Combined magnetic core structure and magnetic component

Abstract

The utility model discloses a combined type magnetic core structure and a magnetic component. The magnetic core structure comprises a base and a middle column. The middle column comprises a column core and a magnetic ring set, and the column core is sleeved with the magnetic ring set. The bases are arranged at the two ends of the middle column. The middle column comprises a first middle column and a second middle column which are arranged in parallel, the base comprises a first base and a second base which are parallel to each other, and the first middle column and the second middle column are bonded with the first base and the second base to form a closed magnetic circuit. The magnetic component comprises a coil and the combined magnetic core structure, and the coil is wound on the middle column. According to the combined magnetic core structure, a plurality of standard magnetic rings are sleeved outside a standard small-size column core and are further combined with a coil to form a magnetic component, so that the quality of a finished product of the magnetic component is improved, the inductance value is customized and adjustable, the high-frequency, high-voltage and high-power requirements are met, meanwhile, the mechanical grinding and cutting processing cost and the mold opening cost are greatly saved, and the waste of raw materials is avoided; the product cost is greatly reduced, and the environmental pollution is reduced.

Description

Technical Field

[0001] The utility model relates to the field of magnetic components, in particular to a combined magnetic core structure and a magnetic component. Background Art

[0002] Magnetic components are electronic components that utilize the principle of electromagnetic induction to convert electrical energy into magnetic energy, thereby achieving energy conversion and transmission. They are primarily categorized into two types: transformers and inductors. Transformers utilize the principle of electromagnetic induction to change the AC voltage across a circuit. Inductors convert electrical energy into magnetic energy and store it. Their primary function is to pass DC and block AC, isolating and filtering AC signals, or forming resonant circuits with capacitors and resistors.

[0003] Magnetic components are mainly composed of a magnetic core and an external winding. The determining factor of its performance is the magnetic core. The magnetic core structure mainly includes a base and a cylindrical core, which form a closed magnetic circuit.

[0004] With the development of emerging industries such as new energy vehicles, charging piles, photovoltaics, servers, and industrial energy storage, high frequency, high voltage, and high power have become the development trend of magnetic component products. The cylindrical cores used in high-power inductors (with an outer diameter of more than 50mm) require large presses (more than 3,000 tons) and large, expensive molds for processing, but most magnetic core manufacturers do not have such presses and molds. The current industry solution usually involves splicing multiple strips of cylindrical cores and then machining them into cylindrical cores through a grinder to meet production needs. The problems with the above solution are:

[0005] 1. This method costs a lot of processing fees and labor costs. The core fragments and magnetic powder cut off by grinding can only be scrapped, resulting in huge material waste. It is impossible to achieve a balance between high-performance magnetic components and low-cost processing and production.

[0006] 2. Due to the different bonding processes used by different manufacturers when splicing the cores, there is a possibility that the cores will crack or become loosely bonded during use, resulting in noise and product failure. Utility Model Content

[0007] In order to solve the technical problems existing in the above-mentioned background technology, the utility model provides a combined magnetic core structure, which adopts a standard small-size cylindrical core and is surrounded by a plurality of standard magnetic rings with an inner diameter slightly larger than the outer diameter of the cylindrical core. Without adding a large press or opening a new large mold, the standard cylindrical core and standard magnetic rings can be used to form a magnetic core structure for high-power inductors of various sizes, thereby achieving adjustable inductance to meet the needs of high frequency, high voltage and high power.

[0008] The utility model also provides a magnetic component having the combined magnetic core structure.

[0009] According to the first embodiment of the present invention, the combined magnetic core structure includes a base and a center column;

[0010] The middle column includes a column core and a magnetic ring group, wherein the magnetic ring group includes at least one magnetic ring, and the magnetic ring group is sleeved outside the column core;

[0011] The base is arranged at both ends of the central column;

[0012] The center column includes a first center column and a second center column, which are placed side by side; the base includes a first base and a second base, which are parallel to each other; the first center column and the second center column are bonded to the first base and the second base to form a closed magnetic circuit.

[0013] As an embodiment, the first middle column includes a first column core, and the second middle column includes a second column core; the first column core and the second column core are two columns with the same shape and size.

[0014] As an embodiment, the magnetic rings of the magnetic ring group have the same shape and size, and the hollow spaces between the magnetic rings are aligned and bonded together.

[0015] As an embodiment, the shape of the magnetic ring is the same as the cross-sectional shape of the cylindrical core on which it is mounted.

[0016] As an embodiment, the magnetic ring material is manganese zinc ferrite, nickel zinc ferrite or metal soft magnetic powder core.

[0017] As an embodiment, the magnetic ring is coated with an insulating layer.

[0018] As an embodiment, the insulating layer material includes epoxy resin.

[0019] As an embodiment, the cross section of the base consists of a rectangle and two semicircles, or is a rectangle.

[0020] The magnetic component according to the embodiment of the second aspect of the present invention includes a coil and the above-mentioned combined magnetic core structure, wherein the coil is wrapped around the center column.

[0021] As an embodiment, the coil is a flat wire or a round wire.

[0022] Compared with the prior art, the present invention has the following beneficial effects:

[0023] 1. The modular magnetic core structure is based on a standard small-size cylindrical core with multiple standard magnetic rings, which are further combined with coils to form magnetic components. This improves the quality of finished magnetic components and enables customized and adjustable inductance. While meeting the needs of high frequency, high voltage, and high power, it greatly saves mechanical grinding and cutting costs, mold opening costs, and avoids the waste of raw materials, significantly reducing product costs and reducing environmental pollution.

[0024] 2. The combined magnetic core structure adopts the standard magnetic ring and standard cylindrical core commonly used in magnetic core factories, making full use of existing resources for combined design, improving resource utilization, and facilitating processing and production, which is conducive to promotion to magnetic core manufacturers of various sizes. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The accompanying drawings, which constitute a part of the present disclosure, are used to provide a further understanding of the present disclosure. The exemplary embodiments of the present disclosure and their descriptions are used to explain the present disclosure but do not constitute a limitation of the present disclosure.

[0026] Figure 1 It is an existing magnetic core structure;

[0027] Figure 2 A cylindrical core used in existing high-power inductors;

[0028] Figure 3 A schematic diagram of a combined magnetic core structure provided in the first embodiment of the present disclosure;

[0029] Figure 4 A three-dimensional view of the center column of the combined magnetic core structure provided in the first embodiment of the present disclosure before assembly;

[0030] Figure 5 This is a schematic diagram of the overall assembly of the middle column of the combined magnetic core structure provided in the first embodiment of the present disclosure;

[0031] Figure 6 A schematic diagram of a magnetic ring of a combined magnetic core structure provided in the first embodiment of the present disclosure;

[0032] Figure 7 This is a schematic diagram of the overall assembly of the magnetic components provided in the second embodiment of the present disclosure.

[0033] Among them, 1-base; 11-first base; 12-second base; 2-middle column; 21-column core; 22-magnetic ring group; 221-magnetic ring; 2A-first middle column; 2B-second middle column; 21A-first column core; 21B-second column core; 22A-first magnetic ring group; 22B-second magnetic ring group 3-coil. DETAILED DESCRIPTION

[0034] The present disclosure will be further described below with reference to the accompanying drawings and embodiments.

[0035] It should be noted that the following detailed descriptions are exemplary and intended to provide further explanation of the present disclosure. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which the present disclosure belongs.

[0036] For example, the standard magnetic ring and standard cylindrical core described in the present invention can be standard ring cores and rod cores from a magnetic core manufacturer. Those skilled in the art will appreciate that the ring cores and rod cores are both small magnetic rings and cylindrical cores with millimeter-scale dimensions commonly used in magnetic core factories.

[0037] Example 1

[0038] like Figure 1 As shown in FIG, the existing magnetic core structure mainly includes a base and a column core, which form a closed magnetic circuit. In order to enhance the inductance of the magnetic core structure, the existing technology usually splices multiple column cores, such as Figure 2 As shown, the inductance of the magnetic core structure is enhanced by stacking multiple cylindrical cores, and then the cylindrical cores are machined into cylindrical cores by a grinder to meet production needs. However, this processing method is time-consuming and labor-intensive, and is prone to waste of resources and poor quality of finished magnetic components.

[0039] In order to overcome the above problems, this embodiment provides a combined magnetic core structure, including: a base 1 and a middle column 2; the middle column 2 includes a column core 21 and a magnetic ring group 22, the magnetic ring group 22 includes at least one magnetic ring 221, and the magnetic ring group 22 is arranged outside the column core 21; the base 1 is arranged at both ends of the middle column 2.

[0040] like Figure 3 FIG. 1 is a schematic diagram of a combined magnetic core structure provided in this embodiment. In this combined magnetic core structure, center leg 2 includes a first center leg 2A and a second center leg 2B, which are placed side by side. Base 1 includes a first base 11 and a second base 12, which are parallel to each other. First center leg 2A and second center leg 2B are bonded to first base 11 and second base 12 to form a closed magnetic circuit. Preferably, epoxy resin glue is used to bond the center leg and base.

[0041] In this specific embodiment, the cross section of the base consists of a rectangle and two semicircles, or is a rectangle to meet different production needs.

[0042] This specific embodiment reduces the processing cost caused by the traditional method of splicing multiple column cores and cutting excess materials through the nested combination of magnetic rings and column cores, enhances the stability of the magnetic core structure, improves product quality, and ensures the safety of production and processing.

[0043] In this specific embodiment, the first middle column 2A includes a first column core 21A and a first magnetic ring group 22A, and the second middle column 2B includes a second column core 21B and a second magnetic ring group 22B. The first column core 21A and the second column core 21B are two columns of the same shape and size.

[0044] like Figure 4 As shown, a perspective view of the center column of the assembled magnetic core structure provided in this embodiment is shown before assembly. The individual magnetic rings 221 of the magnetic ring assembly 22 are identical in shape and size, and the hollow spaces between the magnetic rings 221 are aligned and bonded together using an adhesive. The number of magnetic rings 221 in the magnetic ring assembly 22 can be adjusted according to actual needs, thereby achieving customizable inductance.

[0045] like Figure 5 As shown, the overall assembly diagram of the middle column of the combined magnetic core structure provided in this embodiment, the shape of the magnetic ring corresponds to the shape of the column core it is mounted on, and the shape of the magnetic ring 221 is the same as the cross-sectional shape of the column core 21 it is mounted on, thereby ensuring the normal operation of the magnetic core structure.

[0046] Specifically, such as Figure 6 As shown, the magnetic ring 221 can be an elliptical ring, a triangular ring or a polygonal ring, and the corresponding column core 21 with an elliptical, triangular or polygonal cross-section is matched inside; in some specific embodiments, the outer periphery of the magnetic ring 221 can have chamfers or rounded corners, and the material of the magnetic ring 221 can be manganese zinc ferrite, nickel zinc ferrite or a metal soft magnetic powder core, which can be adjusted according to actual needs to meet different product requirements and adapt to more usage scenarios.

[0047] In some specific embodiments, the magnetic ring 221 is coated with an insulating layer. The insulating layer is made of epoxy resin or other insulating coatings to avoid current loss and damage and ensure the performance and life of the magnetic core structure.

[0048] The combined magnetic core structure is mainly aimed at high-power inductors. The magnetic cores of high-power inductors are generally large in size (the outer diameter of the middle column is more than 50mm), and large presses or molds are required for processing, and the quality is difficult to guarantee. The current conventional horizontal or vertical cutting and splicing methods are prone to cause cracking of the magnetic core and loose bonding, and structural instability leads to product failure. The combined magnetic core structure proposed in the present invention uses a combination of magnetic rings and column cores, adopts a standard small-sized column core, and is surrounded by multiple standard magnetic rings with an inner diameter slightly larger than the outer diameter of the column core. Without adding large presses or opening new large molds, the stability of the structure can be enhanced, thereby meeting the needs of high frequency, high voltage and high power. In addition, "standard" means that the combined magnetic rings are of fixed size (inner diameter, outer diameter, thickness, etc.), and standard column cores and standard magnetic rings are used to form the magnetic core structure used for high-power inductors of various sizes. The factory can adjust the inductance according to the combination of standard magnetic rings to meet the needs of different customers.

[0049] Example 2

[0050] like Figure 7 As shown, this embodiment provides a magnetic component, comprising: the combined magnetic core structure of the above-mentioned embodiment 1, and a coil 3 , wherein the coil 3 is wound around the central column 2 .

[0051] In some specific embodiments, the coil 3 is a flat wire or a round wire.

[0052] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that the present invention is susceptible to various modifications and variations. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention shall be included within the scope of protection of the present invention.

Claims

1. A combined magnetic core structure, characterized in that: include: Base and center column; The middle column comprises a column core and a magnetic ring group, wherein the magnetic ring group comprises at least one magnetic ring, and the magnetic ring group is sleeved outside the column core; The base is arranged at both ends of the central column; The center column includes a first center column and a second center column, which are placed side by side; the base includes a first base and a second base, which are parallel to each other; the first center column and the second center column are bonded to the first base and the second base to form a closed magnetic circuit.

2. A combined magnetic core structure as claimed in claim 1, characterized in that: The first center column includes a first column core and a first magnetic ring group, and the second center column includes a second column core and a second magnetic ring group; the first column core and the second column core are two columns with the same shape and size.

3. A combined magnetic core structure as claimed in claim 1, characterized in that: The magnetic rings of the magnetic ring group have the same shape and size, and the hollow parts between the magnetic rings are aligned and bonded together.

4. A combined magnetic core structure as claimed in claim 1, characterized in that: The shape of the magnetic ring is the same as the cross-sectional shape of the sleeved column core.

5. A combined magnetic core structure as claimed in claim 1, characterized in that: The magnetic ring material is manganese-zinc ferrite, nickel-zinc ferrite or metal soft magnetic powder core.

6. A combined magnetic core structure as claimed in claim 1, characterized in that: The outer surface of the magnetic ring is plated with an insulating layer.

7. A combined magnetic core structure as claimed in claim 6, characterized in that: The insulating layer is made of epoxy resin.

8. A combined magnetic core structure as claimed in claim 1, characterized in that: The cross section of the base consists of a rectangle and two semicircles, or is a rectangle.

9. A magnetic component, characterized in that: include: The combined magnetic core structure according to any one of claims 1 to 8; The coil is wound around the center column.

10. A magnetic component according to claim 9, characterized in that: The coil is a flat wire or a round wire.

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