EP1444706B1 - Induktives bauelement und verfahren zu seiner herstellung - Google Patents

Induktives bauelement und verfahren zu seiner herstellung Download PDF

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Publication number
EP1444706B1
EP1444706B1 EP02785387A EP02785387A EP1444706B1 EP 1444706 B1 EP1444706 B1 EP 1444706B1 EP 02785387 A EP02785387 A EP 02785387A EP 02785387 A EP02785387 A EP 02785387A EP 1444706 B1 EP1444706 B1 EP 1444706B1
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EP
European Patent Office
Prior art keywords
powder
inductive component
casting resin
particles
alloy powder
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
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EP02785387A
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German (de)
English (en)
French (fr)
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EP1444706A1 (de
Inventor
Markus Brunner
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Vacuumschmelze GmbH and Co KG
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Vacuumschmelze GmbH and Co KG
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    • 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
    • H01F41/02—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 for manufacturing cores, coils, or magnets
    • H01F41/04—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 for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/041—Printed circuit coils
    • H01F41/046—Printed circuit coils structurally combined with ferromagnetic material
    • 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
    • H01F17/045—Fixed inductances of the signal type  with magnetic core with core of cylindric geometry and coil wound along its longitudinal axis, i.e. rod or drum core
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00—Cores, Yokes, or armatures
    • H01F3/08—Cores, Yokes, or armatures made from powder
    • 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
    • H01F41/005—Impregnating or encapsulating
    • 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
    • H01F41/02—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 for manufacturing cores, coils, or magnets
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
    • H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
    • 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
    • H01F27/02—Casings
    • H01F27/027—Casings specially adapted for combination of signal type inductors or transformers with electronic circuits, e.g. mounting on printed circuit boards

Definitions

  • the invention relates to an inductive component having at least one winding and a soft magnetic core of a ferromagnetic powder composite material.
  • Soft magnetic powder materials as pressed magnetic cores or as cast or injection molded magnetic cores have long been known.
  • Suitable alloys for this application are iron powder, iron alloy powder, in particular FeSi or FeAlSi alloys, and various NiFe alloys.
  • plastic-bonded composites of soft magnetic materials and thermoplastic or thermosetting materials which are processed as a pressed part, injection molded part or as non-pressure casting.
  • shape-anisotropic magnetic particles and the production of composite parts of increased permeability from these particles with alignment of the particles by application of pressure, directed flow and external magnetic fields is also known.
  • the use of magnetic powders in combination with the finest ceramic particles is known as insulating spacers.
  • the use of magnetic powders of significantly different particle size (2 - 3 fractions) to optimize the packing density at atmospheric pressure Potting is the JP 11218256 refer to. From the DE 333 4827 or DE 245 2252 It is known to encase a coil with a material containing soft magnetic material.
  • the EP 0 921 534 A1 and the JP 04343207 describe an inductive component with a winding and a soft magnetic core of a ferromagnetic powder composite material, wherein the ferromagnetic powder composite material contains a powder mixture of powders with formanisotropic and formisotropic powder particles.
  • the DC pre-load capacity is a measure of the energy stored in the magnetic material (for the definition of DC pre-load capacity, see R. Boll: “Soft Magnetic Materials” Siemens AG, 1990 p. 114f).
  • the usual manufacturing method is the pressing of cores in appropriate tools, for example, toroidal or E-core shape.
  • pressures in the range of about 5 to 15 t / cm 2 are required.
  • heat treatment in the temperature range above 500 ° C to restore good soft magnetic properties.
  • the last variant also has narrow limits, since on the one hand the flowability of the mixture has to be ensured and on the other hand the orientation of the formanisotropic particles in the magnetic field can not be made very effective.
  • the force effect that can be achieved by an external magnetic field on the particles is extremely limited, since only the shape anisotropy of the particles can be used for alignment.
  • This alignment is far from being as effective as, for example, possible alignment with the permanent magnet alloys via the crystal anisotropy of the magnetic powder particles.
  • This has the consequence that an alignment of formanisotropic particles by magnetic fields in high-viscosity injection molding compositions is virtually impossible and in casting compounds with relatively low-viscosity casting resins only a very moderate orientation of the powder particles can be achieved. Therefore, over the major part of the component volume, these formanisotropic particles are virtually statically distributed even after being aligned by magnetic fields. It is unavoidable that even a significant proportion of the magnetic particle with its surface normal parallel to the direction of magnetization in the device and thus virtually no longer contributes to the magnetization in the device.
  • the object of the invention is therefore to provide an inductive component and a method for its production, which allows a wrapping of prefabricated coils with soft magnetic material, this material comparatively high permeabilities ( ⁇ > 40) and a high Gleichfeldvorbelastiana (B 0 > 0, 3 T).
  • inductive components with universal design and high packing density at high permeability ( ⁇ > 40) and high Gleichfeldvorbelastles (B 0 > 0.3 T) can be created.
  • the ferromagnetic powder composite material has an alloy powder mixture of an alloy powder with formanisotropic and an alloy powder with formisotropic powder particles and a casting resin.
  • the alloy powder mixture preferably has a coercive field strength of less than 150 mA / cm, a saturation magnetostriction and a crystal anisotropy of approximately zero, a saturation induction> 0.7 T and a specific electrical resistance of greater than 0.4 ohm * mm 2 / m.
  • the formanisotropic powder particles can be both flakes of amorphous or nanocrystalline alloys and elliptical Include parts of crystalline alloys with an aspect ratio greater than 1.5.
  • the formanisotropic powder particles preferably have a particle diameter of 30-200 ⁇ m.
  • both the formanisotropic and the formisotropic powder particles may be surface-isolated. The surface insulation can be produced for example by oxidation and / or by treatment with phosphoric acid.
  • the alloy powder mixture has, in addition to the anisotropic alloy powder, two formisotropic powders of which one powder has coarse alloy particles with a particle diameter of 30-200 ⁇ m and the other powder consists of carbonyl iron particles with a particle diameter of less than 10 ⁇ m.
  • the proportion of alloy powder having formanistropic particles is 5 to 65% by volume
  • the alloy powder having coarse form isotropic particles is 5 to 65% by volume
  • the carbonyl iron powder having fine formisotropic particles is 25 to 30% by volume of the alloy powder mixture.
  • the formanisotropic powder particles may contain FeSi alloys and / or FeAlSi alloys and / or FeNi alloys and / or amorphous or nanocrystalline Fe or Co base alloys.
  • the casting resin has a viscosity of less than 50 mPas in the uncured state and a continuous use temperature of more than 150 ° C in the cured state.
  • casting resin for example, a resin from the group of epoxides, the epoxidized polyurethanes, the polyamides and the methacrylate ester in question.
  • the proportion of the alloy powder mixture is preferably at 70 to 75 percent by volume, the proportion of the casting resin at 25 -30 volume percent.
  • the powder composite material may additionally contain an addition of flow aids, for example based on silicic acid.
  • the inductive component may have a housing.
  • this procedure avoids that the powder particles are subjected to a mechanical load during the production process. Furthermore, especially when using a stocked with a prefabricated windings shape, which on the Winding wires applied insulation layer not damaged, since the filling of the lowest possible viscosity casting resin or casting resin powder formulation into the mold due to the gentle introduction of the formulations does not damage them. Particularly preferred are cast resin formulations having viscosities of a few millipascal seconds.
  • the alloy powder mixture is mixed with the casting resin formulation before it is filled into the mold.
  • the mold is then vibrated by a suitable means, such as a compressed air vibrator, which results in the casting resin powder formulation being well permeated.
  • the casting resin powder formulation is degassed.
  • the alloy powder mixture has a very high density in comparison to the casting resin, the alloy powder mixture in the mold settles easily, so that the casting resin excess used can be collected for example in a gate, which can be removed after curing of the powder composite.
  • the mold which is filled with the alloy powder mixture and the casting resin formulation or which is already filled with a preformed casting resin powder formulation is "reused" as the housing of the inductive component. That is, in this embodiment of the present invention, the mold serves as "lost formwork".
  • the component produced or the soft magnetic core made of powder composite material produced must always be removed from the mold in a complicated manner, which leads to longer production times.
  • Cast resin formulations typically include polymer building blocks mixed with a polymerization initiator (initiator).
  • initiator a polymerization initiator
  • polymer building blocks are also conceivable, for example lactams.
  • the Methacryl Acidmethylester be polymerized during curing then to polyacrylic.
  • lactams are polymerized via a polyaddition reaction to polyamides.
  • Suitable polymerization initiators are dibenzoyl peroxide or, for example, 2,2'-azo-isobutyric acid dinitrile.
  • the powder particles are aligned during and / or after filling the mold with the alloy powder mixture by applying a magnetic field.
  • a magnetic field This can be done in particular by the use of forms that are already equipped with a winding, by passing a current through the winding and the associated magnetic field.
  • magnetic fields which expediently have field strengths of more than 10 A / cm, the powder particles are aligned.
  • casting resin formulation takes place or casting resin powder formulation by shaking a compaction or sedimentation of the alloy powder mixture.
  • the achievable permeability or the achievable DC field resilience can be controlled by the mixing ratio between the isotropic and anisotropic component to be selected.
  • a formanisotropic powder particles for example, flakes of amorphous, nanocrystalline or crystalline alloys can be used and elliptical particles with aspect ratios greater than 1.5, as they can be produced for example by appropriately adapted Gasverdüsungsclar.
  • the use of carbonyl iron powders is an ideal isotropic mixture component.
  • These powders are preferably surface-insulated, so that in addition to the flow guidance by the fine magnetic powder particles additionally an insulating effect in the powder mixture occurs.
  • These fine powder particles act as electrically insulating spacers in the mixture between the larger formanisotropic powder particles.
  • ternary magnetic powder mixtures preferably a combination of on the one hand coarser formanisotropic powder particles having dimensions in the range of 30-200 ⁇ m, preferably 50-200 ⁇ m, in the lateral extent and an aspect ratio of greater than 1.5 and on the other hand a second isotropic powder component with particle diameters in the range of 30 - Used 200 microns with spherical particle shape and a third isotropic powder component with particle diameters in the range below 10 microns.
  • the latter powder component preferably consists of surface-isolated carbonyl iron powder.
  • the ternary mixture with coarser spherical powder particles is also characterized by a significantly improved flowability of the casting compound than the previously described binary powder mixture of flakes and fine powder.
  • the movement of the powder particles in the magnetic field is greatly facilitated by the increased proportion of coarser spherical particles.
  • coarser particles of both the formisotropic and the formanisotropic powder particles a very wide alloy spectrum can be used.
  • the basic requirement for use in this powder mixture is an alloy with the lowest possible coercive field strength, vanishingly small saturation magnetostriction and crystal anisotropy, and the highest possible specific electrical resistance.
  • FeSi alloys FeAlSi alloy powders, FeNi alloy powders and the amorphous and nanocrystalline Fe or Co base alloy powders. Furthermore, it is important that all necessary heat treatment steps can be completed before the core is made. This is also the case with the alloys mentioned.
  • a homogeneous powder mixture is produced in a suitable mixer.
  • silica-based flow aids to this powder mixture has proven itself.
  • the pourable mixture is then prepared by mixing 70-75 volume percent magnetic powder mixture and 25-30 volume percent of a selected resin. This mixture is degassed with stirring in a vacuum and then filled into the intended casting mold. In the form by mechanical shaking, a compaction or sedimentation of the magnetic powder and at the same time by an external magnetic field or by energizing the inserted copper coil, an orientation of the formanisotropic portion of the magnetic powder. Following the alignment of the formanisotropic powder fraction, the curing of the resins takes place at elevated temperature.
  • the FIG. 1 shows an inductive component 10.
  • the inductive component 10 consists of a soft magnetic core 11 and a winding 12, which consists of relatively thick copper wire with few turns.
  • the winding can be made of both round wire and flat wire in one or more layers.
  • Especially by the use of copper flat wire can be increased by the more compact winding structure with constant component volume of the copper cross section of the wire which in turn leads to a reduction of the ohmic losses in the winding. With constant winding resistance can be inversely reduced by this measure, accordingly, the component volume.
  • FIG. 1 shows the device 10 during manufacture.
  • the component 10 is introduced into a mold 1a, which here consists of aluminum.
  • the FIG. 2 also shows an inductive component 20, which consists of a soft magnetic core of a powder composite material 21 in which a layer winding bobbin 22 is introduced.
  • the layer winding bobbin 22 is connected at its winding ends with pins 23 which protrude from the soft magnetic core 21 and serve for connection to a bottom plate, for example a printed circuit board.
  • the inductive component 20 in the FIG. 2 is also like in the FIG. 1 shown during its manufacture. This means, that the inductive component 20 is shown here in the form 1b, is poured in the powder composite material.
  • FIG. 3 also shows like that Figures 1 and 2 an inductive component.
  • the inductive component 30 shown here consists of a soft magnetic core 31, made of a powder composite material, in turn, a layer winding bobbin 32 is introduced.
  • the sheet winding bobbin 32 is connected at its winding ends with connecting pins 33, which protrude from the mold 1 c, which also serves as a housing 34.
  • powder composite material As starting material for the powder composite material, one of the following powder mixtures is provided in the three exemplary embodiments:
  • Comparative Example 1 Casting cores with low permeability
  • the following formulation can be used: 72 g pre-annealed and surface-insulated powder of Fe 84 Al 6 Si 10 or Ni 78 Fe 18 with an average particle diameter of about 50 ⁇ m and a spherical shape 21 g phosphated carbonyl iron 9 g casting resin
  • casting cores having a permeability of about 40, a Gleichfeldvorbelastiana of about 0.35 T and Ummagnetleitersleen of about 90 - 110 W / kg at 100 kHz and Mattaus horreptept of 0.1 can be produced.
  • Example 1 Cores with medium permeability
  • the following formulation can be used: 16 g pre-annealed and surface-insulated powder of Fe 84 Al 6 Si 10 , Ni 78 Fe 18 or Fe 73.5 Cu 1 Nb 3 Si 15.5 B 7 with an average particle size of 40-200 ⁇ m and an aspect ratio> 1.5 48 g pre-annealed and surface-insulated powder of Fe 84 Al 6 Si 10 or Ni 78 Fe 18 with an average particle diameter of about 50 ⁇ m and a spherical shape 21 g phosphated carbonyl iron 9 g casting resin
  • casting cores having a permeability of about 65, a Gleichfeldvorbelastiana of about 0.30 T and re-magnetization losses of about 90 - 110 W / kg at 100 kHz and Mattausberichtmaschine of 0.1 T can be produced.
  • Example 2 G clothkern with higher permeability
  • casting cores having a permeability of about 85, a Gleichfeldvorbelastiana of about 0.27 T and Ummagnetleitersleen of about 90 - 110 W / kg at 100 kHz and 0.1 T alternator
  • alloy powder mixtures are only exemplary in nature. There is a wide range of alloy powder mixtures other than the above listed formulations.
  • the formanisotropic powder particles also called flakes by reason of their shape, were subjected to heat and surface treatment to improve their dynamic magnetic properties.
  • the treatment of the formisotropic powder particles with phosphoric acid which forms electrically insulating iron phosphate on the surface thereof.
  • thermoplastic methacrylate formulation had the following composition: 100 g methacrylate 2 g Methacryltrimethoxysilan 6 g Dibenzoyl peroxide and 4.5 g N, N p-toluidine
  • thermoplastic methacrylate formulation was also charged, this methacrylate formulation having the following composition: 100 g methacrylate 2 g Methacryltrimethoxysilan 10 g Diglycoldimethacrylat 6 g Dibenzoyl peroxide and 4.5 g N, N p-toluidine
  • the above chemical ingredients were dissolved sequentially in the methacrylic ester.
  • the finished mixture was water clear in both cases and was then poured into molds 1a and 1b.
  • the cast resin formulations in both cases cured at room temperature within about 60 minutes. Subsequently, a post-curing at about 150 C for an additional hour was made.
  • thermosetting thermoplastic methacrylate formulation having the following composition was used: 100 g methacrylate 0.1 g 2,2'-azo-isobutyric dinitrile
  • This casting resin formulation was in the form 1c, as in FIG. 3 is shown, filled and cured within 15 hours at a temperature of about 50 ° C. Since the form 1c in the FIG. 3 is used as a "lost formwork", that is, then after the manufacturing process as a housing 34 was used for the inductive component, it has proven particularly well to use a thermosetting G automatzformultechnik, as a particularly intensive and good contact between the existing plastic Form 1c and the powder composite succeeded.
  • thermoplastic polyamides in particular melts of ⁇ -caprolactam and phenyl isocyanate can be used, so in further experiments, a melt of 100 g of ⁇ -caprolactam and 0.4 g of phenyl isocyanate proved to be suitable, which was mixed together at 130 ° C. This melt was then poured into a preheated to 150 ° C mold. The curing of the caprolactam to a polyamide was then carried out within about 20 minutes. A post cure at higher temperatures was usually not required in this approach.
  • caprolactam instead of a caprolactam it is of course also possible to use another lactam, for example laurolactam, with a corresponding binder phase. However, when processing laurolactam, process temperatures in excess of 170 ° C are required.
  • thermosetting molding materials In addition to the previously described thermoplastic binder resin formulations, of course, the use of reaction resins that provide thermosetting molding materials is conceivable. In particular, the use of two-component thermosetting epoxy resins is possible here.
  • a casting resin from this group has, for example, the following composition: 100 g Cycloaliphatic epoxy resin with a molecular weight ⁇ 700 g / mol, an epoxide content of 5.7 - 6.5 equiv.
  • the potting resin is prepared by mixing at room temperature.
  • the mixture is heated to temperatures around 80 ⁇ 10 ° C. This reduces the viscosity of the mixture to values ⁇ 20 mPas.
  • For curing, made of this mixture components is heated to temperatures of about 150 ° C for a period of about 30 minutes.
  • the cast resin formulations described above were used to fabricate inductive components with soft magnetic cores made of ferromagnetic powder composites that exhibit core loss losses, such as permeable core cores made of FeAlSi or nickel-containing NiFe alloys.
  • the achievable permeability of about 20 and 100 is determined by the size of the formanisotropic particles and their volume fraction in the total powder mixture. Concerning the Gleichfeldvorbelastles values are achieved by 0.3 - 0.35 T.
EP02785387A 2001-11-14 2002-11-13 Induktives bauelement und verfahren zu seiner herstellung Expired - Lifetime EP1444706B1 (de)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE10155898A DE10155898A1 (de) 2001-11-14 2001-11-14 Induktives Bauelement und Verfahren zu seiner Herstellung
DE10155898 2001-11-14
PCT/EP2002/012708 WO2003043033A1 (de) 2001-11-14 2002-11-13 Induktives bauelement und verfahren zu seiner herstellung

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EP1444706A1 EP1444706A1 (de) 2004-08-11
EP1444706B1 true EP1444706B1 (de) 2009-01-14

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US (1) US7230514B2 (ja)
EP (1) EP1444706B1 (ja)
JP (1) JP2005510049A (ja)
DE (2) DE10155898A1 (ja)
WO (1) WO2003043033A1 (ja)

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WO2003043033A1 (de) 2003-05-22
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JP2005510049A (ja) 2005-04-14
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