KR100300161B1 - Amorphous magnetic core and manufacturing method thereof - Google Patents

Abstract

PURPOSE: An amorphous magnetic core and a manufacturing method thereof are provided to improve the amorphous magnetic core by processing an amorphous ribbon to which a non-magnetic material bobbin is attached. CONSTITUTION: An internal side bobbin(30) is made of a non-magnetic metal and has a through hole(35). An amorphous magnetic core(40) has magnetic characteristics by winding a ribbon-formed amorphous alloyed to an external surface of the internal side bobbin(30). An external side bobbin(45) is made of a non-magnetic metal and encloses the magnetic core(40) so as to prevent an external end of the magnetic core(40) from becoming disentangled. A case(50) is made of a non-magnetic material and covers the internal side bobbin (30), the magnetic core(40), and the external of the external side bobbin(45).

Description

Amorphous Magnetic Core and Manufacturing Method Thereof

TECHNICAL FIELD The present invention relates to an amorphous magnetic core and a method for manufacturing the same. In particular, when winding a slit amorphous ribbon, a nonmagnetic bobbin is attached to the inside and the outside to heat-treat, impregnate, dry, and cut a state in which a bobbin is attached. The present invention relates to an amorphous magnetic core and a method for manufacturing the same, which fundamentally solve various problems occurring during the manufacturing process by going through an assembly process and the like, thereby improving product characteristics, improving quality uniformity and productivity.

In recent years, power supply (SMPS) is widely used as a stabilizing power supply for computer peripherals or general communication devices. The main element constituting such a magnetic amplifier is a saturable reactor, and its core requires a magnetic core material having excellent angular magnetization characteristics, that is, excellent angular ratio.

Conventionally, a permalloy having Fe-Ni as a main component has been used as such a magnetic core material, but the maximum use frequency is limited to several tens of KHz, thereby limiting the increase in switching frequency.

Recently, a method of making an amorphous magnetic core having a large or small angular ratio according to a direction in which magnetic fields are applied during heat treatment of an amorphous alloy has been proposed.

Generally, amorphous is a disordered structure in which a member is similar to a liquid state, and is obtained by cooling a molten liquid metal at a very high rate of about 106 ° C. per second. The amorphous alloy thus produced has various characteristics different from the existing crystalline materials because of its disordered atomic structure. In particular, the amorphous alloy has excellent characteristics in the field of soft magnetic materials and has various uses.

Amorphous soft magnetic alloys are classified into iron (Fe), nickel (Ni), and cobalt (Co) based on their main components, and iron-based amorphous alloys have high saturation magnetic flux density and iron loss is smaller than that of conventional silicon steel. It is applied as a core of transformer or high frequency transformer using up to several hundred KHz band.Cobalt-based amorphous oil alloy has high permeability and low iron loss and coercivity, so it is applied as a small magnetic core for high frequency or for magnetic head. have.

One of the remarkable characteristics of amorphous magnetic alloys compared to general crystalline magnetic materials is that there is no crystal magnetic anisotropy in which the magnetism is different depending on the crystal direction because amorphous has no crystal structure. Accordingly, since the influence of the induced ground anisotropy is relatively large, different magnetic properties can be obtained by applying a magnetic field during heat treatment. For example, when the magnetic field is applied in the circumferential direction of the toroidal magnetic core at a high temperature below the Curie temperature (Tc) of the alloy, the angular ratio defined by the ratio of the saturation magnetic flux density (Bs) and the residual magnetic flux density (Br) ( High squarness.Br/Bs) can be obtained and low square ratio can be obtained by applying a magnetic field in the direction of the ground of the ground core.

Therefore, products using high-angle ratio characteristics include MAG amplifiers for SMPS, spark killer bead cores, magnetic modulators and magnetic switches.

Moreover, the amorphous magnetic core has high efficiency due to the low hysteresis loss and eddy current loss of the core compared to the existing materials, excellent high frequency characteristics due to eddy current loss such as large electrical resistivity, noise permeability due to high permeability and high saturation magnetic flux density, DC Due to its excellent responsiveness to bias and miniaturization requirements, the demand for replacement of existing magnetic materials such as silicon steel sheet, permalloy and ferrite and the demand for new applications are increasing.

For example, the products utilizing low iron loss characteristics include a choke core, a high frequency transformer for inverters, a transformer for power distribution, and various reactors. The products utilizing high permeability characteristics include pulse transformers, boost transformers, audio transformers, Current transformer, noise filter, etc. are mentioned.

In this case, the shape of the magnetic core is largely divided into a relatively small gap type toroidal core and a large rectangular cut core.

Referring to the conventional manufacturing method for manufacturing such an amorphous magnetic core is as follows.

First, a ribbon-shaped amorphous alloy is obtained by spraying a molten liquid metal on a cooling roller made of a high thermal conductor (Cu, etc.) rotating at a high speed and cooling it at a high speed of 106 ° C./sec or more.

Then, a ribbon slitting process for cutting the amorphous alloy of the wide ribbon to a desired size width, a winding process for winding the amorphous alloy ribbon around the support rod (bar) and winding in a toroidal or square shape, and a wound toroidal or square shape Heat treatment process to remove basic magnetic properties and stress during winding, and to immerse in an impregnation solution to maintain toroidal or square shape to cut heat treated magnetic core Process, forming a gap of a certain size to give the intrinsic magnetic properties of the gap-type amorphous toroidal magnetic core or amorphous cut magnetic core, and the assembly process of assembling the gap-formed magnetic core into the case to make the final product Following the completion of the product.

The processes of the six products described above are not independent of each other, and there is an influence on the final product, and all processes except the heat treatment process are formed in the form of a magnetic core.

However, according to the process characteristics, core shape defects in the initial process or the intermediate process may proceed without being corrected in the final process step, and the workability and efficiency of workers are inferior in order to correct the shape defects of the core for each process. .

In the actual manufacturing process, the aluminum support rod f is inserted to wind the ribbon, and the support rod f is improved after the winding process, the heat treatment process, the drying process, or the cutting process. Although it continues to occur, the case of the shape defect of the core for each manufacturing process is summarized as follows with reference to Figs.

1. Winding and heat treatment process

(A) If the supporting rod (f) is removed after the winding process

(1) Shape deformation of the toroidal or rectangular cores 1 and 11 as shown in FIGS. 1A and 1B during the removal of the supporting rods 5 and 15.

(2) The loosening phenomenon of the inner and outer shaft ribbons 2 and 12 as shown in FIGS. 2A and 2B during the removal of the supporting rods 5 and 15.

(3) Shape deformation of the core as shown in Figs. 1A and 1B during the transport and heat treatment of the cores 1 and 11.

(4) A phenomenon in which shape deformation is continuously maintained by heat treatment while maintaining the shape of the deformed cores 1a and 11a (see FIGS. 1A and 1B).

(B) If the supporting rod (f) is removed after the heat treatment process

(1) Shape deformation of the toroidal or rectangular cores (1, 11) as shown in FIGS. 1A and 1B during removal of the supporting rods (5, 15).

(2) Loosening of the inner and outer ribbons 2 and 12 as shown in FIGS. 2A and 2B during the removal of the supporting rods 5 and 15

2. Impregnation / drying process

(A) When the support bar is removed in the above step 1

(1) Shape deformation of the toroidal or rectangular core 1.1 as shown in FIGS. 1A and 1B during the impregnation operation.

(2) Loosening phenomenon of the inner and outer ribbons 2 and 12 as shown in FIGS. 2A and 2B during the impregnation operation.

(3) The phenomenon in which the shape is continuously maintained by drying while maintaining the shape of the deformed cores 1a and 11a (see FIGS. 1A and 1B).

(B) If the supporting rod is removed after the drying process

(1) Breaking phenomenon of the inner and outer ribbon 21 as shown in FIG. 9 due to the impact during the removal of the supporting rods 5 and 15

3. Cutting process

(A) When the support bar is removed in the above steps 1 and 2

(1) Cutting edge edge flaring (4, 14), splitting (6, 16), cutting face flaring of the gap portions (3, 13) generated when cutting the core (1, 11) as shown in Figs. (7, 17), Falling (8, 18) failure of the ribbons 2, 12.

(2) The phenomenon in which the diagonal cuts 9 and 19 are made by cutting the uncorrected deformed cores 1a and 11a as shown in FIG.

(B) If the support bar is removed after the cutting process

(1) Cutting edge edge flaring (4, 14), splitting (6.16), cutting face flaring of the gap portions (3, 13) generated when cutting the core (1, 11) as shown in Figs. (7, 17), dropping of ribbons (2, 12) (8.18)

(2) Breakage phenomenon of the inner and outer ribbon 21 as shown in Fig. 9 due to the impact during the removal of the support bar (5.15).

4. Assembly process

(1) Inability to assemble deformed cores 1a and 11a not corrected in steps 1 to 3 above.

(2) The phenomenon that the ribbon 22 dropped at the time of assembly as shown in FIG. 8 adheres to the surface of the core 1 and is assembled.

Such defects are caused by problems such as deterioration of the magnetic properties of the final product, the generation of abnormal sounds, deterioration of workability and work efficiency due to the removal of support rods, and the loss of raw materials and labor costs due to various shape defects. There is a great difficulty in the production of amorphous toroidal magnetic cores or amorphous cut gore.

Accordingly, the present invention has been made in view of the problems of the prior art, the object of which is to heat the heat treatment, impregnation, drying in the state attached to the non-magnetic bobbin attached to the inside and outside, respectively, when winding the slitting amorphous ribbon The present invention provides an amorphous magnetic core and a method of manufacturing the same, which can fundamentally solve various problems occurring during the manufacturing process by going through a process of cutting, assembling, etc., thereby improving product characteristics, improving quality uniformity and productivity.

1A and 1B are schematic plan views respectively showing a molding failure phenomenon of a toroidal core and a rectangular core during a supporting rod removing process in a conventional method of manufacturing an amorphous magnetic core;

2A and 2B are schematic perspective views showing ribbon loosening phenomena of a toroidal core and a square core during a support rod removing process in a conventional method of manufacturing an amorphous magnetic core, respectively.

Figure 3a and 3b is a schematic plan view showing the edge swelling phenomenon of the toroidal core and the rectangular core during the support bar removal process in the conventional method for manufacturing an amorphous magnetic core, respectively.

4A and 4B are schematic plan views showing cracks of a toroidal forming core and a rectangular nose during a support rod removing process in a conventional method of manufacturing an amorphous magnetic core, respectively.

5A and 5B are schematic plan views showing the phenomena of the toroidal core and the quadrangular core during the support bar removing process in the conventional method for manufacturing an amorphous magnetic core, respectively.

6A and 6B are schematic plan views showing ribbon dropping phenomena of a toroidal core and a rectangular core during a support bar removing process in a conventional method of manufacturing an amorphous magnetic core, respectively.

7A and 7B are schematic plan views showing diagonal cutting phenomena of a toroidal core and a rectangular core during a support rod removing process in a conventional method of manufacturing an amorphous magnetic core, respectively.

8 is a schematic perspective view illustrating a phenomenon in which a ribbon piece is attached to a toroidal core in an assembling process in a conventional method of manufacturing an amorphous magnetic core;

9 is a schematic perspective view showing a phenomenon in which the inner or outer ribbon of the rectangular core breaks during the support rod removal process and the cap portion cutting in the conventional method of manufacturing an amorphous magnetic core;

10 is a manufacturing process chart showing a method of manufacturing a gap type toroidal amorphous magnetic core using an inner and outer bobbin according to the present invention.

11 is a perspective view of a cut core showing a wound body and a cut state of a rectangular amorphous cut core according to the present invention.

* Explanation of symbols for main parts of the drawings

30 inner bobbin 35 through hole

40 core 45 outer bobbin

50 case 60 inner bobbin

65: outer bobbin G: gap

In order to achieve the above object, the present invention is an amorphous magnetic core made of a non-magnetic metal and having a through-hole in the center and a ribbon-shaped amorphous alloy wound around the inner bobbin to impart magnetic properties. A sieve, an outer bobbin made of a nonmagnetic metal and surrounding the magnetic core body so as to prevent the outer end of the magnetic core body from being loosened, and an outer bobbin made of a nonmagnetic metal, the outer bobbin of the inner bobbin, the magnetic core body and the outer bobbin Comprising a case to cover, and provides an amorphous magnetic core, characterized in that for forming a gap by cutting a portion of the core consisting of the inner bobbin and the magnetic core body and the outer bobbin.

The inner and outer bobbin is made of a non-magnetic metal material, in particular, made of any one selected from aluminum, copper alloy, stainless steel.

The method of manufacturing the amorphous magnetic core includes a winding step of winding an amorphous alloy ribbon on an inner bobbin having a through hole at the center of the nonmagnetic metal to form a core body, and basic magnetic properties of the core alloy core body. A heat treatment step for forming a magnetic core by relieving stress during application and winding, an impregnation / drying step of immersion in an impregnation liquid in a vacuum state and then drying to maintain the shape of the heat treated magnetic core, and In order to impart intrinsic magnetic properties, the inner and outer bobbins and a portion of the magnetic core are cut together to form a gap of a certain size, and the gap is formed by assembling the core into the case.

When the inner and outer bobbins have a cylindrical shape, one gap is formed. When the inner and outer bobbins have a rectangular shape, two gaps are formed.

As described above, the present invention does not have any influence on the magnetic properties of the magnetic core on the inside and the outside when the slitting amorphous ribbon is wound, and has the appropriate mechanical strength and the proper workability while the workability and the work efficiency. Use bobbins with materials and shapes to maximize them. Materials satisfying such bobbin conditions are nonmagnetic materials such as aluminum (Al), copper (Cu), stainless steel, and the like, and proper strength and workability can be ensured by appropriate treatment such as alloying.

By attaching these non-magnetic bobbins to the inner and outer sides of the core, various problems arising during the manufacturing process can be fundamentally solved by going through heat treatment, impregnation, drying, cutting, and assembling processes with the bobbin attached, thereby improving the product characteristics. It is possible to improve the uniformity and productivity of quality.

EXAMPLE

Hereinafter, with reference to the accompanying drawings showing a preferred embodiment of the present invention described above in more detail.

10 is a manufacturing process diagram showing a method for manufacturing a gap type toroidal amorphous magnetic core using inner and outer bobbins according to the present invention, and FIG. 11 is a cut-away state of a rectangular amorphous cut core according to the present invention and a cut state. It is a perspective view of a cut core.

First, a manufacturing method of a gap type toroidal amorphous magnetic core will be described with reference to the manufacturing process diagram shown in FIG. 10.

In the present invention, using a ribbon obtained by setting a cylindrical inner bobbin 30 having a through hole 35 in the center of the winder instead of a conventional aluminum support rod, and then slitting a ribbon made of a wide amorphous alloy in a predetermined width. The core 40 is formed by winding the inner bobbin 30 to a predetermined diameter (S1).

Thereafter, the core 40 formed on the outer circumference of the inner bobbin 30 is inserted into the cylindrical outer bobbin 45 so as to prevent the wound ribbon from being unwound from the inner bobbin 30.

Here, the inner and outer bobbins 30 and 45 are non-magnetic metals made of any one of aluminum alloy, copper, alloy, and stainless steel, respectively, and have no influence on the magnetic properties of the finished magnetic core, and are initially wound up. It is required to have durability against core shape deformation factors such as external impact when forming from the process to the final assembling process, and to have the appropriate mechanical strength to form a beautiful cutting part during cutting.

At the same time, when a material satisfying magnetic properties and mechanical strength is processed to a certain shape to satisfy workability and work efficiency, appropriate workability is required, and material properties that do not degrade due to bobbin finishing or weight, etc. .

In this case, the thicknesses of the bobbins 30 and 45 can be selected within a range of at least 0.5 mm to at most 5 mm.

Subsequently, the toroidal core 40 whose ribbon is prevented from being loosened by the inner and outer bobbins 30 and 45 is heated together with the bobbin at a temperature below the Curie temperature. By applying a magnetic field in the circumferential direction or the height direction of the core, the magnetic core is formed to have a desired square ratio and to relieve stress at the time of winding.

Thereafter, an impregnation process is performed in which the epoxy is applied to the interlayer and the surface of the ribbon by immersion in the immersion liquid using a one-component epoxy as the immersion liquid to maintain the toroidal form when cutting the heat-treated magnetic core.

Thereafter, the epoxy-impregnated core is raised to cause unnecessary impregnation liquid to flow out, followed by a drying process of curing the impregnation liquid on the core surface.

Thereafter, the toroidal core 40 is cut using a ceramic wheel to form a gap G having a predetermined size so as to have the intrinsic magnetic properties of the gap type amorphous toroidal magnetic core as in step S3.

Subsequently, a double cylindrical case manufactured by inserting an insulating paper (not shown) to maintain the gap G of the core 40 formed by the cutting process to a predetermined size and then injection molding a flame-retardant polymer in the step S4 ( 50) to complete the assembly process to make the toroidal magnetic core.

Subsequently, after winding a predetermined coil through a magnetic property test to measure the inductance of the completed magnetic core, a final toroidal choke core is formed.

In the above embodiment of the manufacturing process, the toroidal magnetic core was manufactured using a ring-shaped inner and outer bobbin made of aluminum alloy, and as a result, magnetic properties such as inductance, core loss, permeability, coercivity, square ratio and DC superimposition characteristics of the final product were obtained. It was confirmed that there is no effect on the characteristics.

However, the defect rate in the manufacturing process was completely eliminated defects due to the removal of the support rod, the defect in the cutting process was reduced by 87.5%, the defect in the assembly process was reduced by 83%.

This is because the inner and outer bobbins fix the core to effectively prevent the deformation of the core shape due to external impact and at the same time block the unwinding of the ribbon. In addition, the cutting surface defects that occurred during the cutting process was also significantly reduced, and the problems such as abnormal noise caused by the cutting surface defects were fundamentally solved, thereby improving the characteristics and quality uniformity. In this case, the reduction of the cut surface defect is because the inner bobbin effectively prevents the edge gap that occurs at the end of cutting when the cutting wheel cuts the core.

As a result, it is possible to improve the uniformity of quality, to eliminate the problem of correcting defects during the process and to be careful of the whole work, and to eliminate the conventional process of removing the aluminum rods, thereby improving the work efficiency of the entire process. It is possible to increase productivity and increase productivity.

Meanwhile, as shown in FIG. 11, the rectangular amorphous cut core may be manufactured in the same manner as the toroidal magnetic core described above. In this case, the rectangular amorphous cut core may be manufactured by using the rectangular inner and outer bobbins 60 and 55. Only the points are different. The material of the rectangular inner and outer bobbins 60 and 55 is also made of the same material as the cylindrical inner and outer bobbins 30 and 45, and the thickness of the bobbin is also set within the range of at least 0.1 mm to at most 5 mm.

As a result, the rectangular amorphous cut cores were manufactured by using the rectangular inner and outer bobbins made of the same aluminum alloy of the gap type amorphous toroidal magnetic cores, and as a result, the magnetic properties of the final product had no effect. The defective rate in the manufacturing process is greatly reduced compared with the conventional.

As a result, it is possible to improve the uniformity of quality, and to reduce the raw material cost and improve the work efficiency of the overall process and increase productivity due to the reduction of defects during the process.

In the above embodiment, the material of the inner and outer bobbin is a nonmagnetic material other than any one selected from aluminum alloy, copper alloy, and stainless steel, and other alloy materials may be used as long as the durability, mechanical strength, and workability requirements are satisfied.

In addition, although the bobbin may be manufactured using a polymer, it is a material that is not particularly suitable because of its low thermal conductivity and mechanical strength compared to the nonmagnetic metal.

However, the polymer may be used as the material of the case.

In addition, while the above embodiment illustrates the simultaneous adoption of the inner and outer bobbins, the basic spirit of the present invention includes at least any one of the inner and outer bobbins, or both.

As described above, the present invention has no influence on the magnetic properties of the magnetic core on the inside and the outside when the slitting amorphous ribbon is wound, and has the appropriate mechanical strength and the proper workability while the workability and the work efficiency. By attaching non-magnetic bobbins with materials and shapes that can be maximized to the inside and outside of the core, they undergo heat treatment, coalescing, drying, cutting, and assembly processes with the bobbins attached to fundamentally solve various problems that occur during the manufacturing process. It can be solved by improving the product's characteristics, quality uniformity and productivity.

In the above, a preferred embodiment of the features of the present invention has been illustrated and described by way of example, but the present invention is not limited to the above-described embodiment, and ordinary knowledge in the art to which the nickname belongs without departing from the spirit of the present invention. Various changes and modifications will be possible by those who have the same.

Claims (4)

An inner bobbin made of a non-magnetic metal and having a through hole in the center, an amorphous magnetic core body having magnetic properties given by a ribbon-shaped amorphous alloy wound around the inner bobbin, and a non-magnetic metal. It consists of an outer bobbin surrounding the magnetic core body to prevent the outer end of the core body from loosening, and a case for covering the outside of the inner bobbin, the magnetic core body and the outer bobbin, and the inner bobbin An amorphous magnetic core characterized by cutting a portion of a core consisting of a magnetic core body and an outer bobbin to form a gap. 2. The amorphous magnetic core of claim 1, wherein the case is made of any one selected from nonmagnetic metals and polymers. 3. The amorphous magnetic core of claim 1 or 2, wherein the nonmagnetic metal is made of any one selected from aluminum, copper alloy, and stainless steel. Winding step of winding the amorphous alloy ribbon to the inner bobbin made of non-magnetic metal and having a plate-hole in the middle to form the core body, giving basic magnetic properties to the core body of the amorphous alloy and stress at the time of winding A heat treatment step for eliminating the formation of the magnetic core, an impregnation / drying step of immersion in an impregnation liquid in a vacuum state and drying to maintain the shape of the heat treated magnetic core, and imparting intrinsic magnetic properties of the magnetic core. Cutting the inner and outer bobbin and a portion of the magnetic core together to form a gap having a predetermined size, and assembling the gap-shaped magnetic core into a case.