Composite magnetic core high-frequency anti-saturation common mode inductor

Abstract

The invention relates to the technical field of inductors, and discloses a composite magnetic core high-frequency anti-saturation common mode inductor which comprises a base, an outer shell, a winding framework and a composite magnetic core. According to the magnetic core, the mode that the amorphous nanocrystals and the ferrite form the composite magnetic core is adopted, integration of high saturation flux density, high magnetic conductivity and excellent high-frequency performance is achieved in a small size, and miniaturization and high-performance development of electronic equipment are facilitated. The high saturation flux density of the nanocrystalline material is combined with the stability of the ferrite material at high frequency, so that the anti-saturation capability of the inductor is effectively improved, and the inductor can still keep stable inductance value in a high-frequency large-current environment. Meanwhile, due to the low loss characteristic of the ferrite layer under high frequency and the collaborative optimization magnetic conductivity after the nanocrystalline layer and the ferrite layer are compounded, the inductor has a low loss factor under the scene of high frequency (1 MHz to 100 MHz), the loss factor tan delta is smaller than 0.05 under the frequency of 10 MHz, and the strict requirement of a high-frequency circuit for the inductor performance is met.

Description

Technical Field

[0001] The present invention relates to the technical field of inductors, and particularly to a composite magnetic core high-frequency anti-saturation common-mode inductor. Background Art

[0002] Inductors are core components in power electronics and radio frequency systems, and their performance directly affects circuit efficiency, EMI, and stability. With the rapid development of electronic technology, electronic devices are constantly moving towards miniaturization and high performance, and the circuit system poses more stringent technical requirements for the anti-saturation characteristics and high-frequency stability of inductor components.

[0003] Traditional inductors mainly use ferrite magnetic cores. However, in high-frequency circuits, traditional inductors are prone to saturation, resulting in a decrease in inductance and deterioration of circuit performance. Specifically, due to their high magnetic permeability and low losses, ferrite magnetic cores are widely used in the high-frequency field, but their saturation magnetic induction intensity is low, which leads to magnetic saturation easily occurring under high-current conditions, causing a sharp drop in inductance (typical value attenuation ≥ 40%) and harmonic distortion problems (THD ≥ 15%).

[0004] Summary of the Invention

[0005] The technical problem to be solved by the present invention is that the existing inductor structure is prone to saturation and has insufficient performance in the high-frequency case.

[0006] The object of the present invention can be achieved by the following technical solutions:

[0007] A composite magnetic core high-frequency anti-saturation common-mode inductor, comprising:

[0008] A base, on which a wire passing hole is provided;

[0009] An outer shell body, which is fixedly arranged on the base and has an annular accommodation chamber formed therein;

[0010] A winding structure, which is composed of wires wound around the outer shell body, and the ends of the wires are passed through the wire passing hole;

[0011] A composite magnetic core, which is arranged in the accommodation chamber and comprises a first magnetic core and a second magnetic core arranged coaxially, and both the first magnetic core and the second magnetic core are of annular structures. The first magnetic core is an amorphous nanocrystalline magnetic core, and the second magnetic core is a ferrite magnetic core.

[0012] In one aspect of the present invention: The outer shell body and the base are fixedly connected by epoxy glue.

[0013] In one aspect of the present invention: The outer shell body comprises two semi-shell bodies that are detachably installed and connected.

[0014] In one embodiment of the present invention: The semi-housing includes an end plate with an annular structure. On one side of the end plate, a surrounding plate is fixedly arranged on the inner circle and the outer circle respectively. After the two outer housings are butted, a receiving chamber is formed by enclosing with the surrounding plate and the end plate.

[0015] In one embodiment of the present invention: A separation layer is arranged between the first magnetic core and the second magnetic core, and the separation layer is a plate-like structure fixedly connected to the outer housing.

[0016] In one embodiment of the present invention: The number of the winding structures is multiple, and a partition board is arranged between two adjacent windings.

[0017] In one embodiment of the present invention: Each winding structure includes a plurality of wires.

[0018] In one embodiment of the present invention: The number of the winding structures is two groups, and the number of turns of the two groups of windings is the same, and the winding directions are opposite.

[0019] In one embodiment of the present invention: A clamping groove is arranged on the inner circle of the outer housing, and the end of the partition board is arranged in the clamping groove.

[0020] In one embodiment of the present invention: The partition board is in a straight shape or a cross shape.

[0021] According to a composite magnetic core high-frequency anti-saturation common-mode inductor of the present invention, it has at least one of the following technical effects:

[0022] This application adopts the method of using amorphous nanocrystalline and ferrite to form a composite magnetic core, realizing the integration of high saturation magnetic induction intensity, high magnetic permeability and excellent high-frequency performance in a smaller volume, which is beneficial to the miniaturization and high-performance development of electronic devices. Compared with similar inductors, the volume can be reduced by 20-30%. It has the advantage of being usable in the full frequency band, improving the space utilization rate, reducing the processing procedures, providing the saturation current and reducing the cost at the same time.

[0023] Among them, the high saturation magnetic induction intensity of the nanocrystalline material is combined with the stability of the ferrite material at high frequencies, effectively improving the anti-saturation ability of the inductor, so that the inductor can still maintain a stable inductance value in a high-frequency large-current environment. Compared with the traditional ferrite inductor, the saturation current is increased by 30-50%. At the same time, the low-loss characteristic of the ferrite layer at high frequencies, and the synergistically optimized magnetic permeability after the nanocrystalline layer and the ferrite layer are combined, make the inductor have a lower loss factor in the high-frequency (1MHz-100MHz) scenario, and the loss factor tanδ is less than 0.05 at a frequency of 10MHz, meeting the strict requirements of high-frequency circuits for the performance of inductors. It solves the problems of easy saturation and insufficient performance of existing inductors at high frequencies, and improves the stability and reliability of the inductor in high-frequency circuits.

[0024] Additional aspects and advantages of the present invention will be given in part in the following description, become apparent in part from the following description, or be learned through the practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The above and / or additional aspects and advantages of the present invention will become apparent and be readily understood in conjunction with the description of the embodiments with reference to the following drawings. Apparently, the drawings in the following description are only some embodiments of the present invention, and those of ordinary skill in the art can obtain other drawings according to these drawings without creative efforts. Among them:

[0026] Figure 1 is a schematic structural diagram of the overall high-frequency anti-saturation common-mode inductor with a composite magnetic core according to the present invention;

[0027] Figure 2 is a high-frequency anti-saturation common-mode inductor with a composite magnetic core according to the present invention Figure 1 in a schematic bottom-up structural diagram;

[0028] Figure 3 is a schematic exploded structural diagram of the outer housing of the high-frequency anti-saturation common-mode inductor with a composite magnetic core according to the present invention;

[0029] Figure 4 is a schematic structural diagram of the composite magnetic core of the high-frequency anti-saturation common-mode inductor with a composite magnetic core according to the present invention;

[0030] Figure 5 is a schematic structural diagram of a half housing of the high-frequency anti-saturation common-mode inductor with a composite magnetic core according to the present invention.

[0031] The reference numerals in the drawings are as follows:

[0032] 1, base; 2, first magnetic core; 3, second magnetic core; 4, outer housing; 5, first winding; 6, second winding; 7, second lead-out head; 8, first lead-out head; 9, second lead-out hole; 10, first lead-out hole; 11, half housing; 12, first receiving groove; 13, second receiving groove; 14, card slot; 15, docking structure; 16, partition; 17, epoxy glue. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0033] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention. Apparently, the described embodiments are only some, rather than all, of the embodiments of the present invention. All other embodiments obtained by those of ordinary skill in the art without creative efforts based on the embodiments of the present invention belong to the scope of protection of the present invention.

[0034] Please refer to Figures 1-5, the present invention is a composite magnetic core high-frequency anti-saturation common-mode inductor, which includes a base 1, an outer casing 4, a winding structure, and a composite magnetic core. Among them, the base 1 is used as a support structure, which can be set as a plate-like structure or a block-like structure. Specifically, the material of the base 1 can be epoxy board or bakelite material. The base 1 is provided with wire passing holes for the ends of the winding wires to penetrate in or out. As an example, the wire passing holes can include a first wire outlet hole 10 and a second wire outlet hole 9 provided on both sides for the wires of different windings to pass through; and, the number of the first wire outlet hole 10 and the second wire outlet hole 9 can both be two for respectively feeding in and out the wires.

[0035] Please refer to Figures 1-5 , in one embodiment of the present invention, the outer casing 4 is used as a receiving structure for the magnetic core and a support structure for the winding, and is fixedly arranged on the base 1. The fixing method between the outer casing 4 and the base 1 can be selected according to the situation. As an example, before or after the winding is arranged, the outer casing 4 and the base 1 are fixedly connected by epoxy glue 17. By connecting with epoxy glue 17, the electromagnetic performance is ensured not to be affected.

[0036] Please refer to Figures 1-5 , in one embodiment of the present invention, an annular receiving chamber is provided inside the outer casing 4; specifically, the outer casing 4 can include two semi-casings 11 that are detachably installed and connected. The two semi-casings 11 can be symmetrically arranged or asymmetrically arranged. The butt joint surface of the two semi-casings 11, that is, the dividing surface, can be arranged along its axial direction to divide the outer casing 4 into two semi-annular structures, or can be arranged along its radial direction to divide it into two annular structures (as Figure 3 shown). As an example, the semi-casing 11 includes an end plate with an annular structure. The inner circle and the outer circle of one side surface of the end plate are respectively fixedly provided with enclosing plates. After the two outer casings 4 are butted, an accommodating chamber is formed by enclosing the enclosing plates and the end plate. Further, a butt joint structure 15 is provided on the enclosing plate to ensure the butt joint position and the butt joint stability of the casing. The butt joint structure 15 can be a snap joint structure or a concave-convex mating structure. As an example, a butt joint notch is provided on the inner side of the enclosing plate of one semi-casing 11, and a butt joint notch is provided on the outer side at the corresponding position of the other semi-casing 11. After the two semi-casings 11 are butted, the butt joint notch plays a role in positioning and stable butt joint.

[0037] Please refer to Figures 1-5, in one embodiment of the present invention, the winding structure is composed of wires wound around the outer housing 4, and the wires can be enameled copper wires or enameled copper-clad aluminum wires. The end of the wire is inserted into the wire passing hole; after passing through the wire passing hole, the end of the wire forms a lead-out head for subsequent connection to other structures. The number of the winding structures is multiple, and a partition 16 is provided between two adjacent windings. Therefore, the partition 16 can be in a straight shape (for two groups) or a cross shape (for four groups), or can be set into a corresponding structure according to the actual number of windings. Each winding structure includes several wires. As a specific example, the number of the winding structures can be two groups, and the number of turns of the two groups of windings is the same, and the winding directions are opposite. The two groups of windings are the first winding 5 and the second winding 6 respectively. The end of the wire of the first winding 5 is fixed in the first wire outlet hole 10, and after passing through the first wire outlet hole 10, its end forms a first lead-out head 8. The end of the wire of the second winding 6 is fixed in the second wire outlet hole 9, and after passing through the second wire outlet hole 9, its end forms a second lead-out head 7. The first winding 5 and the second winding 6 can include a single winding or multiple windings, and the first lead-out head 8 and the second lead-out head 7 can include a single wire or multiple wires.

[0038] Please refer to Figures 1-5 , in one embodiment of the present invention, the composite magnetic core is arranged in the accommodation chamber in the outer housing 4, and it includes at least one first magnetic core 2 and at least one second magnetic core 3 arranged coaxially, and both the first magnetic core 2 and the second magnetic core 3 are in a ring structure. The first magnetic core 2 is an amorphous nanocrystalline magnetic core. Specifically, the first magnetic core 2 is made of an iron-based nanocrystalline alloy material. Among them, the nanocrystalline layer is made of an iron-based nanocrystalline alloy material, such as an Fe-Si-B-Nb-Cu series alloy, which has a high saturation magnetic induction intensity Bs and a high magnetic permeability μi. Generally, Bs≥1.2T and μi≥10000. The second magnetic core 3 is a ferrite magnetic core. Specifically, the second magnetic core 3 is made of manganese-zinc ferrite or nickel-zinc ferrite with excellent high-frequency performance, which has the characteristic of low loss at high frequencies, and its initial magnetic permeability μi ranges from 1000 to 10000, and the loss tangent tanδ is less than 0.01 at a frequency of 1MHz.

[0039] Please refer to Figures 1-5 , in one embodiment of the present invention, a separation layer is provided between the first magnetic core 2 and the second magnetic core 3, and the separation layer is a plate-like structure fixedly connected to the outer housing 4. The separation layer can be an annular plate-like structure fixed on one of the half shells 11 and then used as the separation layer after docking, or can be plate-like structures respectively arranged on the two half shells 11 (such as Figure 3 , 5) After docking, a complete partition layer is formed. After the half shells 11 are docked to form the outer shell 4, the two sides of the partition layer respectively enclose a first receiving groove 12 and a second receiving groove 13 with the outside and inside of the outer shell 4, so as to be used for accommodating the first magnetic core 2 and the second magnetic core 3 respectively. By providing a partition layer, it plays a role in separating the two, avoiding mutual interference between them, ensuring the collaborative use effect after the two form a whole, and at the same time ensuring the stability of the magnetic core.

[0040] Please refer to Figures 1-5 , in one embodiment of the present invention, a clamping groove 14 is provided on the inner wall of the inner ring of the outer shell 4, and the length direction of the clamping groove 14 is arranged along the axis direction of the outer shell 4. The end of the partition plate 16 is arranged in the clamping groove 14. By providing the clamping groove 14 for cooperating with the structure of the partition plate 16 for installation, further, epoxy glue 17 can be provided at the position where the partition plate 16 cooperates with the clamping groove 14 for further fixation.

[0041] The working principle of the present invention:

[0042] This application adopts the method of combining amorphous nanocrystalline and ferrite to form a composite magnetic core, achieving the integration of high saturation magnetic induction intensity, high magnetic permeability and excellent high-frequency performance in a smaller volume, which is beneficial to the miniaturization and high-performance development of electronic devices. Compared with similar inductors, the volume can be reduced by 20-30%. It has the advantage of being usable in the full frequency band, improving the space utilization rate. The structure of this application is simple, the production and processing are convenient, and the processing procedures can be reduced compared with the traditional inductor structure, reducing costs while providing the saturation current.

[0043] Among them, the high saturation magnetic induction intensity of the nanocrystalline material is combined with the stability of the ferrite material at high frequencies, effectively improving the anti-saturation ability of the inductor, enabling the inductor to maintain a stable inductance value in a high-frequency large-current environment. Compared with the traditional ferrite inductor, the saturation current is increased by 30-50%. At the same time, the low-loss characteristic of the ferrite layer at high frequencies, and the synergistically optimized magnetic permeability after the nanocrystalline layer and the ferrite layer are combined, make this inductor have a lower loss factor in the high-frequency (1MHz-100MHz) scenario, and the loss factor tanδ is less than 0.05 at a frequency of 10MHz, meeting the strict requirements of high-frequency circuits for the performance of inductors. It solves the problems of easy saturation and insufficient performance of existing inductors at high frequencies, and improves the stability and reliability of inductors in high-frequency circuits.

[0044] The above has described a detailed description of an embodiment of the present invention, but the above content is only the preferred embodiment of the present invention and cannot be considered as limiting the scope of implementation of the present invention. All equivalent changes and improvements made according to the scope of the application of the present invention should still fall within the scope covered by the claims of the present invention.

[0045] In the description of the present invention, it should be noted that the orientation or positional relationship indicated by the terms "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. is based on the orientation or positional relationship shown in the drawings, or the orientation or positional relationship in which the product of the present invention is usually placed during use. It is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the present invention. In addition, the terms "first", "second", "third", etc. are only used for distinguishing descriptions and cannot be understood as indicating or implying relative importance. In the description of the present invention, unless otherwise specified, the meaning of "a plurality of" is two or more.

[0046] In the description of the present invention, unless otherwise clearly specified and limited, the first feature being "above" or "below" the second feature may include the first and second features being in direct contact, or may include the first and second features not being in direct contact but being in contact through additional features therebetween. Moreover, the first feature being "above", "over" and "on" the second feature includes the first feature being directly above and obliquely above the second feature, or merely indicating that the first feature has a higher horizontal height than the second feature. The first feature being "under", "beneath" and "under" the second feature includes the first feature being directly below and obliquely below the second feature, or merely indicating that the first feature has a lower horizontal height than the second feature.

[0047] In the description of the present invention, it should also be noted that, unless otherwise clearly specified and limited, the terms "disposed" and "connected" should be understood in a broad sense. For example, it may be a fixed connection, a detachable connection, or an integral connection; it may be a mechanical connection or an electrical connection. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

Claims

1. A composite magnetic core high-frequency anti-saturation common-mode inductor, characterized in that, Including: A base (1) with a wire passing hole formed thereon; An outer housing (4) fixedly arranged on the base (1) and having an annular accommodation chamber formed therein; A winding structure composed of wires wound around the outer housing (4), and the ends of the wires are passed through the wire passing hole; A composite magnetic core arranged in the accommodation chamber, which includes a first magnetic core (2) and a second magnetic core (3) arranged coaxially, and both the first magnetic core (2) and the second magnetic core (3) are of annular structure. The first magnetic core (2) is an amorphous nanocrystalline magnetic core, and the second magnetic core (3) is a ferrite magnetic core.

2. The composite magnetic core high-frequency anti-saturation common mode inductor according to claim 1, wherein The outer housing (4) and the base (1) are fixedly connected by an epoxy adhesive (17).

3. The composite magnetic core high-frequency anti-saturation common-mode inductor according to claim 2, characterized in that, The outer housing (4) includes two semi-housings (11) detachably installed and connected.

4. A composite magnetic core high-frequency anti-saturation common-mode inductor according to claim 3, characterized in that Each semi-housing (11) includes an end plate of annular structure, and an inner ring and an outer ring on one side of the end plate are respectively fixedly provided with enclosing plates. After the two outer housings (4) are butted, the accommodation chamber is formed by enclosing with the enclosing plates and the end plate.

5. A composite magnetic core high-frequency anti-saturation common-mode inductor according to claim 1, characterized in that, A separation layer is arranged between the first magnetic core (2) and the second magnetic core (3), and the separation layer is a plate-like structure fixedly connected to the outer housing (4).

6. The composite magnetic core high-frequency anti-saturation common mode inductor according to claim 1, wherein, The number of the winding structures is multiple, and a partition plate (16) is arranged between adjacent two windings.

7. A composite magnetic core high-frequency anti-saturation common-mode inductor according to claim 6, characterized in that, Each winding structure includes a plurality of wires.

8. A composite magnetic core high-frequency anti-saturation common-mode inductor according to claim 6, characterized in that, The number of the winding structures is two groups, and the number of turns of the two groups of windings is the same and the winding directions are opposite.

9. The common mode inductor with high frequency anti-saturation of a composite magnetic core according to claim 6, characterized in that A card slot (14) is arranged on the inner ring of the outer housing (4), and the end of the partition plate (16) is arranged in the card slot (14).

10. A composite magnetic core high-frequency anti-saturation common-mode inductor according to claim 9, characterized in that, The partition plate (16) is in a shape of one character or cross.

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