Low-loss, high-current, wide-bandwidth shielded core device for mobile power supplies

Abstract

The present invention relates to the technical field of magnetic core devices, and discloses a low-loss, high-current, wide-band shielded magnetic core device suitable for mobile power sources, including a magnetic core device body, a middle column is provided in the middle of the magnetic core device body, the cross-section of the middle column is square and flat, an annular groove is provided between the magnetic core device body and the middle column, the annular groove is rectangular and has round chamfers at the corners, a rectangular notch is provided between the outer side wall of the annular groove and the magnetic core device body, and two magnetic core device bodies can be symmetrically assembled into one. In the present invention, the middle column provided in the middle of the magnetic core device body can be used to wrap the wire, and the wire is placed through the annular groove, thereby improving the shape of traditional magnetic core devices, which are mostly annular, E-shaped or can-shaped, etc. These shapes may only have a semi-enclosed or three-quarters enclosed shielding structure, which limits their shielding effect, and therefore, in practical applications, the problem of poor anti-interference ability is prone to occur.

Description

Technical Field

[0001] The invention relates to the technical field of magnetic core devices, in particular to a low-loss, high-current, wide-band shielded magnetic core device suitable for a mobile power source. Background Art

[0002] Magnetic core devices are a very important type of component in electronic devices. Magnetic cores are usually made of magnetic materials such as ferrite. From a structural point of view, they are generally in various shapes such as ring, E-shaped or can shape. In terms of function, magnetic core devices are mainly used in inductors and transformers. In inductors, magnetic cores can increase the inductance. For example, in the filter inductor in the power supply circuit, with a magnetic core, it is possible to more effectively filter out unwanted clutter frequency components and allow DC current to pass more smoothly. For transformers, the magnetic core is a key medium for energy transfer. It can couple the electric energy of the primary coil to the secondary coil, and at the same time, by changing the turns ratio of the primary and secondary coils, the voltage can be increased or decreased. For example, in common mobile phone chargers, the transformer core helps to reduce the voltage of 220V AC to a low-voltage DC suitable for mobile phone charging. Moreover, the performance parameters of the magnetic core, such as magnetic permeability and saturation flux density, have a great influence on the overall performance of the device. A magnetic core with high magnetic permeability can generate a strong magnetic field at a small current, and the saturation flux density determines the maximum magnetic flux that the magnetic core can withstand without performance degradation.

[0003] Traditional magnetic core devices are mostly in the shape of rings, E-shapes or cans, etc. These shapes may only have semi-enclosed or three-quarters enclosed shielding structures, which limits their shielding effects. Therefore, in practical applications, they are prone to poor anti-interference capabilities. Summary of the invention

[0004] In view of the deficiencies in the prior art, the present invention provides a low-loss, high-current, wide-band shielded magnetic core device suitable for a mobile power supply, which solves the problem that most traditional magnetic core devices are in the shape of a ring, E-shape or can, etc. These shapes may only have a semi-closed or three-quarters closed shielding structure, which limits their shielding effect. Therefore, in practical applications, they are prone to poor anti-interference ability.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solutions: a low-loss, high-current, wide-band shielded magnetic core device suitable for a mobile power supply, comprising a magnetic core device body, a middle column is provided in the middle of the magnetic core device body, the cross-section of the middle column is square and flat, an annular groove is provided between the magnetic core device body and the middle column, the annular groove is rectangular and has circular chamfers at the corners, a rectangular notch is provided between the outer side wall of the annular groove and the magnetic core device body, and two of the magnetic core device bodies can be symmetrically assembled into one.

[0006] Preferably, the length of the magnetic core device body is 15.7 mm±0.2 mm, the width of the magnetic core device body is 8.0 mm±0.2 mm, and the height of the magnetic core device body is 13.7 mm±0.2 mm.

[0007] Preferably, the length of the center column is 7.7 mm ± 0.15 mm, the width of the center column is 6.2 mm ± 0.2 mm, and the height of the center column is 5.7 mm ± 0.15 mm.

[0008] Preferably, the width of the annular groove is 2.6 mm, and the depth of the annular groove is 6.2 mm±0.2 mm.

[0009] Preferably, the width of the rectangular notch is 3.2 mm.

[0010] Preferably, the upper portion of the magnetic core device body is provided with two outer chamfers with a radius of 1.0 mm, the outer wall of the annular groove is provided with three inner chamfers with a radius of 2.3 mm, and the four corners of the center column are provided with positive angles with a radius of 2.3 mm.

[0011] Preferably, the magnetic core device body and the middle column include the following raw materials in percentage: 49 mol% Fe2O3, 32 mol% Mn, 13 mol% ZnO, 5 mol% Ni, 1 mol% Co, 0.02-0.07wt% Co2O3, 0.01-0.06wt% CaCO3, 0.02-0.05wt% SnO2, 0.02-0.05wt% Nb2O5, 0.01-0.02wt% ZrO2 and 0.01-0.02wt% Ta2O5.

[0012] Preferably, the manufacturing process of the magnetic core device body and the center column comprises the following steps:

[0013] S1. Weigh the corresponding raw materials according to weight, mix them and add them into the punching machine;

[0014] S2. The forming pressure of the punching machine is controlled at 120T;

[0015] S3. After stamping, the magnetic core device is placed in a sintering furnace and sintered in a three-temperature zone manner;

[0016] First temperature zone: put the magnetic core device into the sintering furnace, start heating from 25℃ for 4 hours, increase the temperature by 120℃ per hour, and heat it to 500℃. After heating, keep it at 500℃ for 8 hours;

[0017] Second temperature zone: start heating from 500℃ for 3 hours, increase the temperature by 130℃ per hour, and heat to 900℃. After heating, keep the temperature at 900℃ for 9 hours.

[0018] The third temperature zone: start heating from 900℃ for 6 hours, increase the temperature by 100℃ per hour, and heat to 1500℃. After heating, keep the temperature at 1500℃ for 3 hours;

[0019] S4. Take out the magnetic core device and cool it to room temperature.

[0020] The invention provides a low-loss, high-current, wide-band shielded magnetic core device suitable for a mobile power source.

[0021] It has the following beneficial effects:

[0022] 1. In the present invention, the wire can be wound around the middle column arranged in the middle of the magnetic core device body, and the wire can be placed through the annular groove. The magnetic core device body can shield the interference from the top, bottom, left, right, front and back, thereby improving the shape of traditional magnetic core devices, which are mostly ring-shaped, E-shaped or can-shaped. These shapes may only have a semi-closed or three-quarters closed shielding structure, which limits its shielding effect. Therefore, in practical applications, it is easy to have a problem of poor anti-interference ability.

[0023] 2. In the present invention, Ae can be increased by designing the middle column to be square and flat, thereby reducing the height of the middle column and making the saturation current larger.

[0024] 3. In the present invention, a small amount of metal nickel (Ni) is added to the powder mainly composed of manganese-zinc material, thereby reducing the initial magnetic permeability and improving the performance of the magnetic device in the high temperature zone, which is beneficial to increase the frequency of use, improve the magnetic saturation performance, and increase the saturation current.

[0025] 4. In the present invention, a very small amount of metal cobalt (Co) is added to the powder mainly composed of manganese-zinc material, so as to fine-tune the magnetism, thereby compensating for the decrease in initial magnetic permeability caused by metal nickel, reducing thermal conductivity at high temperature, and combining with metal nickel (Ni) to facilitate overall power consumption and heat generation.

[0026] 5. In the present invention, by increasing the punching force to 120T, the molding density can be increased, so that the energy storage or energy conversion per unit area is increased.

[0027] 6. In the present invention, during sintering, the overall performance and stability of the magnetic core device can be improved through partitioned sintering after sintering. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1It is a schematic diagram of the cross-sectional structure of the present invention;

[0029] Figure 2 It is a schematic diagram of the front three-dimensional structure of the present invention;

[0030] Figure 3 It is a schematic diagram of the bottom three-dimensional structure of the present invention;

[0031] Figure 4 It is a schematic diagram of the top structure of the present invention;

[0032] Figure 5 It is a front view structural schematic diagram of the present invention;

[0033] Figure 6 It is a side view structural schematic diagram of the present invention. DETAILED DESCRIPTION

[0034] The technical solution of the present invention will be described clearly and completely below in conjunction with the accompanying drawings of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0035] Embodiment 1:

[0036] Please see attached Figure 1 -Attached Figure 6 An embodiment of the present invention provides a low-loss, high-current, wide-band shielded magnetic core device suitable for a mobile power supply, including a magnetic core device body, a middle column is provided in the middle of the magnetic core device body, the cross-section of the middle column is square and flat, an annular groove is provided between the magnetic core device body and the middle column, the annular groove is rectangular and has circular chamfers at the corners, a rectangular notch is provided between the outer side wall of the annular groove and the magnetic core device body, and two magnetic core device bodies can be symmetrically assembled into one.

[0037] Specifically, the magnetic core device body can protect the internal wires, the middle column can support the wires, the square and flat cross-section of the middle column can increase Ae, thereby reducing the height of the middle column and making the saturation current larger. The annular groove can house the wires, and the rectangular notch can lead out the wires.

[0038] Please see attached Figure 1 The length of the magnetic core device body is 15.7 mm ± 0.2 mm, the width of the magnetic core device body is 8.0 mm ± 0.2 mm, and the height of the magnetic core device body is 13.7 mm ± 0.2 mm.

[0039] Specifically, the length of the magnetic core device body is A in the figure, the width of the magnetic core device body is B in the figure, and the height of the magnetic core device body is C in the figure.

[0040] Please see attached Figure 1 The length of the middle column is 7.7mm±0.15mm, the width of the middle column is 6.2mm±0.2mm, and the height of the middle column is 5.7mm±0.15mm.

[0041] Specifically, the length of the center column is A1 in the figure, the width of the center column is D in the figure, and the height of the center column is C1 in the figure.

[0042] Please see attached Figure 1 , the width of the annular groove is 2.6mm, and the depth of the annular groove is 6.2mm±0.2mm.

[0043] Specifically, the widths of the annular groove are A2, A3, C2 and C3 in the figure, and the depth of the annular groove is D in the figure.

[0044] Please see attached Figure 1 , the width of the rectangular notch is 3.2mm.

[0045] Specifically, the width of the rectangular notch is A4 in the figure.

[0046] Please see attached Figure 1 Two outer chamfers with a radius of 1.0 mm are arranged on the upper part of the core device body, three inner chamfers with a radius of 2.3 mm are arranged on the outer wall of the annular groove, and positive angles with a radius of 2.3 mm are arranged at the four corners of the middle column.

[0047] Specifically, the outer chamfer set on the upper part of the core device body is R3 in the figure, the inner chamfer set on the outer wall of the annular groove is R2 in the figure, and the positive angles set at the four corners of the middle column are R1 in the figure.

[0048] The magnetic core device body and the middle column include the following raw materials in percentage: 49 mol% Fe2O3, 32 mol% Mn, 13 mol% ZnO, 5 mol% Ni, 1 mol% Co, 0.02-0.07wt% Co2O3, 0.01-0.06wt% CaCO3, 0.02-0.05wt% SnO2, 0.02-0.05wt% Nb2O5, 0.01-0.02wt% ZrO2 and 0.01-0.02wt% Ta2O5.

[0049] Specifically, 5 mol% Ni can reduce the initial magnetic permeability and improve the performance of magnetic devices in high temperature zones, which is beneficial to increasing the frequency of use, improving the magnetic saturation performance, and increasing the saturation current. 1 mol% Co can fine-tune the magnetism, thereby compensating for the decrease in initial magnetic permeability caused by metal nickel and reducing thermal conductivity at high temperatures. The combination with metal nickel (Ni) is beneficial to overall power consumption and heat generation.

[0050] The manufacturing process of the magnetic core device body and the center column includes the following steps:

[0051] S1. Weigh the corresponding raw materials according to weight, mix them and add them into the punching machine;

[0052] S2. The forming pressure of the punching machine is controlled at 120T;

[0053] S3. After stamping, the magnetic core device is placed in a sintering furnace and sintered in a three-temperature zone manner;

[0054] First temperature zone: put the magnetic core device into the sintering furnace, start heating from 25℃ for 4 hours, increase the temperature by 120℃ per hour, and heat it to 500℃. After heating, keep it at 500℃ for 8 hours;

[0055] Second temperature zone: start heating from 500℃ for 3 hours, increase the temperature by 130℃ per hour, and heat to 900℃. After heating, keep the temperature at 900℃ for 9 hours.

[0056] The third temperature zone: start heating from 900℃ for 6 hours, increase the temperature by 100℃ per hour, and heat to 1500℃. After heating, keep the temperature at 1500℃ for 3 hours;

[0057] S4. Take out the magnetic core device and cool it to room temperature.

[0058] Specifically, by controlling the forming punching force of the punching machine at 120T, the forming density can be increased, so that the energy storage or energy conversion per unit area can be increased. Through the first temperature zone, the second temperature zone and the third temperature zone, the overall performance and stability of the magnetic core device can be improved after sintering.

[0059] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A low-loss, high-current, wide-band shielded magnetic core device suitable for a mobile power source, comprising a magnetic core device body, characterized in that: A middle column is provided in the middle of the magnetic core device body, and the cross-section of the middle column is square and flat. An annular groove is provided between the magnetic core device body and the middle column. The annular groove is rectangular and has round chamfers at the corners. A rectangular notch is provided between the outer wall of the annular groove and the magnetic core device body. The two magnetic core device bodies can be symmetrically assembled into one body.

2. The low-loss, high-current, wide-bandwidth shielded magnetic core device suitable for mobile power supply according to claim 1, characterized in that: The length of the magnetic core device body is 15.7 mm±0.2 mm, the width of the magnetic core device body is 8.0 mm±0.2 mm, and the height of the magnetic core device body is 13.7 mm±0.2 mm.

3. The low-loss, high-current, wide-bandwidth shielded magnetic core device suitable for mobile power supply according to claim 1, characterized in that: The length of the center column is 7.7 mm ± 0.15 mm, the width of the center column is 6.2 mm ± 0.2 mm, and the height of the center column is 5.7 mm ± 0.15 mm.

4. The low-loss, high-current, wide-bandwidth shielded magnetic core device suitable for mobile power supply according to claim 1, characterized in that: The width of the annular groove is 2.6 mm, and the depth of the annular groove is 6.2 mm±0.2 mm.

5. The low-loss, high-current, wide-bandwidth shielded magnetic core device suitable for mobile power supply according to claim 1, characterized in that: The width of the rectangular notch is 3.2 mm.

6. The low-loss, high-current, wide-bandwidth shielded magnetic core device suitable for mobile power supply according to claim 1, characterized in that: The upper part of the magnetic core device body is provided with two outer chamfers with a radius of 1.0 mm, the outer wall of the annular groove is provided with three inner chamfers with a radius of 2.3 mm, and the four corners of the center column are provided with positive corners with a radius of 2.3 mm.

7. The low-loss, high-current, wide-bandwidth shielded magnetic core device suitable for mobile power supply according to claim 1, characterized in that: The magnetic core device body and the middle column include the following raw materials in percentage: 49 mol% Fe2O3, 32 mol% Mn, 13 mol% ZnO, 5 mol% Ni, 1 mol% Co, 0.02-0.07wt% Co2O3, 0.01-0.06wt% CaCO3, 0.02-0.05wt% SnO2, 0.02-0.05wt% Nb2O5, 0.01-0.02wt% ZrO2 and 0.01-0.02wt% Ta2O5.

8. The low-loss, high-current, wide-bandwidth shielded magnetic core device suitable for mobile power sources according to claim 7, characterized in that: The manufacturing process of the magnetic core device body and the center column includes the following steps: S1. Weigh the corresponding raw materials according to weight, mix them and add them into the punching machine; S2. The forming pressure of the punching machine is controlled at 120T; S3. After stamping, the magnetic core device is placed in a sintering furnace and sintered in a three-temperature zone manner; First temperature zone: put the magnetic core device into the sintering furnace, start heating from 25℃ for 4 hours, increase the temperature by 120℃ per hour, and heat it to 500℃. After heating, keep it at 500℃ for 8 hours; Second temperature zone: start heating from 500℃ for 3 hours, increase the temperature by 130℃ per hour, and heat to 900℃. After heating, keep the temperature at 900℃ for 9 hours. The third temperature zone: start heating from 900℃ for 6 hours, increase the temperature by 100℃ per hour, and heat to 1500℃. After heating, keep the temperature at 1500℃ for 3 hours; S4. Take out the magnetic core device and cool it to room temperature.

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