Combined type magnetic core low-cost high-performance differential mode inductor
Through the combined core structure, the amplified core and ferrosilicon materials with high permeability are used to improve the light load and heavy load performance of differential mode inductors, solving the problem of increasing inductor volume and cost in the prior art, and realizing the realization of The lightweight and low loss effect of the inductor.
Patent Information
- Application Number
- CN202421117067.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-05-22
- Publication Date
- 2025-01-03
- Estimated Expiration
- 2034-05-22
AI Technical Summary
When existing differential mode inductors increase the light load inductance, they usually need to increase the core cross-sectional area or the number of winding turns, resulting in an increase in the inductor volume and cost, making it difficult to reduce production costs while ensuring performance.
Using a combined magnetic core structure, including an upper jaw core, a middle column core and a lower jaw core, the effective cross-sectional area is increased by amplifying the magnetic core, and the light load is increased by using iron-based amorphous blocks or ferrite materials with high permeability. Inductive, reduce the number of turns to achieve high performance, reduce inductor weight and cost.
Under the same inductor volume, the light load and heavy load performance of differential mode inductors is improved, the production cost and weight of the inductor are reduced, and the inductors are reduced and the inductors are achieved.
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Figure CN222300425U_ABST
Abstract
Description
Technical Field
[0001] The utility model belongs to the technical field of electronic components, and more specifically, relates to a combined magnetic core low-cost and high-performance differential mode inductor. Background Art
[0002] Differential mode inductors, as an inductor device specifically used to resist differential mode high-frequency interference, are widely used in power supply filtering and signal lines of electronic equipment. This type of inductor, also commonly known as a differential mode choke coil, has a unique property that it has a great inductive reactance to differential mode high-frequency interference, and can effectively reduce or eliminate the impact of such interference on the normal operation of the equipment. In the production of differential mode inductors, the selection of core materials is crucial. There are currently three main core materials on the market: Sendust magnetic powder core, FeNi 50 magnetic powder core and FeNiMo magnetic powder core. Among them, Sendust magnetic powder core has become the preferred material for civilian differential mode inductors due to its lowest unit volume cost. FeNi 50 and FeNiMo magnetic powder cores are more suitable for military applications or special occasions with extremely high requirements for volume and performance due to their high price and excellent performance.
[0003] The working principle of differential mode inductors is based on their unique inductance characteristics. When the frequency of AC power is constant, the greater the inductance of the inductor, the stronger its ability to block AC power; conversely, the smaller the inductance, the weaker its ability to block AC power. At the same time, when the inductance remains unchanged, the higher the frequency of AC power, the stronger the inductor's ability to block AC power; and the lower the frequency, the weaker the ability to block AC power. This characteristic enables differential mode inductors to effectively block the passage of AC power and allow DC power to pass smoothly.
[0004] In the design of power supply filtering and signal lines, higher requirements are usually placed on differential mode inductors. In order to ensure the stability of the power supply and the purity of the signal, the differential mode inductor needs to have a higher inductance under both light and heavy loads. To achieve this goal, most conventional designs currently use a combination of iron silicon or iron silicon aluminum as the core material. The magnetic permeability of these two materials is between 26-125u, but due to the limitations of the materials themselves, increasing the light load inductance can often only be achieved by increasing the core cross-sectional area or the number of winding turns. This will undoubtedly increase the size and cost of the inductor, bringing certain challenges to design and production.
[0005] To this end, the utility model provides a combined magnetic core low-cost and high-performance differential mode inductor. Utility Model Content
[0006] The utility model aims to provide a combined magnetic core low-cost and high-performance differential mode inductor to solve the problems raised in the above background technology.
[0007] The purpose of the utility model can be achieved through the following technical solutions:
[0008] A combined magnetic core low-cost and high-performance differential mode inductor comprises a combined magnetic core, wherein the combined magnetic core is provided with an upper magnetic core, a middle column magnetic core is connected to the left and right sides of the bottom end of the upper magnetic core, the bottom ends of the pair of middle column magnetic cores are connected to the lower magnetic core, and the upper magnetic core, the middle column magnetic core and the lower magnetic core together constitute a combined magnetic core with a "mouth"-shaped magnetic core structure; coils are symmetrically wound around the two sides of the combined magnetic core, the coils are wound around the middle column magnetic cores on the corresponding sides, and isolation plates are provided between the coils and the upper magnetic core and the lower magnetic core; amplifier magnetic cores are provided on the front and rear sides of the upper magnetic core and the lower magnetic core.
[0009] As a further preferred technical solution of the present invention, the cross-sections of the upper magnetic core and the lower magnetic core are elliptical racetrack-shaped, and the upper magnetic core and the lower magnetic core are an integral part made of iron silicon or sendustine.
[0010] As a further preferred technical solution of the present invention, the middle column magnetic core is cylindrical or rectangular, and the middle column magnetic core is an integral piece made of iron silicon material.
[0011] As a further preferred technical solution of the utility model, the outer contour of the isolation plate is in the shape of an elliptical racetrack, and the isolation plate is further provided with circular or rectangular slots for nesting with the pair of middle column magnetic cores.
[0012] As a further preferred technical solution of the present invention, the coil is made of two layers of NOMEX material, and the coil is vertically wound with a flat wire.
[0013] As a further preferred technical solution of the present utility model, the amplifying magnetic core is in the shape of a rectangular block, and the amplifying magnetic core is an integral part made of iron-based amorphous or ferrite power material.
[0014] As a further preferred technical solution of the present invention, the isolation board is an epoxy FR4 board.
[0015] As a further preferred technical solution of the utility model, the upper magnetic core and the middle magnetic core are fixed with epoxy resin single-component glue, and the lower magnetic core and the middle magnetic core are also fixed with epoxy resin single-component glue.
[0016] As a further preferred technical solution of the utility model, the upper magnetic core is fixed to the amplifying magnetic cores placed on the front and rear sides of the upper magnetic core by applying a single-component epoxy resin glue, and the lower magnetic core is fixed to the amplifying magnetic cores placed on the front and rear sides of the lower magnetic core by applying a single-component epoxy resin glue.
[0017] As a further preferred technical solution of the present utility model, the cross-sectional area of the amplification cores on the front and rear sides of the upper magnetic core or the lower magnetic core accounts for 30% to 50% of the cross-sectional area of the upper magnetic core or the lower magnetic core.
[0018] As described above, the utility model provides a combined magnetic core low-cost high-performance differential mode inductor, which has the following beneficial effects:
[0019] 1. The utility model utilizes the above-mentioned combined magnetic core low-cost and high-performance differential mode inductor. Compared with the prior art, an amplifying magnetic core is provided. The effective cross-sectional area of the upper magnetic core and the lower magnetic core is increased by the amplifying magnetic core. In addition, the material used for the amplifying magnetic core has a high magnetic permeability, and the light-load inductance can be improved by splicing it with the upper magnetic core and the lower magnetic core.
[0020] 2. The utility model utilizes the above-mentioned combined magnetic core low-cost and high-performance differential mode inductor. Compared with the prior art, the combined magnetic core of the upper and lower magnetic cores made of iron silicon or iron silicon aluminum material, and the amplifying magnetic core made of iron-based amorphous block or ferrite power material, increases the light load inductance of the differential mode inductor, and improves the heavy load performance of the differential mode inductor. Under the same inductor volume, the equivalent performance of the prior art can be achieved by reducing the number of turns, reducing the copper loss of the inductor, achieving the advantages of reduced inductor weight, low iron loss, and low copper loss, and reducing the production cost of the inductor.
[0021] Additional aspects and advantages of the present invention will be given in part in the following description, and in part will become apparent from the following description, or will be learned through the practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS
[0022] In order to more clearly illustrate the embodiments of the utility model or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the utility model. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.
[0023] Figure 1 This is a schematic diagram of the structure of a combined magnetic core low-cost and high-performance differential mode inductor applied for by the utility model;
[0024] Figure 2 A schematic diagram of the structure of a combined magnetic core of a low-cost, high-performance differential mode inductor applied for by the utility model;
[0025] Figure 3 This is a schematic diagram of the isolation board structure of a combined magnetic core low-cost and high-performance differential mode inductor applied for by the utility model.
[0026] Summary of reference numerals and their descriptions:
[0027] 100, combined magnetic core; 110, upper magnetic core; 120, middle magnetic core; 130, lower magnetic core; 200, coil; 300, isolation plate; 310, slot; 400, amplifier magnetic core. DETAILED DESCRIPTION
[0028] The following is a description of the implementation of the present invention by means of specific embodiments. People familiar with the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification.
[0029] It should be noted that the structures, proportions, sizes, etc. illustrated in the drawings of this specification are only used to match the contents disclosed in the specification for people familiar with this technology to understand and read, and are not used to limit the limiting conditions that can be implemented in this utility model, so they have no substantial technical significance. Any modification of the structure, change of the proportional relationship or adjustment of the size, without affecting the effects that can be produced by the utility model and the purposes that can be achieved, should still fall within the scope of the technical content disclosed in this utility model. At the same time, the terms such as "upper", "lower", "left", "right", "middle" and "one" quoted in this specification are only for the convenience of description, and are not used to limit the scope of the implementation of this utility model. The change or adjustment of their relative relationship, without substantial change in the technical content, should also be regarded as the scope of the implementation of this utility model. The specific structure can be described with reference to the drawings of the patent application.
[0030] The utility model provides a combined magnetic core low-cost high-performance differential mode inductor, please refer to Figures 1 to 3 As shown, it includes a combined magnetic core 100, wherein the combined magnetic core 100 is provided with an upper magnetic core 110, and a middle column magnetic core 120 is connected to the left and right sides of the bottom end of the upper magnetic core 110, and the bottom ends of the pair of middle column magnetic cores 120 are connected to the lower magnetic core 130, and the upper magnetic core 110, the middle column magnetic core 120 and the lower magnetic core 130 together constitute a combined magnetic core 100 with a "mouth"-shaped magnetic core structure; coils 200 are symmetrically wound around both sides of the combined magnetic core 100, and the coils 200 are wound on the middle column magnetic core 120 on the corresponding side, and isolation plates 300 are provided between the coils 200 and the upper magnetic core 110 and the lower magnetic core 130; the front and rear sides of the upper magnetic core 110 and the lower magnetic core 130 are provided with amplifier magnetic cores 400.
[0031] It should be noted that the effective cross-sectional area of the upper magnetic core 110 and the lower magnetic core 130 is increased by the amplifying magnetic core 400. In addition, the material used in the amplifying magnetic core 400 has a high magnetic permeability, and the light-load inductance can be improved after being spliced with the upper magnetic core 110 and the lower magnetic core 130.
[0032] Specifically, the specific structures of the upper magnetic core 110 and the lower magnetic core 130 are shown below. Figure 1 and Figure 2 As shown, in this embodiment, the cross-sections of the upper magnetic core 110 and the lower magnetic core 130 are elliptical racetrack-shaped. The upper magnetic core 110 and the lower magnetic core 130 are integral parts made of iron silicon or sendustine. The magnetic permeability of conventional iron silicon and sendustine magnetic powder cores is 26-125u.
[0033] Specifically, the specific structure of the middle column magnetic core 120 is shown below. Figure 1 and Figure 2 As shown, in this embodiment, the middle column magnetic core 120 is cylindrical or rectangular. In this embodiment, the middle column magnetic core 120 is cylindrical and is an integral piece made of iron silicon material.
[0034] Specifically, the specific structure of the isolation plate 300 is shown below. Figure 1 and Figure 3 As shown, in the present embodiment, the outer contour of the isolation plate 300 is in the shape of an elliptical runway, and the isolation plate 300 is also provided with a circular or rectangular slot 310 for nesting with the pair of center column magnetic cores 120. In the present embodiment, the slot 310 is circular, and the isolation plate 300 is an epoxy FR4 board.
[0035] The coil 200 is made of two layers of NOMEX material. The coil 200 is wound vertically with a flat wire, and the inter-turn distributed capacitance is smaller. The assembly method is more convenient, the gaps between the copper wires of the flat wire are uniform, the heat of the coil 200 is easier to dissipate from the gaps, the magnetic leakage is small, the application efficiency is high, the product appearance and performance consistency are very good, and it is more suitable for automated production equipment operations.
[0036] Specifically, the specific structure of the amplifying magnetic core 400 is shown below. Figure 1 and Figure 2 As shown, in this embodiment, the amplifier core 400 is in the shape of a rectangular block, and the amplifier core 400 is an integral part made of iron-based amorphous or ferrite power material. The magnetic permeability of the iron-based amorphous block or ferrite power material is about 1000-2200u, and the cross-sectional area of the amplifier core 400 on the front and rear sides of the upper magnetic core 110 or the lower magnetic core 130 accounts for 30% to 50% of the cross-sectional area of the upper magnetic core 110 or the lower magnetic core 130.
[0037] It should be noted that amorphous is a new type of soft magnetic alloy material. It uses internationally advanced ultra-rapid cooling technology to directly cool the molten metal at a speed of one million degrees per second to form an amorphous thin strip with a thickness of 25 to 35µm, and obtains an amorphous alloy structure with short-range order and long-range disorder in the atomic arrangement and combination. It is completely different from traditional metal and alloy materials in microstructure. Therefore, it has incomparable excellent properties of traditional metal materials in many aspects such as physical properties, chemical properties, and mechanical properties. In addition, the preparation process is also completely different from the traditional metallurgical process. The amorphous thin strip is made from molten steel in one step, eliminating the casting, forging, intermediate annealing, rolling and other processes in the traditional metallurgical process, saving a lot of energy, and no pollutants are discharged. Feijing alloy is known as a new type of green material that is environmentally friendly, energy-saving, and efficient; iron-based amorphous strip has an ultra-fine grain structure. With its high magnetic permeability, high saturation magnetic induction, low iron loss and excellent stability, it meets the needs of today's electronic products to develop in the direction of medium and high frequency, high current, miniaturization, and energy saving.
[0038] The upper magnetic core 110 and the middle column magnetic core 120 are fixed with epoxy resin single-component glue, and the lower magnetic core 130 and the middle column magnetic core 120 are also fixed with epoxy resin single-component glue; the upper magnetic core 110 and the amplification magnetic core 400 placed on the front and rear sides of the upper magnetic core 110 are fixed with epoxy resin single-component glue, and the lower magnetic core 130 and the amplification magnetic core 400 placed on the front and rear sides of the lower magnetic core 130 are fixed with epoxy resin single-component glue.
[0039] It should be noted that: the combined magnetic core 100 of the upper magnetic core 110 and the lower magnetic core 130 made of iron silicon or sendust material, and the amplifier magnetic core 400 made of iron-based amorphous block or ferrite power material, the light load inductance of the differential mode inductor is increased, and the heavy load performance of the differential mode inductor is improved. Under the same inductor volume, the equivalent performance of the existing technology can be achieved by reducing the number of turns, reducing the copper loss of the inductor, achieving the advantages of reduced inductor weight, low iron loss, and low copper loss, and reducing the production cost of the inductor.
[0040] It is obvious to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the present invention can be implemented in other specific forms without departing from the spirit or essential features of the present invention. Therefore, the embodiments should be regarded as exemplary and non-restrictive from any point of view, and the scope of the present invention is defined by the appended claims rather than the above description, and it is intended that all changes falling within the meaning and scope of the equivalent elements of the claims be included in the present invention. Any reference numeral in a claim should not be regarded as limiting the claim to which it relates.
Claims
1. A combined magnetic core low-cost high-performance differential mode inductor, characterized in that: The invention comprises a combined magnetic core, wherein the combined magnetic core is provided with an upper magnetic core, a middle column magnetic core is connected to the left and right sides of the bottom end of the upper magnetic core, the bottom ends of the pair of middle column magnetic cores are connected to the lower magnetic core, and the upper magnetic core, the middle column magnetic core and the lower magnetic core together constitute a combined magnetic core with a "mouth"-shaped magnetic core structure; Coils are symmetrically wound on both sides of the combined magnetic core, and the coils are wound on the middle column magnetic cores on the corresponding sides, and isolation plates are provided between the coils and the upper and lower magnetic cores; Amplifying magnetic cores are arranged on the front and rear sides of the upper magnetic core and the lower magnetic core. The amplifying magnetic cores are made of a material with higher magnetic permeability than the upper magnetic core and the lower magnetic core.
2. A combined magnetic core low-cost high-performance differential mode inductor according to claim 1, characterized in that: The cross-sections of the upper magnetic core and the lower magnetic core are in an elliptical racetrack shape, and the upper magnetic core and the lower magnetic core are an integral part made of iron silicon or iron silicon aluminum.
3. The combined magnetic core low-cost high-performance differential mode inductor according to claim 1, characterized in that: The middle column magnetic core is cylindrical or rectangular, and is an integral piece made of iron silicon material.
4. The combined magnetic core low-cost and high-performance differential mode inductor according to claim 1, characterized in that: The outer contour of the isolation plate is in the shape of an elliptical racetrack, and the isolation plate is also provided with circular or rectangular slots for nesting with the pair of middle column magnetic cores.
5. The combined magnetic core low-cost high-performance differential mode inductor according to claim 1, characterized in that: The coil is made of two layers of NOMEX material and is vertically wound with a flat wire.
6. The combined magnetic core low-cost high-performance differential mode inductor according to claim 1, characterized in that: The amplifying magnetic core is in a rectangular block shape and is an integral piece made of iron-based amorphous or ferrite power material.
7. The combined magnetic core low-cost high-performance differential mode inductor according to claim 4, characterized in that: The isolation board is an epoxy FR4 board.
8. A combined magnetic core low-cost and high-performance differential mode inductor according to any one of claims 1 to 5, characterized in that: The upper magnetic core and the middle magnetic core are fixed with epoxy resin single-component glue, and the lower magnetic core and the middle magnetic core are also fixed with epoxy resin single-component glue.
9. The combined magnetic core low-cost high-performance differential mode inductor according to claim 6, characterized in that: The upper magnetic core is fixed to the amplifying magnetic cores disposed at the front and rear sides of the upper magnetic core by applying epoxy resin single-component glue, and the lower magnetic core is fixed to the amplifying magnetic cores disposed at the front and rear sides of the lower magnetic core by applying epoxy resin single-component glue.
10. The combined magnetic core low-cost high-performance differential mode inductor according to claim 9, characterized in that: The cross-sectional area of the amplifying cores at the front and rear sides of the upper magnetic core or the lower magnetic core accounts for 30% to 50% of the cross-sectional area of the upper magnetic core or the lower magnetic core.