Hybrid nanocrystalline magnetic core and manufacturing method
By adopting a combined structure of stacked nanocrystal strip-shaped magnetic core and broken nanocrystal stacked magnetic core in the nanocrystal core, the problems of eddy current loss and edge temperature rise in the nanocrystal core are solved, and higher system transmission efficiency and more uniform heat distribution are achieved.
Patent Information
- Application Number
- CN202311583427.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2023-11-24
- Publication Date
- 2025-05-27
AI Technical Summary
The nanocrystalline magnetic core has high eddy current loss and edge temperature rise in application, resulting in a reduction in overall application efficiency and the edge current loss effect has not been effectively solved.
A hybrid nanocrystalline magnetic core is adopted, including a stacked nanocrystalline ribbon-shaped magnetic core and a crushed nanocrystalline laminated magnetic core. The core gap is eliminated by the laminated structure of stacked nanocrystalline ribbon and insulating adhesive, reducing eddy current loss, and edge shielding is performed by setting the broken nanocrystalline laminated magnetic core at the edge to reduce edge loss.
It effectively reduces the edge effect in the nanocrystalline magnetic core, reduces internal losses, improves the system transmission efficiency, maintains a more uniform heat distribution, and improves the overall reliability of the system.
Smart Images
Figure CN120048626A_ABST
Abstract
Description
Technical Field
[0001] The embodiments of this specification relate to the technical field of wireless power transmission, and particularly to a hybrid nanocrystalline magnetic core and a manufacturing method thereof. Background Art
[0002] Inductive power transfer (IPT) system is a form of wireless power transfer technology that can conveniently and efficiently achieve energy conversion. Magnetic materials are an important part of the inductive power transfer system to achieve high-power output. In traditional IPT systems, manganese-zinc ferrite is used for IPT development, but the core loss of manganese-zinc ferrite is relatively large, which limits the maximum efficiency of the IPT system. Nanocrystalline materials have been effectively applied in IPT systems due to their high design flexibility, excellent magnetic permeability, and saturation magnetic induction intensity.
[0003] However, due to the characteristics of nanocrystalline materials, there are certain eddy current losses in themselves. When applied to IPT, there are relatively high eddy current losses and edge temperature rise conditions, thus reducing the overall application efficiency. Although the core gap can be eliminated through the nanocrystalline ribbon core structure to improve efficiency and reduce the temperature level, the edge losses caused by the edge current have not been well solved. Therefore, there is an urgent need for a technical solution that can effectively reduce the edge effect in nanocrystalline magnetic cores. Summary of the Invention
[0004] The purpose of the embodiments of this specification is to provide a hybrid nanocrystalline magnetic core and a manufacturing method thereof to solve the problem of how to reduce the edge effect in nanocrystalline magnetic cores.
[0005] To solve the above technical problems, the embodiments of this specification propose a hybrid nanocrystalline magnetic core, including a laminated nanocrystalline ribbon core and a crushed nanocrystalline laminated core; the laminated nanocrystalline ribbon core is made by laminating multiple layers of nanocrystalline ribbons and insulating adhesives; the crushed nanocrystalline laminated core is disposed at the edge of the laminated nanocrystalline ribbon core.
[0006] In some embodiments, the crushed nanocrystalline laminated core is made by compressing and crushing a nanocrystalline ribbon layer and a thin adhesive layer, and then laminating through lamination.
[0007] In some embodiments, the lamination directions of the laminated nanocrystalline state core and the crushed nanocrystalline laminated core are orthogonal to the direction of the main magnetic flux of the hybrid nanocrystalline magnetic core.
[0008] In some embodiments, the layer thickness of the hybrid nanocrystalline magnetic core is 12um - 15um.
[0009] In some embodiments, the layer thickness of the crushed nanocrystalline laminated magnetic core is 12um - 20um, and the fine flakes formed by an additional crushing process are 100um - 500um.
[0010] In some embodiments, the hybrid nanocrystalline magnetic core is applied to an inductive power transfer charging board.
[0011] Based on the above embodiments, the inductive power transfer charging board includes the hybrid nanocrystalline magnetic core and a winding; the hybrid nanocrystalline magnetic core is attached to the winding.
[0012] Based on the above embodiments, the winding is a double-D winding; the winding includes Litz wire with a PET film.
[0013] In some embodiments, it further includes an aluminum plate covering the laminated nanocrystalline ribbon magnetic core.
[0014] The embodiments of this specification also propose a manufacturing method for a hybrid nanocrystalline magnetic core, including: laminating multiple layers of nanocrystalline ribbons and an insulating adhesive to form a laminated nanocrystalline ribbon magnetic core; compressing and crushing the nanoribbon material and a thin adhesive layer to form crushed nanocrystals; laminating the crushed nanocrystals to form a crushed nanocrystalline laminated magnetic core; and disposing the crushed nanocrystalline laminated magnetic core at the edge of the laminated nanocrystalline ribbon magnetic core to obtain a hybrid nanocrystalline magnetic core.
[0015] As can be seen from the technical solutions provided by the embodiments of this specification above, for the hybrid nanocrystalline magnetic core in the embodiments of this specification, the laminated nanocrystalline ribbon magnetic core is used as the main magnetic coupler to achieve the effect of enhancing the coupling factor and self-inductance. At the same time, by laminating multiple layers of nanocrystalline ribbons and an insulating adhesive in the laminated nanocrystalline ribbon magnetic core, the magnetic core gap is eliminated, thereby reducing the eddy current loss in the main magnetic coupler. At the same time, the crushed nanocrystalline laminated magnetic core is disposed at the edge of the laminated nanocrystalline ribbon magnetic core, and the edge loss effect is minimized and the magnetic saturation level is ensured through the edge shielding effect. Based on the hybrid nanocrystalline magnetic core, the internal loss is reduced, thereby improving the system transmission efficiency, and a more uniform thermal distribution can also be maintained when applied to an IPT system, improving the overall reliability of the system, and having good practical application value. Description of the Drawings
[0016] In order to more clearly illustrate the technical solutions in the embodiments of this specification or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the drawings in the following description are only some embodiments recorded in this specification. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.
[0017] Figure 1Schematic diagram of an equivalent magnetic circuit model of a laminated nanocrystalline ribbon magnetic core according to an embodiment of this specification;
[0018] Figure 2 Schematic diagram of a hybrid nanocrystalline magnetic core according to an embodiment of this specification;
[0019] Figure 3 Flow schematic diagram of a manufacturing method of a hybrid nanocrystalline magnetic core according to an embodiment of this specification. Detailed implementation manners
[0020] Next, the technical solutions in the embodiments of this specification will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of this specification. Obviously, the described embodiments are only a part of the embodiments of this specification, rather than all the embodiments. Based on the embodiments in this specification, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of this specification.
[0021] Inductive power transfer (IPT) is a form of wireless power transfer technology, and the magnetic materials applied in IPT systems are an important part for achieving high-power output. In traditional applications, manganese-zinc ferrites are generally used for IPT development, but the core loss of manganese-zinc ferrites is relatively large, which limits the maximum efficiency of IPT systems. As a substitute for manganese-zinc ferrites, nanocrystalline materials have good flexibility in IPT applications.
[0022] However, the nanocrystalline materials themselves have eddy current losses, which reduces the overall application efficiency. As shown in Figure 1 , it is the equivalent magnetic circuit model of a laminated nanocrystalline ribbon magnetic core (NRC). Where F m_lateral is the magnetomotive force of the transverse winding. Φ total is the total flux in the path, and the total number of nanocrystalline ribbon layers is n. Therefore represents the magnetic resistance of the i-th nanocrystalline layer, and are the magnetic resistances of air and resin respectively. Compared with nanocrystalline materials, the magnetic permeability of resin is significantly reduced, resulting in a significant increase in the magnetic resistance of resin. The relationship between the finally determined magnetic resistance and magnetic flux is as shown in formula .
[0023] Based on the relationship between magnetic resistance and magnetic flux, the flux in the NRC is mainly concentrated in the first few layers. Over time, the non-uniform distribution of the magnetic flux density leads to unbalanced losses and temperature rise in the magnetic core, thereby reducing its thermal stability. This model can be extended to cover the entire magnetic core structure. The integration of gaps between different magnetic rods exacerbates the edge effect. Each magnetic rod in the structure is affected by self-edge effect and collective edge effect, significantly amplifying the overall magnetic core loss.
[0024] Although the core loss has been reduced by eliminating the core gap and other means at present, there has always been no good coping strategy for the edge current loss effect. When applying NRC, the edge effect will still affect the overall efficiency, thus affecting the overall efficiency. Therefore, there is an urgent need for a technical solution that can reduce the edge effect in nanocrystalline cores.
[0025] Therefore, to solve the above technical problems, the embodiments of this specification propose a hybrid nanocrystalline core. As Figure 2 shown, the hybrid nanocrystalline core includes a laminated nanocrystalline ribbon core and a crushed nanocrystalline laminated core.
[0026] The laminated nanocrystalline ribbon core is made by laminating multiple layers of nanocrystalline ribbons and insulating adhesives.
[0027] The nanocrystalline ribbon is generated by controlling the growth of crystal nuclei and controlling the grain size at the nanoscale. Compared with amorphous ribbon materials, it has higher magnetic permeability and conductivity, thereby reducing losses. However, when used as a magnetic conductor, it will cause large eddy current losses. Therefore, in the embodiments of this specification, by laminating the nanocrystalline ribbon and the insulating adhesive, the effective conductivity can be reduced by using the characteristics of the insulating adhesive, and the eddy current loss can be reduced. The specific type of the insulating adhesive can be selected according to actual needs, and no limitation is made thereto.
[0028] Specifically, the layer thickness of the laminated nanocrystalline ribbon core can be controlled between 12 um and 25 um.
[0029] In addition, the lamination direction of the nanocrystalline ribbons in the laminated nanocrystalline ribbon core can be perpendicular to the magnetic flux lamination, which can also achieve the effect of reducing the effective conductivity and thus reducing the eddy current loss.
[0030] In addition, in the specific application process, as the core gap increases, the core loss also increases continuously. The loss can be reduced by eliminating the core gap to improve the overall efficiency. Through the above lamination method, the core gap in the laminated nanocrystalline ribbon core is eliminated, and the core gap will cause inconsistent magnetic flux density between different mandrels. Therefore, it also achieves the effect of reducing the eddy current loss in the main magnetic coupler.
[0031] The stacking factor F is the ratio between the effective magnetic material and the overall material. When the stacking factor F = 1, it means that the core is a homogenized nanocrystalline core without other materials. By adjusting the stacking coefficient, the magnetic permeability and conductivity can be flexibly adjusted to meet the specific application requirements in actual applications.
[0032] The adaptable features of the nanocrystalline ribbon magnetic core enable a high aspect ratio, which is beneficial for application to inductive power transfer systems. Processing the nanocrystalline ribbon magnetic core into an elongated core rod can span the entire length of the solder tube without introducing any air gaps, thereby enhancing the coupling between the primary and secondary and minimizing leakage flux.
[0033] In some embodiments of practical applications, an aluminum plate can be covered on the laminated nanocrystalline ribbon magnetic core to reduce leakage flux through the shielding of the aluminum plate.
[0034] To mitigate the edge losses in the laminated nanocrystalline ribbon magnetic core, a fragmented nanocrystalline laminated magnetic core can be used for edge shielding. Edge shielding is mainly used to mitigate eddy currents in the sidewalls and distribute the high magnetic flux density concentrated at the edges. By placing additional magnetic materials as shields near the edges, the magnetic flux density can be effectively dispersed from the nanocrystalline ribbon core. At the same time, this magnetic material can redirect the vertical magnetic flux entering the sidewalls, thereby reducing eddy current losses. The magnetic material must exhibit minimal losses and sufficient magnetic permeability to be effectively used as a magnetic flux distributor. In addition, the material needs to have the same solid or different laminated structures as the laminated nanocrystalline ribbon magnetic core to prevent experiencing similar edge loss effects.
[0035] Therefore, based on the above requirements, the fragmented nanocrystalline laminated magnetic core can be arranged at the edge of the laminated nanocrystalline ribbon magnetic core to achieve the effect of edge shielding.
[0036] The fragmented nanocrystalline laminated magnetic core also includes multiple layers of fragmented nanocrystalline layers. Each crystalline layer can be made by compressing a nanocrystalline ribbon layer and a thin adhesive layer together and then fragmenting them into fine pieces of a certain size. Based on the fragmentation operation, when applied, the current path is cut off to significantly reduce eddy currents. At the same time, the multiple layers of fragmented nanocrystalline layers are also made into a magnetic core by laminating, making the structure similar to that of the laminated nanocrystalline ribbon magnetic core, ensuring that the two can be effectively applied after mixing.
[0037] Specifically, the specific fragmentation degree of the nanocrystalline carbon ribbon and the thin release film for the fragmented nanocrystalline laminated magnetic core can also be set according to the actual application requirements, and no limitation is imposed on this.
[0038] Correspondingly, the lamination direction of the fragmented nanocrystalline laminated magnetic core is also perpendicular to the direction of the main magnetic flux of the hybrid nanocrystalline magnetic core, redirecting the magnetic flux entering the laminated nanocrystalline ribbon magnetic core to avoid generating high eddy currents, so as to achieve the effect of reducing eddy current losses.
[0039] Specifically, the layer thickness of the fragmented nanocrystalline laminated magnetic core is 12um - 20um, and the size of the fine pieces obtained after additional fragmentation in the nanocrystalline ribbon layer and the thin adhesive layer is 100um - 500um.
[0040] It should be noted that the length of the broken nanocrystalline laminated core only covers the central edge of the NRC, but does not extend to the flux window, thus avoiding the generation of eddy currents on the surface of the broken nanocrystals by the vertical flux, so as to reduce the excessive losses introduced by this shielding.
[0041] The application effect of the hybrid nanocrystalline core is further illustrated by comparing specific simulation results. The edge core loss and the average loss of 4 cores are defined as where dV represents the volume of the small tetrahedron used for the calculation of Maxwell's equations in the FEM simulation. floss_i is the core loss function at the local tetrahedron. By integrating over the entire core volume of the 4 cores placed at the edge, the corresponding edge loss can be obtained. The average loss is basically the sum of the average losses of 4 individual cores, and the total number of cores in the design is 18. This calculation can be completed by the field calculator in Ansys Maxwell.
[0042] For a core structure with a uniform loss distribution, the loss of 4 cores should be equal to the average loss of 4 cores. A significant difference between these two values indicates a more obvious edge effect. As the core gap increases, the total core loss increases significantly. The Edge loss follows the opposite trend and reaches the highest value of 50.9 W when the core gap is 0 mm. This means that when using the NRC alone without a core gap, even though the system efficiency is improved, more than half of the core losses occur in the 2 outer cores on the primary and secondary sides, resulting in a significant temperature increase. By using the hybrid core, the overall system efficiency is improved because the total core loss is reduced by 5 W. More importantly, the edge loss is reduced to 36.6 W, thus allowing a more uniform distribution of losses.
[0043] The hybrid nanocrystalline core can be applied to an IPT system. Specifically, it can be applied to an inductive power transfer charging board.
[0044] The inductive power transfer charging board may include a hybrid nanocrystalline core and windings. The hybrid nanocrystalline core is attached to the windings. The windings are double-D windings; the windings include Litz wire with PET film.
[0045] Specifically, a 13-kW 600-V 85-kHz wireless charging platform based on a hybrid NRC and NFR has been built and tested. Among them, the SiC module CCB021M12FM3 is used as a full-bridge AC inverter; the Schottky diode C4D40120D is used for the passive rectifier; the BSL800-10 is used to provide a DC power supply of up to 800 V; the Tektronix MSO46 with the probes THDP0200 and TCP0030A is used to observe the current and voltage waveforms, and the power supply kit SUP4-PS2 is also embedded; the data recorder LR8450 with a K-type thermocouple is used for rapid temperature data recording; the FLIR E6-XT is used to capture the thermal distribution. The test setup is designed with a circulating current loop configuration, where the rectifier output and the inverter input are directly connected to handle high-power operations, allowing high power to circulate within the system while the external power demand remains significantly reduced. The power required externally is only for system losses and can be directly used to calculate the DC-DC efficiency. The specific application method can be adjusted according to the requirements in the actual application, and no restrictions are imposed on this.
[0046] By adding an NFR edge shield, the edge loss effect can be alleviated. It is used to evaluate the severity of the edge effect. The edge core loss and the average of 4 core losses are defined as where dV represents the volume of the small tetrahedron used for the calculation of Maxwell's equations in the FEM simulation. floss_i is the core loss function at the local tetrahedron. By integrating over the entire core volume of the 4 cores placed at the edge, the corresponding edge loss can be obtained.
[0047] Based on the above evaluation method, a specific scenario application example is used for further illustration. When the hybrid nanocrystalline core is put into practical application, compared with other core structures, the hybrid nanocrystalline core has a higher self-inductance and coupling coefficient, and thus can achieve higher efficiency. When using the hybrid nanocrystalline core to generate the same power, the primary current will decrease, thereby reducing winding losses, core losses, and inverter conduction losses. Using the hybrid nanocrystalline core, the efficiency is significantly improved, reaching a peak of 96.04%. At the same output power of up to 13 kW, it is nearly 2% higher than the DMR44. At the same time, in terms of thermal performance, the hybrid nanocrystalline core reduces the maximum temperature from 156 °C to 74.8 °C. The maximum temperature of the hybrid nanocrystalline core is significantly reduced compared with other core structures, with a lower maximum temperature and a more uniform temperature distribution. This uniform heat distribution reduces the risk of component failure due to overheating, thereby improving the overall reliability of the system.
[0048] From the introduction of the above embodiments and scenario examples, it can be seen that for the hybrid nanocrystalline magnetic core, by using the laminated nanocrystalline ribbon magnetic core as the main magnetic coupler, the effects of enhancing the coupling factor and self-inductance are achieved. At the same time, in the laminated nanocrystalline ribbon magnetic core, through the lamination of multiple layers of nanocrystalline ribbons and insulating adhesives, the magnetic core gap is eliminated, thereby reducing the eddy current loss in the main magnetic coupler. Meanwhile, the crushed nanocrystalline laminated magnetic core is arranged at the edge of the laminated nanocrystalline ribbon magnetic core, and the edge loss effect is minimized and the magnetic saturation level is ensured through the edge shielding effect. Based on the hybrid nanocrystalline magnetic core, the internal loss is reduced, thereby improving the system transmission efficiency. When applied to the IPT system, it can also maintain a more uniform heat distribution, improve the overall reliability of the system, and has good practical application value.
[0049] Based on the above hybrid nanocrystalline magnetic core, an embodiment of this specification also proposes a manufacturing method for the hybrid nanocrystalline magnetic core. As Figure 3 shown, the manufacturing of the hybrid nanocrystalline magnetic core includes the following specific implementation steps.
[0050] S310: Layer multiple layers of nanocrystalline ribbons and insulating adhesives to form a laminated nanocrystalline ribbon magnetic core.
[0051] The laminated nanocrystalline ribbon magnetic core is formed by laminating multiple layers of nanocrystalline ribbons and insulating adhesives.
[0052] By controlling the nucleation growth of the nanocrystalline ribbon, the grain size is controlled at the nanoscale. Compared with amorphous ribbon materials, it has higher magnetic permeability and conductivity, thereby reducing losses. However, when used as a magnetic conductor, it will cause significant eddy current losses. Therefore, by laminating the nanocrystalline ribbon with an insulating adhesive, the effective conductivity can be reduced and the eddy current loss can be decreased.
[0053] Specifically, the layer thickness of the laminated nanocrystalline ribbon magnetic core can be controlled within 12um - 25um.
[0054] In addition, in the laminated nanocrystalline ribbon magnetic core, the lamination direction of the nanocrystalline ribbons can be perpendicular to the magnetic flux lamination, which can also achieve the effect of reducing the effective conductivity and further decreasing the eddy current loss.
[0055] In addition, in the specific application process, as the magnetic core gap increases, the magnetic core loss also continuously increases. The loss can be reduced by eliminating the magnetic core gap to improve the overall efficiency. Through the above lamination method, the magnetic core gap in the laminated nanocrystalline ribbon magnetic core is eliminated, and the magnetic core gap will cause inconsistent magnetic flux density between different mandrels. Therefore, it also has the effect of reducing the eddy current loss in the main magnetic coupler.
[0056] The stacking factor F is the ratio between the ribbon material and the overall core material. When the stacking factor F = 1, it means the core is a solid nanocrystalline core. By adjusting the stacking coefficient, the magnetic permeability and conductivity can be flexibly adjusted to meet the specific application requirements in practical applications.
[0057] Preferably, an aluminum plate can also be covered on the laminated nanocrystalline ribbon core to reduce the leakage flux through the shielding of the aluminum plate.
[0058] S320: Compress and crush the nanoribbon with a thin adhesive layer to make crushed nanocrystals.
[0059] To reduce the edge losses in the laminated nanocrystalline ribbon core, a crushed nanocrystal laminated core can be used for edge shielding. Edge shielding is mainly used to reduce the eddy currents in the sidewalls and distribute the high magnetic flux density concentrated at the edges. By placing additional magnetic materials as shields near the edges, the magnetic flux density can be effectively dispersed from the nanocrystal ribbon core. At the same time, this magnetic material can redirect the vertical magnetic flux entering the sidewalls, thereby reducing the eddy current losses. The magnetic material must exhibit minimal losses and sufficient magnetic permeability to be effectively used as a magnetic flux distributor. In addition, the material needs to have the same solid or different laminated structures as the laminated nanocrystalline ribbon core to prevent experiencing similar edge loss effects.
[0060] Therefore, based on the above requirements, the crushed nanocrystal laminated core can be arranged at the edge of the laminated nanocrystalline ribbon core to achieve the effect of edge shielding.
[0061] S330: Stack the crushed nanocrystals to make a crushed nanocrystal laminated core.
[0062] The crushed nanocrystal laminated core also includes multiple layers of crushed nanocrystal layers. Each crystal layer can be made by compressing the nanocrystal ribbon layer and the thin adhesive layer together and then crushing them into fine pieces of a certain size. Based on the crushing operation, when applied, the current path is cut off to significantly reduce the eddy currents. At the same time, the multiple layers of crushed nanocrystal layers are also made into a core by stacking, making the structure similar to that of the laminated nanocrystalline ribbon core, ensuring that the two can be effectively applied after mixing.
[0063] The crushed nanocrystal laminated core also includes multiple layers of crushed nanocrystal layers. Each crystal layer can be made by compressing the nanocrystal ribbon layer and the thin adhesive layer together and then crushing them into fine pieces of a certain size. Based on the crushing operation, when applied, the current path is cut off to significantly reduce the eddy currents. At the same time, the multiple layers of crushed nanocrystal layers are also made into a core by stacking, making the structure similar to that of the laminated nanocrystalline ribbon core, ensuring that the two can be effectively applied after mixing.
[0064] Specifically, the specific degree of fragmentation of the nanocrystalline carbon tape and the thin release film for the fragmented nanocrystalline laminated magnetic core can also be set according to the requirements of actual applications, and no limitation is imposed thereon.
[0065] Correspondingly, the lamination direction of the fragmented nanocrystalline laminated magnetic core is also perpendicular to the direction of the main magnetic flux of the hybrid nanocrystalline magnetic core, redirecting the magnetic flux entering the laminated nanocrystalline ribbon magnetic core to avoid the generation of high eddy currents, so as to achieve the effect of reducing eddy current loss.
[0066] Specifically, the layer thickness of the fragmented nanocrystalline laminated magnetic core is 12um - 20um, and the size of the fine pieces obtained after additional fragmentation in the nanocrystalline tape layer and the thin adhesive layer is 100um - 500um.
[0067] S340: Place the fragmented nanocrystalline laminated magnetic core at the edge of the laminated nanocrystalline ribbon magnetic core to obtain a hybrid nanocrystalline magnetic core.
[0068] After placing the fragmented nanocrystalline laminated magnetic core at the edge of the laminated nanocrystalline ribbon magnetic core, edge shielding is effectively achieved through the fragmented nanocrystalline laminated magnetic core, thereby reducing internal losses and improving overall efficiency.
[0069] It should be noted that the length of the fragmented nanocrystalline laminated magnetic core only covers the central edge of the NRC but does not extend to the magnetic flux window, thereby avoiding the transmission of vertical magnetic flux to reduce the excessive loss introduced by this shielding.
[0070] The hybrid nanocrystalline magnetic core can be applied to an IPT system. Specifically, it can be applied to an inductive power transfer charging board.
[0071] The inductive power transfer charging board may include a hybrid nanocrystalline magnetic core and a winding. The hybrid nanocrystalline magnetic core is attached to the winding. The winding is a double-D winding; the winding includes Litz wire with a PET film.
[0072] Specifically, a wireless charging platform based on a 13-kW 600-V 85-kHz hybrid NRC and NFR has been built and tested. Among them, the SiC module CCB021M12FM3 is used as a full-bridge AC inverter; the Schottky diode C4D40120D is used for the passive rectifier; the BSL800-10 is used to provide a DC power supply of up to 800 V; the Tektronix MSO46 with the probes THDP0200 and TCP0030A is used to observe the current and voltage waveforms, and the power supply kit SUP4-PS2 is also embedded; the data recorder LR8450 with a K-type thermocouple is used for rapid temperature data recording; the FLIR E6-XT is used to capture the thermal distribution. The test setup is designed with a circulating current loop configuration, where the rectifier output and the inverter input are directly connected to handle high-power operations, allowing high power to circulate within the system while the external power demand remains significantly reduced. The power required externally is only for system losses and can be directly used to calculate the DC-DC efficiency.
[0073] The specific application method can be adjusted according to the requirements in actual applications, and no restrictions are imposed on this.
[0074] By adding an NFR edge shield, the edge loss effect can be alleviated. It is used to evaluate the severity of the edge effect. The edge core loss and the average of 4 core losses are defined as where dV represents the volume of the small tetrahedron used for the calculation of Maxwell's equations in the FEM simulation. floss_i is the core loss function at the local tetrahedron. By integrating over the entire core volume of the 4 cores placed at the edge, the corresponding edge loss can be obtained.
[0075] A specific scenario application example is used for further illustration. When the hybrid nanocrystalline core is put into actual application, compared with other core structures, the hybrid nanocrystalline core has a higher self-inductance and coupling coefficient, and thus can achieve higher efficiency. When the same power is generated using the hybrid nanocrystalline core, the primary current will decrease, thereby reducing winding losses, core losses, and inverter conduction losses. Using the hybrid nanocrystalline core, the efficiency is significantly improved, reaching a peak of 96.04%. At the same output power of up to 13 kW, it is nearly 2% higher than the DMR44. At the same time, in terms of thermal performance, the hybrid nanocrystalline core reduces the maximum temperature from 156 °C to 74.8 °C. The maximum temperature of the hybrid nanocrystalline core is significantly lower compared to other core structures, with a lower maximum temperature and a more uniform temperature distribution. This uniform heat distribution reduces the risk of component failure due to overheating, thereby improving the overall reliability of the system.
[0076] Based on the introduction of the above embodiments and scenario examples, the hybrid nanocrystalline magnetic core obtained by the above manufacturing method uses a laminated nanocrystalline ribbon magnetic core as the main magnetic coupler to achieve the effect of enhancing the coupling factor and self-inductance. At the same time, in the laminated nanocrystalline ribbon magnetic core, the multilayer nanocrystalline ribbons and the insulating adhesive are laminated to eliminate the magnetic core gap, thereby reducing the eddy current loss in the main magnetic coupler. At the same time, the crushed nanocrystalline laminated magnetic core is arranged at the edge of the laminated nanocrystalline ribbon magnetic core, and the edge loss effect is minimized and the magnetic saturation level is ensured through the edge shielding effect. Based on the hybrid nanocrystalline magnetic core, the internal loss is reduced, thereby improving the system transmission efficiency. When applied to the IPT system, it can also maintain a more uniform heat distribution, improve the overall reliability of the system, and has good practical application value.
[0077] The above hybrid nanocrystalline magnetic core and manufacturing method can be applied to the field of wireless power transmission technology, and can also be applied to other technical fields except the field of wireless power transmission technology, and there is no limitation in this regard.
[0078] Each embodiment in this specification is described in a progressive manner. For the same or similar parts among the embodiments, reference can be made to each other. Each embodiment focuses on the differences from other embodiments. In particular, for the system embodiment, since it is basically similar to the method embodiment, the description is relatively simple, and the relevant parts can refer to the partial description of the method embodiment. In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples", etc. means that the specific features, structures, materials, or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the embodiments of this specification. In this specification, the schematic expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described can be combined in a suitable manner in any one or more embodiments or examples. In addition, without contradiction, those skilled in the art can combine and combine the different embodiments or examples described in this specification and the features of different embodiments or examples.
[0079] Although the process flow described above includes multiple operations that occur in a specific order, it should be clearly understood that these processes can include more or fewer operations, and these operations can be executed sequentially or in parallel (for example, using a parallel processor or a multi-threaded environment).
[0080] Any numerical value recited herein includes all values from the lower value to the upper value incremented by one unit therebetween, provided that there is a separation of at least two units between any lower value and any higher value. For example, if a value for the number of components or for a process variable (such as temperature, pressure, time, etc.) is recited as being from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70, it is intended that values such as 15 to 85, 22 to 68, 43 to 51, 30 to 32, etc. are also expressly recited in this specification. For values less than 1, a unit is appropriately considered to be 0.0001, 0.001, 0.01, 0.1. These are merely examples of what is intended to be specified, and all possible combinations of numerical values recited between the lowest value and the highest value are to be considered to be expressly recited in this specification in a similar manner.
[0081] The above are only examples of the embodiments of the present application and are not intended to limit the present application. For those skilled in the art, various changes and modifications can be made to the present application. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included within the scope of the claims of the present application.
[0082] All articles and references disclosed, including patent applications and publications, are incorporated herein by reference for various purposes. The term “consisting essentially of” describing a combination should include the identified elements, ingredients, components, or steps as well as other elements, ingredients, components, or steps that do not materially affect the basic novel features of the combination. The use of the terms “comprising” or “including” to describe the combinations of elements, ingredients, components, or steps herein also contemplates embodiments consisting essentially of these elements, ingredients, components, or steps. By using the term “may” herein, it is intended that any of the attributes described as “may” include are optional.
[0083] A plurality of elements, ingredients, components, or steps can be provided by a single integrated element, ingredient, component, or step. Alternatively, a single integrated element, ingredient, component, or step can be separated into discrete plural elements, ingredients, components, or steps. The disclosure of “a” or “an” to describe an element, ingredient, component, or step is not intended to exclude other elements, ingredients, components, or steps.
[0084] It should be understood that the above description is for purposes of illustration and not limitation. Many embodiments and many applications other than the examples provided will be apparent to those skilled in the art upon reading the above description. For the sake of completeness, all articles and references including patent applications and published disclosures are incorporated herein by reference.
Claims
1. A hybrid nanocrystalline magnetic core, characterized in that, it includes a laminated nanocrystalline ribbon magnetic core and a crushed nanocrystalline laminated magnetic core; the laminated nanocrystalline ribbon magnetic core is made by laminating multiple layers of nanocrystalline ribbons and insulating adhesives; the crushed nanocrystalline laminated magnetic core is arranged at the edge of the laminated nanocrystalline ribbon magnetic core.
2. The hybrid nanocrystalline magnetic core according to claim 1, characterized in that, the crushed nanocrystalline laminated magnetic core is made by compressing and crushing a nanocrystalline ribbon layer and a thin adhesive layer, and then laminating through lamination.
3. The hybrid nanocrystalline magnetic core according to claim 1, characterized in that, the lamination direction of the laminated nanocrystalline state magnetic core and the crushed nanocrystalline laminated magnetic core is perpendicular to the direction of the main magnetic flux of the hybrid nanocrystalline magnetic core.
4. The hybrid nanocrystalline magnetic core according to claim 1, characterized in that, the layer thickness of the laminated nanocrystalline ribbon magnetic core is 12um - 25um.
5. The hybrid nanocrystalline magnetic core according to claim 2, characterized in that, the layer thickness of the crushed nanocrystalline laminated magnetic core is 12um - 20um, and the size of the fine pieces obtained after additional crushing in the nanocrystalline ribbon layer and the thin adhesive layer is 100um - 500um.
6. The hybrid nanocrystalline magnetic core according to claim 1, characterized in that, the hybrid nanocrystalline magnetic core is applied to an inductive power transfer charging board.
7. The hybrid nanocrystalline magnetic core according to claim 6, characterized in that, the inductive power transfer charging board includes the hybrid nanocrystalline magnetic core and a winding; the hybrid nanocrystalline magnetic core is attached to the winding.
8. The hybrid nanocrystalline magnetic core according to claim 7, characterized in that, the winding is a double D winding; the winding includes Litz wire with a PET film.
9. The hybrid nanocrystalline magnetic core according to claim 1, characterized in that, it further includes an aluminum plate covering the laminated nanocrystalline ribbon magnetic core.
10. A manufacturing method of a hybrid nanocrystalline magnetic core, characterized in that, it includes: making a laminated nanocrystalline ribbon magnetic core by laminating multiple layers of nanocrystalline ribbons and insulating adhesives in layers; compressing and crushing a nanoband material and a thin adhesive layer to make crushed nanocrystals; laminating the crushed nanocrystals to make a crushed nanocrystalline laminated magnetic core; arranging the crushed nanocrystalline laminated magnetic core at the edge of the laminated nanocrystalline ribbon magnetic core to obtain a hybrid nanocrystalline magnetic core.