WO2015106594A1

WO2015106594A1 - Hybrid excitation magnetic integrated inductor

Info

Publication number: WO2015106594A1
Application number: PCT/CN2014/089966
Authority: WO
Inventors: 邵革良; 江明
Original assignee: 田村（中国）企业管理有限公司; 株式会社田村制作所
Priority date: 2014-01-20
Filing date: 2014-10-31
Publication date: 2015-07-23
Also published as: CN103714946A; CN103714946B

Abstract

The present invention relates to a hybrid excitation magnetic integrated inductor comprising a magnetic core and two sets of coils. The magnetic core is formed by tight assembly of the following parts: two tablet magnetic cores, where the two tablet magnetic cores are arranged at either of the upper and lower sides of the magnetic core; two first magnetic core columns, where the two first magnetic core columns are arranged between the two tablet magnetic cores and respectively arranged at the left and right extremities of the tablet magnetic cores, and the two first magnetic core columns are used for winding of two sets of coils; and, two second magnetic core columns, where the two second magnetic core columns respectively are arranged at center positions in an overlooking angle on either side of the tablet magnetic cores. The hybrid excitation magnetic integrated inductor of the present invention not only is capable of maintaining high coupling effects, but also increases to the greatest extent the inductance of coil self-coupling.

Description

Hybrid magnetic circuit magnetic integrated inductor

Field of invention

The present invention relates to an inductor, and more particularly to a hybrid magnetic circuit magnetic integrated inductor.

Background technique

In the prior art, the magnetic core material of the magnetic integrated inductor generally adopts a ferrite core with high frequency characteristics, relatively low loss, and relatively high relative magnetic permeability, and generally has a relative magnetic permeability of 2000 H/m or more. However, since the magnetic core material of each part of the magnetic circuit is the same, the magnetic permeability is high, and the magnetic core is extremely saturated, in order to prevent this problem from occurring, the inner core of the coil winding and the triangular magnetic core column outside the winding are arranged. A plurality of fine air gaps are attempted to achieve the purpose of preventing core saturation and reducing magnetic flux leakage around the air gap.

Although the above structure can largely avoid the phenomenon that the coil is inductively heated due to a large amount of magnetic flux leakage around the winding coil, the structure is complicated, which is not conducive to mass production; and at the same time, due to the existence of a certain physical size air gap, it is impossible to fundamentally Solve the problem of coil eddy current loss caused by core leakage.

In order to effectively solve the above problem, the physical size of the air gap is controlled to be zero or to a minimum, and at the same time, the core saturation problem caused by the decrease of the magnetic resistance in the magnetic circuit can be avoided, and the present invention proposes a solution to solve the problem. New method.

Summary of invention

In order to solve the above technical problems in the prior art, the present invention provides a novel hybrid magnetic circuit magnetic integrated inductor by modifying the material composition of the magnetic core in the integrated inductor to realize different magnetic permeability.

The invention provides a hybrid magnetic circuit magnetic integrated inductor, comprising a magnetic core and two sets of coils, the magnetic core is closely assembled by the following parts: two flat magnetic cores, two flat magnetic cores are located on the upper and lower sides of the magnetic core Side; two first magnetic core columns, two first magnetic core columns are located between two flat magnetic cores and respectively located at the left and right ends of the flat magnetic core, and the two first magnetic core columns are used for winding two sets of coils And two second magnetic core columns, wherein the two second magnetic core columns are respectively located at a center position of upper and lower sides of the planar core of the planar core; wherein the flat magnetic core is composed of a first magnetic permeability ferrite material, A magnetic permeability is higher than 1000H/m, and all or a part of the first magnetic core column is composed of a second magnetic permeability metal powder material, the second magnetic permeability is lower than 500H/m, and the second magnetic core column is A three-permeability metal powder material having a third magnetic permeability of less than 500 H/m and lower than the second magnetic permeability.

According to an aspect of the invention, the cross-section of the flat core is an approximately hexagonal shape in which the upper and lower sides are parallel and the upper and lower sides are symmetrical, wherein the two second magnetic cores are located between the two flat cores.

According to an aspect of the invention, the cross-section of the flat core is an approximately hexagonal shape in which the upper and lower sides are parallel and the upper and lower sides are symmetric, but the center positions of the upper and lower sides of the hexagon are respectively matched with the shape of the second magnetic core column. The notch, wherein the sides of the two second core legs near the coil are closely fitted to the sides of the notch.

According to an aspect of the invention, the central portion of the first magnetic core column in the up and down direction is composed of a metal powder material, and the remaining portion is composed of a ferrite material.

According to an aspect of the invention, the shape of the first magnetic core column is a cylinder, an elliptical cylinder or a polygonal prism.

According to an aspect of the invention, the shape of the second magnetic core column is a triangular prism.

According to an aspect of the invention, the sides of the two second magnetic core legs adjacent to the coil are arcuate concave or polygonal concave parallel to the coil.

According to an aspect of the invention, the metal powder material is a ferrosilicon powder core, a ferrosilicon powder core or an amorphous powder core.

According to an aspect of the invention, the first magnetic permeability is in the range of 1000 to 4000 H/m.

According to an aspect of the invention, the second magnetic permeability and the third magnetic permeability are in the range of 20 to 300 H/m.

The foregoing description of the preferred embodiments of the present invention

Brief description of the drawing

The accompanying drawings are included to provide a further understanding of the embodiments of the invention In the figure:

1 is a perspective exploded view of a magnetic core in a hybrid magnetic circuit magnetic integrated inductor according to a first embodiment of the present invention.

2 is a perspective exploded view of a magnetic core in a hybrid magnetic circuit magnetic integrated inductor in accordance with a second embodiment of the present invention.

Figure 3 (a) is a perspective exploded view of a magnetic core in a hybrid magnetic circuit magnetic integrated inductor in accordance with a third embodiment of the present invention.

Figure 3 (b) is a side view of a magnetic core in a hybrid magnetic circuit magnetic integrated inductor in accordance with a third embodiment of the present invention.

Detailed description of the invention

Embodiments of the present invention will now be described in detail with reference to the drawings.

1 is a perspective exploded view of a magnetic core 100 in a hybrid magnetic circuit magnetic integrated inductor in accordance with a first embodiment of the present invention. As shown in FIG. 1, the magnetic core 100 in the hybrid magnetic circuit integrated inductor of the present invention is closely assembled from the following parts: two flat cores 110, and two flat cores 110 are located on the upper and lower sides of the magnetic core 100. Two first magnetic core pillars 120 are disposed between the two flat cores 110 and are respectively located at the left and right ends of the flat core 110, and the two first magnetic cores 120 are used for Two sets of coils are wound; and two second core legs 130 are respectively located at the center of the upper and lower sides of the plane of view of the flat core 110. The plate core 110 is composed of a ferrite material of a first magnetic permeability, and the first magnetic permeability is higher than 1000 H/m. The first magnetic core column 120 is composed of a second magnetic permeability metal powder material, and the second magnetic permeability is less than 500 H/m. The second magnetic core column 130 is composed of a metal magnetic powder material of a third magnetic permeability, and the third magnetic permeability is lower than 500 H/m and lower than the second magnetic permeability. The tightly assembled joints of the various portions of the core have no air gap or have a thin air gap of less than 1 mm. Such a design can ensure a very ideal coupling effect of the two sets of coils wound on the two first magnetic core columns 120 while avoiding saturation of the two second magnetic core columns 130 and minimizing The air gap leakage problem around the coil.

In one embodiment, the first magnetic permeability is in the range of 1000 to 4000 H/m. In one embodiment of the present invention, the cross-section of the plate core 110 is an approximately hexagonal shape in which the upper and lower sides are parallel and the upper and lower sides are symmetrical, but the center positions of the upper and lower sides of the hexagon are respectively provided with the second magnetic core column 130. The shape is a perfectly matched notch, wherein the sides of the two second core legs 130 near the coil are closely fitted to the sides of the notch. The second magnetic core column 130 is assembled with the flat core 110 by the embedded structure, which greatly improves the bonding area of the two magnetic cores, and can prevent the contact area between the flat magnetic core 110 and the second magnetic core 130 from being small. The ferrite is saturated at the contact surface.

In one embodiment, the metal powder material is a ferrosilicon powder core, a ferrosilicon powder core or an amorphous powder core. In one embodiment, the second magnetic permeability is in the range of 20 to 300 H/m. It is convenient to adjust the coupling coefficient of the two coils and maximize the larger autotransformer. In one embodiment of the invention, the first magnetic core post 120 is in the shape of a cylinder, an elliptical cylinder or a polygonal prism.

In one embodiment, the metal powder material is a ferrosilicon powder core, a ferrosilicon powder core or an amorphous powder core. In a In one embodiment, the second magnetic permeability is in the range of 20 to 300 H/m. In one embodiment of the invention, the second core post 130 is triangular prism shaped. In one embodiment, the sides of the two second core legs 130 that are adjacent to the coil are arcuate or polygonal recesses that are parallel to the coil.

The magnetic core 100 and the two sets of coils together constitute the hybrid magnetic circuit magnetic integrated inductor of the present invention, wherein the two sets of coils are wound around the two first magnetic core legs 120, respectively. The coil is wound from a copper wire, a copper clad aluminum wire or an aluminum wire.

2 is a perspective exploded view of a magnetic core 200 in a hybrid magnetic circuit magnetic integrated inductor in accordance with a second embodiment of the present invention. As shown in FIG. 2, the magnetic core 200 in the hybrid magnetic circuit integrated inductor of the present invention is closely assembled from the following parts: two flat cores 210, and two flat cores 210 are located on the upper and lower sides of the magnetic core 200. Two first magnetic core pillars 220 are located between the two flat cores 210 and are respectively located at the left and right ends of the flat core 210, and the two first magnetic cores 220 are used for Two sets of coils are wound; and two second core legs 230 are located between the two flat cores 210 at a center position on the upper and lower sides of the plane of view of the flat core 210. The plate core 210 is composed of a ferrite material having a first magnetic permeability, and the first magnetic permeability is higher than 1000 H/m. The first magnetic core column 220 is composed of a second magnetic permeability metal powder material having a second magnetic permeability of less than 500 H/m. The second magnetic core column 230 is composed of a metal magnetic powder material of a third magnetic permeability, and the third magnetic permeability is lower than 500 H/m and lower than the second magnetic permeability. The tightly assembled joints of the various portions of the core have no air gap or have a thin air gap of less than 1 mm. Such a design can ensure a very ideal coupling effect of the two sets of coils wound on the two first magnetic core columns 120 while avoiding saturation of the two second magnetic core columns 130 and minimizing The air gap leakage problem around the coil.

In one embodiment, the first magnetic permeability is in the range of 1000 to 4000 H/m.

Different from the shape and assembly relationship of the flat core 110 and the second core post 130 shown in FIG. 1, the cross section of the flat core 210 shown in FIG. 2 is parallel to the upper and lower sides, and the upper and lower sides are symmetric. Hexagon, the hexagon has no openings on the upper and lower sides. Two second core legs 230 are located between the two plate cores 210.

In one embodiment, the metal powder material is a ferrosilicon powder core, a ferrosilicon powder core or an amorphous powder core. In one embodiment, the second magnetic permeability is in the range of 20 to 300 H/m. It is convenient to adjust the coupling coefficient of the two coils and maximize the larger autotransformer. In one embodiment of the invention, the first magnetic core post 220 is in the shape of a cylinder, an elliptical cylinder or a polygonal prism.

In one embodiment, the metal powder material is a ferrosilicon powder core, a ferrosilicon powder core or an amorphous powder core. In one embodiment, the second magnetic permeability is in the range of 20 to 300 H/m. In an embodiment of the invention, the first The shape of the two magnetic core columns 230 is a triangular prism. In one embodiment, the sides of the two second core legs 230 that are adjacent to the coil are arcuate or polygonal recesses that are parallel to the coil.

The magnetic core 200 and the two sets of coils together constitute the hybrid magnetic circuit magnetic integrated inductor of the present invention, wherein the two sets of coils are wound around the two first magnetic core legs 220, respectively. The coil is wound from a copper wire, a copper clad aluminum wire or an aluminum wire.

Figure 3 (a) is a perspective exploded view of a magnetic core 300 in a hybrid magnetic circuit magnetic integrated inductor in accordance with a third embodiment of the present invention. Figure 3 (b) is a side view of a magnetic core 300 in a hybrid magnetic circuit magnetic integrated inductor in accordance with a third embodiment of the present invention. 3(a) and 3(b), it is different from the first magnetic core column 120 shown in FIG. 1 that a part of the first magnetic core column 320 is composed of a second magnetic permeability metal powder material. The rest is made up of ferrite materials. The remaining composition of the magnetic core 300 of FIG. 3(a) is the same as that of the magnetic core 100 shown in FIG. 1, and will not be described again.

In one embodiment, the central portion 322 of the first magnetic core post 320 in the up and down direction is composed of a metal powder material, and the remaining portion 324 is composed of a ferrite material. Since the remaining portion 324 of the first magnetic core post 320 is a ferrite material as the flat core 101, it can also be regarded as a part of the flat core 310 and integrally formed. The portion of the first magnetic core 320 in which the metal powder material is formed is shortened and placed at the center of the upper and lower portions, and the ferrite material of the same shape is used in the remaining portion 324. Such a structure can adjust and raise the equivalent relative magnetic permeability of the first magnetic core column 320 inside the coil, so that the equivalent relative magnetic permeability is much larger than that obtained by using only the metal powder material to form the first magnetic core column. The magnetic permeability, and thus, the relative magnetic permeability of the first magnetic core post 320 for winding the coil far exceeds the relative magnetic permeability of the second magnetic core post 330 of the non-wound portion. It will be understood by those skilled in the art that the length of the portion using different materials can be variously adjusted according to the required magnetic permeability, and the portion composed of the metal powder material is not limited to those shown in Figs. 3(a) and (b). Location and length, can also be other locations or lengths. The magnetic integrated inductor constructed in this way can maintain a high coupling effect and maximize the inductance of the coil auto-coupling.

It is apparent to those skilled in the art that various modifications and variations can be made in the above-described embodiments of the present invention without departing from the spirit and scope of the invention. Therefore, it is intended that the present invention cover the modifications and modifications of the invention

Claims

A hybrid magnetic circuit magnetic integrated inductor comprising a magnetic core and two sets of coils, the magnetic core being tightly assembled from the following parts:

Two flat cores, two of which are located on upper and lower sides of the magnetic core;

Two first magnetic core columns, two of the first magnetic core columns being located between two of the flat cores and respectively located at left and right ends of the flat core, and the two first magnetic cores are Winding the two sets of coils;

Two second magnetic core columns, two of the second magnetic core columns are respectively located at a center position of upper and lower sides of the planar view of the flat core;

among them,

The flat core is composed of a first magnetic permeability ferrite material, and the first magnetic permeability is higher than 1000H/m,

All or a portion of the first magnetic core column is composed of a second magnetic permeability metal powder material, and the second magnetic permeability is less than 500H/m,

The second magnetic core column is composed of a metal magnetic powder material of a third magnetic permeability, the third magnetic permeability being lower than 500 H/m and lower than the second magnetic permeability.
The hybrid magnetic circuit magnetic integrated inductor according to claim 1, wherein the flat core has a cross section of an approximately hexagonal shape in which both upper and lower sides are parallel and vertically symmetrical, wherein the two of the second A magnetic core column is located between the two of the planar cores.
The hybrid magnetic circuit magnetic integrated inductor according to claim 1, wherein the cross-section of the flat core is an approximately hexagonal shape in which the upper and lower sides are parallel and the upper and lower sides are symmetrical, but the upper and lower sides of the hexagon are The center positions are respectively provided with notches that exactly match the shape of the second magnetic core post, wherein the sides of the two second magnetic core posts close to the coil are closely fitted to the sides of the notch.
The hybrid magnetic circuit magnetic integrated inductor according to claim 1, wherein a central portion of the first magnetic core column in the up and down direction is made of a metal powder material, and the remaining portion is made of a ferrite material.
The hybrid magnetic circuit magnetic integrated inductor according to claim 1, wherein the shape of the first magnetic core column is a cylinder, an elliptical cylinder or a polygonal prism.
A hybrid magnetic circuit magnetic integrated inductor according to claim 1, wherein said second magnetic core column has a triangular prism shape.
The hybrid magnetic circuit magnetic integrated inductor according to claim 6, wherein a side of the two second magnetic core columns adjacent to the coil is an arc-shaped concave surface or a polygonal edge parallel to the coil concave.
The hybrid magnetic circuit magnetic integrated inductor according to claim 1, wherein the metal powder material is a ferrosilicon powder core, a ferrosilicon powder core or an amorphous powder core.
A hybrid magnetic circuit magnetic integrated inductor according to claim 1, wherein said first magnetic permeability is in the range of 1000 to 4000 H/m.
A hybrid magnetic circuit magnetic integrated inductor according to claim 1, wherein said second magnetic permeability and said third magnetic permeability are in the range of 20 to 300 H/m.