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EP2463869B2 - Composant inductif doté de propriétés de noyau améliorées - Google Patents
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EP2463869B2 - Composant inductif doté de propriétés de noyau améliorées - Google Patents

Composant inductif doté de propriétés de noyau améliorées Download PDF

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Publication number
EP2463869B2
EP2463869B2 EP11191948.6A EP11191948A EP2463869B2 EP 2463869 B2 EP2463869 B2 EP 2463869B2 EP 11191948 A EP11191948 A EP 11191948A EP 2463869 B2 EP2463869 B2 EP 2463869B2
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European Patent Office
Prior art keywords
core
central
inductive component
magnetic
center leg
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EP11191948.6A
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German (de)
English (en)
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EP2463869A1 (fr
EP2463869B1 (fr
Inventor
Kvetoslav Hejny
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TDK Electronics AG
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TDK Electronics AG
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Priority claimed from DE102011055880.2A external-priority patent/DE102011055880B4/de
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00—Cores, Yokes, or armatures
    • H01F3/10—Composite arrangements of magnetic circuits
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00—Cores, Yokes, or armatures
    • H01F3/10—Composite arrangements of magnetic circuits
    • H01F2003/106—Magnetic circuits using combinations of different magnetic materials

Definitions

  • the invention relates to an inductive component with a winding and a core.
  • Inductive components such as chokes, transformers and transmitters are widely used in electrical and electronic circuits.
  • the electrical properties of the inductive components depend on their structure and the properties of the windings and the core.
  • the document DE 10212930 A1 shows an inductive component with a central slug and an outer sleeve.
  • the latter has a permanent magnet section which is glued to another section.
  • the document US 2008/0055034 A1 shows a component with a core which has a part with a double-T-shaped cross-section and a sintered outer jacket which is separate therefrom and which surrounds the outside of the coil.
  • the document EP 1211700 A2 shows a component with a multi-part ferromagnetic core which also has a magnetic part.
  • the document US 4943793 A shows a component with a core in which the material properties of the center column, top and bottom differ from those of the side walls.
  • the document DE 3913558 A1 shows a multi-part ferrite core in which part cores with different material properties can be combined.
  • the document EP 1061140 A1 shows a cylinder with several regions of different magnetic properties.
  • the document DE 10 2006 026 466 B3 shows a core in which an air gap comprises non-ferromagnetic layers and thin ferromagnetic material layers.
  • the desired inductive properties can be achieved, for example, by suitable selection or adaptation of the winding and / or the permeability.
  • the permeability can be reduced by a large air gap, but this increases the leakage flux in the air gap and the associated losses. It is particularly important to improve the properties of the magnetic core.
  • the invention relates to an inductive component with a core, comprising a central slug and on the end Outer core parts adjacent to the middle slug, and a winding which is arranged between the middle slug and the outer core parts.
  • the core includes a plurality of core areas containing different magnetic materials, and the center slug includes areas containing different materials.
  • An inductive component is provided with a winding and a core which comprises a plurality of core regions which contain several different magnetic materials.
  • the inductive component comprises a single-layer and multi-layer winding as well as one of several such windings on a core.
  • the different magnetic materials preferably have different magnetic properties.
  • the term different magnetic materials is to be understood as meaning that it includes at least two different magnetic materials or that it is a material of a physical chemical composition with different magnetic material parameters in certain areas contains. The parameters can, for example, be optimized with regard to the operating conditions of the areas.
  • Such a magnetic core can in principle comprise any core shape, that is to say for example core shapes with the designations C, U, E, P, X, toroidal core and other core shapes or core shapes derived therefrom.
  • the invention can be used particularly advantageously in the case of core molds which have a central column or a central slug.
  • other core areas are to be understood as the legs and the yoke areas connecting them to the central section.
  • the complete core is formed from two core halves, each of which includes legs, yokes and a central slug.
  • the core can comprise a central slug and separate outer core parts. Other forms of separation are conceivable.
  • the central slug itself contains different materials, or the central slug contains a different magnetic material than the other regions of the core, or the core is constructed from a combination of both alternatives.
  • the different materials can be layered, the layers of which are arranged one behind the other in an alternating sequence, for example in the axial direction of the central column. These layers can be disk-shaped and alternately contain a layer with high permeability and a layer with no or low permeability.
  • Another preferred embodiment includes a central slug made of a magnetic material that is different from the magnetic material of the other core areas.
  • Another preferred one Embodiment contains combinations of the two aforementioned embodiments.
  • the mechanical connection of the central section with the other core areas is done by screwing.
  • the central piece preferably has a central hole through which a plastic screw is inserted, which holds the core together. This is particularly useful when two core halves are placed against one another, because then one plastic screw simultaneously holds the two core halves together.
  • an air gap is an important functional component because it significantly reduces the magnetic flux density of the core and, for example, linearizes the magnetization characteristic so that magnetic saturation of the core material only occurs at higher field strengths.
  • a significant part of the magnetic energy is stored in the air gap of storage chokes, which leads to disadvantages such as lower inductance or high forces.
  • the air gap is typically arranged between the two central bleeds of the core halves.
  • the proposed inductive component makes it possible to distribute the air gap virtually over the length of the entire central section.
  • the air gap distributed over several sections can be formed in the central slug by disks, for example made of ferrite material, separated by disks made of other material.
  • the inductive component With the inductive component it is possible to improve disadvantageous properties of the magnetic core. This includes, in particular, a reduction in leakage flux and losses. This will make it possible to get through the losses prevent conditional higher temperatures and reduce the cost of a cooling system. At the same time, it becomes possible to improve the efficiency of the inductive component.
  • Iron powder material or ferrite material that is to say ferromagnetic materials advantageously with high saturation values, are particularly suitable as different magnetic materials for the core. Both materials have disadvantages and advantages which are known per se.
  • An iron powder core for example, has the disadvantage of brittleness, but the advantage of the high saturation value Bs of 1 Tesla (1 T) to 1.5 T, which can be achieved, for example, with an iron powder core.
  • the individual powder grains which are still separated from one another by a non-magnetic or low-magnetic layer, already cause the air gap to be distributed, which improves the induction of saturation and softens the saturation.
  • a standard ferrite material has a saturation value Bs of approximately 0.4 T and a steep saturation behavior.
  • the use of several different magnetic materials makes it possible to optimize the magnetic properties of the core.
  • the resulting saturation value will be in the range between the saturation value of a ferrite material or a powder material, for example iron powder material. This means that the saturation value will be in the range between 0.4 T and 1.5 T.
  • a material with lower permeability for the central slug such as iron powder with an exemplary permeability of 10 to 50 and a ferrite material for the other areas with an exemplary permeability of 1000 to 3000 makes it possible to determine the total permeability as well as the total length of the air gap or the air gaps in the Reduced compared to a core consisting only of ferrite material.
  • ⁇ tot is the total permeability
  • I e, tot is the total effective length of the magnetic circuit
  • I i is the magnetic length of an i-th area
  • ⁇ i is the permeability of the i-th area.
  • the lengths of the partial air gaps are also shorter, which reduces the leakage flux and the resulting losses.
  • the optimization of the magnetic core properties in turn makes it possible to reduce the dimensions of the core and, in particular, to reduce the cross-section or the diameter of the central slug and the winding applied to it, which in turn enables the volume of the winding to be reduced.
  • This in turn makes it possible to reduce the overall dimensions of an inductive component and thus also to reduce the costs for the production of the inductive component.
  • the reduction in the effective area of the central vent when using a material a higher saturation value is accompanied by an increase in the saturation value and is, for example, 0.4T / 1.5T when using a material with 1.5T compared to using a material with 0.4T.
  • the reduction in the central stub diameter is also associated with a reduction in the external dimensions of the component, which allows smaller and more material-saving and thus more cost-effective housings to be used.
  • the effective length of the winding results from the number of turns and the length of the respective winding.
  • the total length of the wire of the winding is therefore reduced.
  • This in turn causes a reduction in the material used for the winding, for example copper, so that resource-saving production and use of the inductive component is ensured. Therefore, not only the reduced costs for the magnetic core but also the lower costs for the winding contribute to reducing the costs and achieving advantages for the inductive component.
  • the electrical properties of the inductive component are improved because the shorter overall length of the wire of the winding reduces the losses in the winding and increases the efficiency of the inductive component.
  • the central slug In the case of the inductive component, it is advantageous to shape the central slug with the aid of ferromagnetic powder material and the remaining parts of the core from ferrite material. Due to the high saturation value of the central bleed created in this way, the saturation behavior of the core is optimized overall and the magnetic flux through the central bleed can affect the adjacent parts of the core optimally distribute from ferrite material.
  • the central slug In order to achieve an optimal transition of the flow from the central slug to the adjacent core parts, the central slug is adapted in its shape, for example by means of a central part with a small diameter, which increases in size towards the transition to the adjacent ferrite material in the foot area of the central slug. The diameter and the thickness of the transition part depend on the limit values of the magnetic saturation of the two ferromagnetic materials.
  • Such a transition part between the central slug and the adjoining other core parts is preferably made of the same material as the material in the central part of the central slug, that is to say, for example, of powder material.
  • the transition part has the advantage that it acts like a flange and is able to guide the winding laterally.
  • the transition part thus fulfills a flange function which is similar to the function of a flange of a winding support.
  • This flange-like transition part can have the same outer diameter as the winding.
  • standard core shapes for example a P or X core, a separate winding carrier is therefore not necessary.
  • the central section and the flange are coated with an insulating material of small thickness or the coil windings themselves are insulated.
  • This insulating coating material on the elements of the central vent has little or no permeability and has the effect that the insulation forms partial air gaps on the end faces of the central vent.
  • the coating of the central portion can be, for example, 0.2 mm thick, which is a common coating thickness.
  • the central slug is formed from disks of different materials
  • disk-shaped magnetic material for example with ferromagnetic powder
  • other disks made of material with little or no permeability are also suitable for compensating for the differences between the height of the central column or the central section and the outer core areas.
  • a further function of such a disc-shaped material with no or little permeability in the central slug causes a distributed air gap. Furthermore, the total permeability can be reduced, the total length of the air gap can be reduced and the magnetic flux can be optimized.
  • the finished core composed of two core halves, comprises as an air gap twice the insulating distance between the two central parts of the middle section and the respective distance between the outer part of the middle section and the adjoining core parts.
  • the central bleed comprises two identical or symmetrical parts, between which a disc of material without permeability or is arranged with low permeability. The disc can compensate for differences, for example with regard to the fit, between the central slug and the outer areas.
  • the disk divides the entire air gap into three parts, namely two between the middle socket ends and the other core areas and one between the two middle socket parts, which reduces the leakage flux.
  • a central bleed made of material with low permeability, for example made of iron powder, or the combination of ferrite areas with iron powder areas as central bleed reduce the leakage flux or the losses.
  • the provision of several air gaps in the central vent reduces the leakage flux, effort and costs for the cooling system and increases the performance of the component.
  • the magnetic core in which the central slug contains one material, for example a ferromagnetic powder, and the outer core part another material, for example ferrite material it is possible to optimize the overall permeability of the core. This is possible because ferromagnetic powder, for example iron powder, has a permeability between 10 and 50, while ferrite material has a permeability in the range from 1000 to 3000.
  • ferromagnetic powder for example iron powder
  • ferrite material has a permeability in the range from 1000 to 3000.
  • An inductive component with a magnetic core as proposed also has the advantage that the temperature behavior of the entire core arrangement can be improved.
  • Ferrite material for example, has a temperature dependency with several loss maxima.
  • the overall temperature dependency of the proposed core arrangement can be improved both through the possibility of variation in the manufacture, e.g. during pressing and sintering, of the ferrite material and through the combination with another ferromagnetic material, e.g. powder material.
  • the permeability can depend on the temperature. Ferrite materials can, for example, have two tips that can be shifted by varying the manufacturing process.
  • the optimization can be directed both to the middle section and to the other core areas, wherein the target specifications of the optimization, for example saturation value, loss or permeability, can differ for the various core areas.
  • the optimization can reduce the overall permeability, the size of the air gap and the leakage flux. Such an optimization is not possible in the case of cores which only consist of the same material.
  • the central slug can be constructed in different embodiments and, for example, contain disks of different material and / or a uniform material that differs from the external core part.
  • the central piece can comprise parts which are integrally formed in the shape of a flange at the end. It is advantageous to provide a central bore for the individual parts of the central port so that they are aligned with a correspondingly aligned bore in the external core parts can be connected by a screw.
  • a screw is in particular made of insulating material and makes it possible to further optimize the overall permeability of the magnetic circuit of the inductive component. This is possible, for example, by adjusting the pressure exerted by the screw on the central hole and thus on the different core elements of the central port and the outer core areas.
  • a change in the pressure exerted by the screw causes a change in the remaining air gap.
  • the central slug also includes panes with little or no permeability, it is possible to choose this material in such a way that it is mechanically flexible.
  • plastic and silicone come into question as materials, so that the pressure exerted by the screw results in a quasi-resilient function.
  • the pressure exerted by the screw on the core parts can be adjusted with a torque wrench, for example.
  • the center column contains ferrite or ferrite disks
  • these can be manufactured in such a way that the minimum of the losses occurs at higher temperatures than in the case of the different ferrite material of the outer core part. Therefore, in this case the temperatures of the central vent can be higher than the temperatures of the outer core part.
  • This provides better cooling conditions for the core arrangement, since the central section can only be cooled by conduction, while the entire core arrangement can also be cooled by convection or fan cooling.
  • such ferrite disks of the middle section can also be made with a material with a higher saturation Bs than the outer core parts.
  • the adaptation of the ferrite materials of the core areas to their operating temperatures in order to reduce the losses can be done by adjusting the pressure, temperature and sintering profile when sintering the areas. Such a variation of the manufacturing process for different core areas is not possible with a one-piece core.
  • Another approach is to use low permeability material, such as iron powder, for the manufacture of the central slug, which reduces the diameter in order to reduce the effective winding length, the volume of the material for the winding and ultimately the losses.
  • the combination of the different materials, the reduced dimensions and the shorter conductor length optimizes the losses in terms of the magnetic material and the windings compared to a component with a one-piece core, which also increases efficiency and reduces costs.
  • the ferrite disks in the central slug can be made of a material with a higher saturation value, adapted to the operating temperature.
  • the operating temperature of the central port is higher than that of the outer core areas; the former is, for example, in the region of 100 degrees Celsius, the latter in the region of 80 degrees Celsius.
  • the saturation value increases with decreasing temperature.
  • the saturation value increases with a temperature drop between the central nozzle and the outer core area by approximately 20mT for a conventional ferrite material.
  • transformers or transmitters can also have a corresponding structure.
  • Different core shapes can also be provided, for example with a P or X shape or as pot or bowl cores.
  • an X core is understood to be a core shape which, adjoining the central neck, comprises at least four radially diverging yoke regions, on each of which a leg is attached in the direction of the central neck.
  • P and X cores have a compact shape with little interference.
  • a P-core is made up of two core parts 1a and 1b placed against one another, which can comprise ferrite material.
  • a slug is arranged in the center of the core and is constructed in the form of a disk from different materials.
  • the central slug contains disks 2 which contain either ferromagnetic powder or a ferrite material that is different from the ferrite material of the outer core part 1a, 1b.
  • a material 3 with little or no permeability is arranged between the panes 2.
  • these are disks made of the material 3 mentioned, advantageously flexible, or the ferromagnetic disks 2 are insulated with an insulating coating.
  • the winding 5 is arranged between the central slug and the outer core parts.
  • the entire arrangement of the inductive component is held together by a screw 4 in a through hole 6, which connects the outer core parts and the central flap with one another.
  • the air gap which is distributed over the areas with little or no permeability between the ferromagnetic disks and the outer core area, is set and adjusted by the pressure exerted by the pressing force of the screw on the outer core part and the central section.
  • Figure 2 shows a throttle arrangement using an X-core.
  • the arrangement shows two outer core halves 1a and b, which can comprise ferrite material, as well as ferromagnetic disks 2 of the middle section, which are separated from one another by a material 3 with little or no permeability or, alternatively, by an insulating coating.
  • the winding 5 of the choke is arranged between the layer structure of the central slug and the outer core parts 1a and 1b, respectively. All parts of the core are tightened by a 4 in a through hole 6 held together and guided, with which the pressing force on the elements of the magnetic core can be adjusted. In this exemplary embodiment, too, there is a spatially distributed air gap.
  • Figure 3 shows a reactor with a P or an X core, in which the external halves 1a and 1b contain ferrite.
  • the central middle section contains two parts 2 which contain a flange 7 at the end of the external core areas.
  • the center slug can comprise iron powder.
  • the flange 7 has the effect that, on the one hand, the magnetic flux from the central slug to the outer core parts is better distributed and, on the other hand, that the winding 5 is at least partially guided.
  • the insulation of the winding 5 with respect to the core 1a and 1b is designed in particular as an insulated winding or as an insulating coating of the central slug. In the latter case, it is possible to apply the winding directly in the intermediate area between the central slug and the external core parts.
  • the insulation coating of the central bleed fulfills the task of distributing the air gap of the throttle over the central area between the central bleed halves and the two outer flange areas. This results in improved loss conditions for the throttle, so that overall a throttle with a smaller design and at the same time improved properties compared to conventional throttles is achieved.
  • a disk made of flexible material in Figure 3 not shown), the permeability of which is low or zero. Due to the flexibility of the disk, it acts as a spring. The screw allows flexibility Using the disc, the distance between the parts 2 of the central stub can be varied.
  • FIG 4 an arrangement with a P or X core shape is shown which differs from the Figure 3 differs in that the flange-shaped areas 7, which are arranged at the end between the central boss parts 2 and the external core parts 1a and 1b, extend from the central bore 6 with the guide screw 4 to the external core parts.
  • This makes it possible to arrange the winding 5 completely in the area formed by the flanges and thus also to dispense with a separate winding carrier for the winding.
  • the stepped enlarged diameter of the central port 2 act as a transition area for distributing the flux and for holding the winding 5. Together, the central part of the central port 2 and the steps give the shape of the winding 5.
  • Figure 5 shows schematically the transition of the magnetic flux from the central nozzle 2 via the flange arranged at the end of this central nozzle 2 to the external core parts.
  • the very large magnetic flux in the central slug 2 is already reduced and distributed in the transition area of the flange 7, so that an adaptation to the flux present in the outer ferrite part 1 of the core is ensured.
  • the central slug 2 comprises iron powder; the other parts of the core comprise ferrite material.
  • the transition area optimizes the flow transition between the parts, in which it is necessary to distribute the flow from the central nozzle 2 with a higher saturation value due to the iron powder to the ferrite material with a lower saturation value.
  • the thickness and diameter of the Transition areas depend on the ratio of the saturation values in the middle section 2 and the other core parts.

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Claims (12)

  1. Composant inductif muni d'un noyau, comprenant une pastille centrale (2) et des parties de noyau externes (la, 1b) adjacentes à la pastille centrale (2) du côté de l'extrémité, et un enroulement (5) qui est disposé entre la pastille centrale (2) et les parties de noyau externes (la, 1b), le noyau comprenant une pluralité de zones de noyau (1, 2) qui contiennent des matériaux magnétiques différents et la pastille centrale (2) contenant des zones avec des matériaux différents, avec lequel, au niveau de la pastille centrale (2), une séquence de couches de matériaux différents sont vissées.
  2. Composant inductif selon la revendication 1, avec lequel les matériaux magnétiques différents présentent des propriétés magnétiques différentes.
  3. Composant inductif selon la revendication 1 ou 2, avec lequel les matériaux magnétiques différents comprennent un type de matériau avec des paramètres magnétiques différents.
  4. Composant inductif selon l'une des revendications 1 à 3, dont les propriétés du noyau magnétique sont différentes des propriétés du noyau magnétique qui sont associées aux matériaux individuels parmi les matériaux magnétiques différents.
  5. Composant inductif selon l'une des revendications 1 à 4, avec lequel les matériaux magnétiques différents de la pastille centrale sont façonnés sous la forme d'une séquence de couches.
  6. Composant inductif selon l'une des revendications 1 à 5, avec lequel la pastille centrale (2) comprend un matériau magnétique différent du matériau magnétique des zones extérieures du noyau.
  7. Composant inductif selon la revendication 6, avec lequel la pastille centrale (2) contient une poudre ferromagnétique et les zones extérieures du noyau de la ferrite.
  8. Composant inductif selon la revendication 6 ou 7, avec lequel la pastille centrale (2) contient plusieurs couches de matériau magnétique réalisées sous la forme de disques.
  9. Composant inductif selon l'une des revendications 6 à 8, avec lequel les matériaux magnétiques en forme de disque de la pastille centrale (2) sont munis d'un revêtement isolant (3) .
  10. Composant inductif selon l'une des revendications 1 à 8, avec lequel un matériau flexible (3) ayant une perméabilité faible ou nulle est disposé entre des zones d'un matériau ayant une perméabilité plus élevée (2).
  11. Composant inductif selon l'une des revendications précédentes, avec lequel la pastille centrale (2) est en deux parties, la pastille centrale possédant deux parties (2) en matériau de perméabilité plus élevée entre lesquelles est disposé un disque en matériau flexible ayant une perméabilité faible ou nulle.
  12. Composant inductif selon l'une des revendications 6 à 11, avec lequel la pastille centrale présente du côté de l'extrémité, vers les zones extérieures du noyau, un façonnage en forme de bride (7).
EP11191948.6A 2010-12-08 2011-12-05 Composant inductif doté de propriétés de noyau améliorées Active EP2463869B2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102010053810 2010-12-08
DE102011055880.2A DE102011055880B4 (de) 2010-12-08 2011-11-30 Induktives Bauelement mit verbesserten Kerneigenschaften

Publications (3)

Publication Number Publication Date
EP2463869A1 EP2463869A1 (fr) 2012-06-13
EP2463869B1 EP2463869B1 (fr) 2015-02-11
EP2463869B2 true EP2463869B2 (fr) 2021-10-20

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US (1) US9019062B2 (fr)
EP (1) EP2463869B2 (fr)
JP (2) JP5931424B2 (fr)
CN (1) CN102543373B (fr)

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US9019062B2 (en) 2015-04-28
JP5931424B2 (ja) 2016-06-08
JP6397444B2 (ja) 2018-09-26
EP2463869A1 (fr) 2012-06-13
EP2463869B1 (fr) 2015-02-11
CN102543373A (zh) 2012-07-04
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CN102543373B (zh) 2016-08-17
US20120200382A1 (en) 2012-08-09

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