the helical axis of the coil is perpendicular to the plane of the base plate.
Preferably, the soft magnetic shell is made of manganese zinc ferrite, nickel zinc ferrite or magnesium zinc ferrite.
Preferably, the magnetic member is a cured mixture or a bulk magnetic member.
Preferably, the magnetic component mass is a metal alloy powder core mass.
Preferably, the mixture is a mixture of magnetic powder and resin; wherein
Magnetic powders include, but are not limited to, carbonyl iron, iron silicon alloys, iron silicon aluminum alloys, iron silicon chromium alloys, iron nickel molybdenum alloys, or amorphous alloys;
resins include, but are not limited to, epoxy, silicone, or phenolic resins.
Compared with the prior art, the utility model discloses magnetic element has following advantage: through the design of the mixed magnetic circuit consisting of the soft magnetic shell and the mixture consisting of the magnetic powder and the resin, the magnetic permeability of the mixture can be controlled in a reasonable range easy to produce, and meanwhile, the space utilization rate of the magnetic element almost reaches 100 percent, which is beneficial to realizing large current. And the magnetic shielding high-current magnetic element easy to automatically produce is further realized, the saturation current of the magnetic element is far larger than that of a common ferrite assembly magnetic element and is equivalent to that of an integrally formed magnetic element, but the reliability of the magnetic element is far superior to that of the ferrite assembly magnetic element, and the magnetic element is more suitable for batch automatic production.
Drawings
Other characteristic objects and advantages of the invention will become more apparent from a reading of the detailed description of non-limiting embodiments with reference to the following figures.
Fig. 1 is a perspective sectional view of a surface mount power inductor according to a first embodiment of the present invention;
fig. 2(a) is a diagram of a two-winding surface-mounted magnetic element according to a second embodiment of the present invention;
fig. 2(b) is a cross-sectional view of a two-winding surface-mount magnetic device according to a second embodiment of the present invention;
fig. 3 is a flow chart of a magnetic component and a manufacturing method thereof according to a third embodiment of the present invention.
In the figure:
1-Soft magnetic housing 1 a-bottom plate 1 b-side wall
1 c-opening 1 d-recess 2-coil
2 a-end 3-mix 4-magnetic component
5-external insulation base 6-external terminal
Detailed Description
The present invention will be described in detail with reference to the following embodiments. The following examples will assist those skilled in the art in further understanding the present invention, but are not intended to limit the invention in any way. It should be noted that various changes and modifications can be made by one skilled in the art without departing from the spirit of the invention.
The above-mentioned prior art solution of using a mixture of magnetic powder and resin to encapsulate the magnetic element has the advantage of substantially no damage to the coil in the magnetic element, contributing to achieving high reliability. However, there are some problems:
1) the shell adopts non-magnetic conductive materials such as plastic or metal and the like, so that the occupied space of the magnetic element is enlarged and larger current cannot be realized;
2) magnetic glue is used for sealing all magnetic circuits, and the magnetic glue has low magnetic permeability, so that the characteristic of a mainstream magnetic element cannot be achieved, and the shielding effect is poor;
3) the process of sealing magnetic glue is added on the basis of the existing assembled inductor, the saturation characteristic of the process is basically determined by the saturation magnetic flux density of a magnetic core inserted into a coil, the achieved technical effect is the same as the effect of reducing an air gap of the existing assembled inductor, the inductance is increased to reduce the saturation current, the characteristic is not improved, and the process difficulty is increased instead.
According to the utility model discloses a magnetic element, include: a soft magnetic casing having a bottom plate, a sidewall formed along an edge of the bottom plate and extending in a vertical direction of the bottom plate, and an opening portion opposed to the bottom plate and providing an accommodation space therein; at least one hollow coil is placed in the accommodating space; the accommodating space is filled with a mixture of magnetic powder and resin, and the mixture completely submerges the air-core coil; the ends of the air core coil protrude from the soft ferrite housing or are connected to external terminals to provide electrical contacts for connecting the magnetic element to an electrical circuit. The opening of the soft magnetic casing is closed by the magnetic member.
In the prior art, a coil is coated by magnetic powder and resin mixture to form an inductor, but the technology has the defects of low equivalent magnetic permeability of a magnetic circuit, more turns of the formed inductor coil and overlarge direct current resistance. Generally speaking, the magnetic permeability of the soft magnetic ferrite shell of the present invention is 6 times or more of the magnetic permeability of the mixture composed of the magnetic powder and the resin, so that the center pillar portion of the air-core coil can still provide the sufficient equivalent magnetic permeability of the magnetic element, although it is filled with the low magnetic permeability mixture composed of the magnetic powder and the resin.
Meanwhile, the magnetic circuit is formed by the mixture of the magnetic powder and the resin and the soft magnetic shell together, and the magnetic permeability of the mixture can be controlled within a proper range, such as 5 u-15 u, so that better electrical characteristics and process performance can be considered.
In order to prevent magnetic leakage from interfering with surrounding devices or generating extra loss, the opening part of the casing closes the magnetic circuit by a magnetic part, and the magnetic part can be formed by filling and solidifying a mixture consisting of magnetic powder and resin or can be a prefabricated magnetic block.
As a form of the utility model, the soft magnetic shell material includes manganese zinc ferrite, nickel zinc ferrite and magnesium zinc ferrite. Compared with other soft magnetic materials, the soft magnetic ferrite material has higher magnetic permeability, so that for the magnetic element, the requirement on the magnetic permeability of the mixture consisting of the magnetic powder and the resin is lower to achieve the same equivalent magnetic permeability, and the good manufacturability is further facilitated.
As a form of the utility model, soft-magnetic shell is provided with sunkenly with hollow coil spiral shaft vertically internal face. The recess can increase the contact surface between the soft magnetic shell and the mixture consisting of the magnetic powder and the resin, so that the separation between the soft magnetic shell and the mixture consisting of the magnetic powder and the resin is prevented when the soft magnetic shell is heated and cured in the manufacturing process or the magnetic element is subjected to reflow soldering in actual use, and in addition, the recess also reduces the risk of local magnetic saturation of two different materials of the soft magnetic shell and the mixture consisting of the magnetic powder and the resin under the condition of high-current application.
As a form of the present invention, the magnetic member of the opening portion of the soft magnetic housing is a prefabricated block. The prefabricated block body such as the metal alloy powder core block body has higher magnetic permeability, and can obtain better shielding effect.
As a form of the utility model, the magnetic prefabricated block body of the opening part of the soft magnetic shell is made of ferrite. Because the ferrite material has higher magnetic permeability, better magnetic shielding effect can be obtained.
As a form of the present invention, the hollow coil is placed according to the bottom plate direction of the screw axis perpendicular to the soft magnetic ferrite case. At the moment, the opening direction of the hollow coil is consistent with that of the soft magnetic ferrite shell, so that the mixture consisting of the magnetic powder and the resin is easier to inject into the accommodating space in the soft magnetic ferrite shell.
As a form of the present invention, the magnetic powder material in the mixture includes, but is not limited to carbonyl iron, iron-silicon alloy, iron-silicon-aluminum alloy, iron-silicon-chromium alloy, iron-nickel-molybdenum alloy, amorphous alloy, etc.; since the mixture of the magnetic metal powder and the resin has a high saturation magnetic flux density, filling the mixture in the center leg portion of the air-core coil helps to reduce the risk of saturation of the magnetic element and increase the magnetic saturation current.
In one form of the present invention, the resin material in the mixture includes, but is not limited to, epoxy resin, silicone resin, phenolic resin, and the like.
According to the magnetic element of the utility model, when the mixture of magnetic powder and resin is uniformly stirred and then injected into the accommodating space, no obvious pressure and damage are generated to the hollow coil; the mixture is in a liquid flowing state or a flowing state after being heated when being injected, which means that the solid content of the magnetic powder in the mixture consisting of the magnetic powder and the resin is not high, and the resin can better coat the magnetic powder, thereby being beneficial to reducing the influence of thermal aging on the insulation of the mixture. Meanwhile, the hollow coil is limited in the accommodating space, and the injection of the mixture consisting of the magnetic powder and the resin and the magnetic part for closing the magnetic circuit can be realized in a simple mode, which means that the magnetic element can be automatically produced very easily.
Example 1
The external dimension of the surface-mounted magnetic element related to the embodiment is 12mm multiplied by 8.5mm, and the surface-mounted magnetic element belongs to the category of power inductors. As shown in fig. 1, a perspective cross-sectional view of the surface mount power inductor is shown. Comprises a soft magnetic shell 1 made of manganese zinc ferrite, the soft magnetic shell is provided with a bottom plate 1a, a side wall 1b formed along the edge of the bottom plate and extending towards the vertical direction of the bottom plate, and an opening part 1c opposite to the bottom plate, and an accommodating space is provided in the shell; a hollow coil 2 is placed in the accommodating space; the air-core coil 2 has a winding screw axis AX, the air-core coil 2 is placed in a direction perpendicular to the bottom plate 1a of the soft magnetic ferrite case in accordance with the screw axis AX, and a recess 1d is provided in an inner wall surface of the soft magnetic ferrite case 1 perpendicular to the screw axis AX (i.e., inside the bottom plate 1a in this embodiment).
Uniformly stirring a mixture 3 consisting of iron-silicon alloy powder and epoxy resin, and injecting the mixture into the accommodating space, wherein the magnetic permeability of the mixture is 9; the mixture 3 completely submerges the hollow coil 2 and is solidified and molded, and the mixture fills the accommodating space of the soft magnetic shell including the recess 1 d; external terminals 6 are connected to the two ends 2a of the air core coil, the two external terminals 6 providing electrical contacts for connecting the magnetic element to an electrical circuit. The end part 2a and the external terminal 6 can be connected by adopting a spot welding mode, and the welding part is fixedly sealed at the corner of the accommodating space by a mixture 3 consisting of iron-silicon alloy powder and epoxy resin so as to ensure that the welding is reliable enough. The opening of the soft ferrite case is closed by a magnetic part 4, the magnetic part 4 is composed of a bulk of an iron-silicon alloy, and has a magnetic permeability of 75. Under the same size condition, the saturation current of the surface mount power inductor of the embodiment is more than one time larger than that of a ferrite assembly inductor and is close to that of an integrally formed inductor, but the direct current resistance of the embodiment is the lowest. The surface mount power inductor of the embodiment can be continuously tested for 1000 hours in a high-temperature environment of 155 ℃ without increasing loss, which is difficult to realize in the conventional integrally formed inductor, and the reliability of the embodiment is also outstanding.
Example 2
The present embodiment relates to a surface-mount magnetic element having a double winding, which can be used as a coupling inductor, a common mode inductor, an isolation transformer, etc., and having outer dimensions of 12mm × 12mm × 8.5 mm. Fig. 2(a) is a perspective view of the magnetic element, and fig. 2(b) is a cross-sectional view along AA'. Comprises a soft magnetic shell 1 made of nickel zinc ferrite with the magnetic permeability of 400; the soft magnetic shell is provided with a bottom plate 1a, a side wall 1b which is formed along the edge of the bottom plate and is extended towards the vertical direction of the bottom plate, and an opening part 1c which is opposite to the bottom plate, and an accommodating space is provided in the shell; the two hollow coils 2 are placed in the accommodating space; the air-core coil 2 has a winding screw axis AX, the air-core coil 2 is placed in a direction perpendicular to the bottom plate 1a of the soft magnetic ferrite case in accordance with the screw axis AX, and a recess 1d is provided in an inner wall surface of the soft magnetic ferrite case 1 perpendicular to the screw axis AX (i.e., inside the bottom plate 1a in this embodiment). Uniformly stirring a mixture 3 consisting of carbonyl iron powder and epoxy resin, and injecting the mixture into the accommodating space, wherein the magnetic permeability of the mixture is 8.5; the mixture 3 fills the accommodating space of the soft magnetic shell, including the recess 1d, and completely submerges the hollow coil 2 and is solidified and molded; four external terminals 6 are connected to the four ends 2a of the two air coils, the four external terminals 6 providing electrical contacts for connecting the magnetic element to an electrical circuit, and the two external terminals 6 at diagonal positions are connected to one air coil. The end part 2a and the external terminal 6 can be connected by adopting a spot welding mode, and the welding part is fixedly sealed at the corner of the accommodating space by the mixture 3 consisting of carbonyl iron powder and epoxy resin so as to ensure that the welding is reliable enough. The opening of the soft ferrite case is closed by a magnetic part 4, the magnetic part 4 is composed of a nickel zinc ferrite block, and the magnetic permeability is 400. Under the same size condition, the surface-mounted magnetic element soft magnetic shell 1 and the magnetic component 4 of the embodiment are both made of nickel-zinc ferrite, the magnetic shielding property is very good, the two hollow coils 2 are not extruded by obvious external force in the production process, and the end parts 2a of the soft magnetic shell 1 and the two hollow coils can pass 1500V alternating voltage test; in contrast, the integrally formed magnetic element test of the same size and specification is difficult to pass the 400V dc voltage test, and is difficult to satisfy the isolation and insulation requirements, again illustrating the reliability advantages of the present embodiment.
Example 3
The embodiment relates to a plug-in magnetic element which can be used as a PFC inductor, a reactor and the like and is widely applied to the fields of industrial power supplies, vehicle-mounted electric control and the like. As shown in FIG. 3, the flow of manufacturing the magnetic component is sequentially from left to right and from top to bottom. Firstly, providing a soft magnetic shell 1 made of manganese zinc ferrite, wherein the magnetic permeability of the manganese zinc ferrite is more than 2000, and the room-temperature saturation magnetic flux density is more than 0.5T; the soft magnetic shell is provided with a bottom plate 1a, a side wall 1b which is formed along the edge of the bottom plate and is extended towards the vertical direction of the bottom plate, and an opening part 1c which is opposite to the bottom plate, and an accommodating space is provided in the shell; a hollow coil 2 is placed in the accommodating space, and is made by vertically winding flat copper wires; the hollow coil 2 has a winding screw axis AX, the hollow coil 2 is placed in a direction perpendicular to the side wall 1b of the soft magnetic ferrite case in accordance with the screw axis AX, and a recess 1d is provided in an inner wall surface (in this embodiment, front and rear inner side walls) of the soft magnetic ferrite case 1 perpendicular to the screw axis AX. A mixture 3 consisting of the iron-silicon-aluminum magnetic powder and the heat-conducting silicon resin is uniformly stirred and then injected into the accommodating space, and the heat-conducting coefficient of the heat-conducting silicon resin is more than 1W/m.K; the mixture 3 fills the accommodating space of the soft magnetic shell, including the recess 1d, and completely submerges the hollow coil 2 and is solidified and molded; the two ends 2a of the air coil 2 protrude directly from the soft magnetic housing 1 and provide electrical contacts for connecting the magnetic element to an electrical circuit. The opening part 1c of the soft magnetic ferrite shell is closed by a magnetic part 4, the magnetic part 4 is composed of manganese zinc ferrite blocks, and the magnetic permeability is more than 2000; and the magnetic member 4 is placed in the opening portion so as to overlap at least a part of the mixture 3, and it is preferable that the magnetic member 4 is fixed together when the mixture 3 is cured. Finally, an external insulating base 5 provides isolation between the body of the inserted magnetic element and the circuit board, and the base 5 may be formed of epoxy board material and does not interfere with the extension of the two ends 2a of the air-core coil 2. The plug-in magnetic element of the embodiment has the advantages of small direct current resistance, small iron core loss, high efficiency, good heat dissipation, simple production process, easy automation and wide application in PFC inductors or reactors with various power levels.
The foregoing description of the specific embodiments of the invention has been presented. It is to be understood that the present invention is not limited to the specific embodiments described above, and that various changes or modifications may be made by those skilled in the art within the scope of the appended claims without departing from the spirit of the invention. The embodiments and features of the embodiments of the present application may be combined with each other arbitrarily without conflict.
Claims (7)
1. A magnetic element, comprising:
the soft magnetic shell is of a hollow structure;
the coil is arranged in the soft magnetic shell, and the end part of the coil extends out of the soft magnetic shell or is connected with an external terminal;
the mixture is filled in the shell, and the coil is immersed in the mixture.
2. The magnetic component of claim 1, wherein the soft magnetic housing is a hollow structure with an opening at one end, the soft magnetic housing comprises a bottom plate and a sidewall connected to the bottom plate and extending along an edge of the bottom plate and in a direction perpendicular to the bottom plate, the sidewall and the bottom plate form an accommodating space, and a free end of the sidewall forms an opening;
a magnetic member is provided in an opening of the soft magnetic housing.
3. The magnetic component of claim 2, wherein a recess is provided on an inner wall surface of the soft magnetic housing perpendicular to the helical axis of the coil.
4. The magnetic element of claim 2, wherein the helical axis of the coil is perpendicular to the plane of the base plate.
5. A magnetic component as claimed in claim 1, 2 or 3, wherein the soft magnetic casing is made of manganese zinc ferrite, nickel zinc ferrite or magnesium zinc ferrite.
6. The magnetic element according to claim 2, wherein the magnetic member is a mixture cured product or a magnetic member block.
7. The magnetic element of claim 6, wherein the magnetic component mass is a metal alloy powder core mass.
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| CN201920383332.0U CN210378730U (en) | 2019-03-25 | 2019-03-25 | Magnetic element |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN109786089A (en) * | 2019-03-25 | 2019-05-21 | 墨尚电子技术(上海)有限公司 | Magnetic element and its manufacturing method |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN109786089A (en) * | 2019-03-25 | 2019-05-21 | 墨尚电子技术(上海)有限公司 | Magnetic element and its manufacturing method |
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