Magnetic core structure and inductor

Abstract

The utility model discloses a magnetic core structure and an inductor. The magnetic core structure comprises a first magnetic core part and a second magnetic core part, the first magnetic core part comprises a high-Bs structure, a coil is wound on the high-Bs structure, the second magnetic core part comprises a low-Bs structure, and the high-Bs structure is arranged on the low-Bs structure; the inductor comprises the magnetic core structure. The magnetic core is applied to the technical field of magnetic cores.

Description

Technical Field

[0001] This utility model relates to the technical field of magnetic cores, and in particular to a magnetic core structure and an inductor. Background Technology

[0002] As electronic products become more functional, more and more electronic components are needed within a given volume, creating a more complex electromagnetic environment. This poses a challenge to the placement of inductors on a limited circuit board area. Inductors are crucial components in circuits, typically consisting of a magnetic core, a frame, and coils. To address these challenges, the magnetic core needs higher requirements, such as high saturation flux density, large DC superposition capability, and low losses. Magnetic core materials generally include ferrite, magnetic powder, and amorphous nanocrystalline materials. Generally, magnetic powder and amorphous nanocrystalline materials offer excellent DC superposition capability and high core losses; ferrite has lower losses but poorer DC superposition capability. To achieve greater anti-saturation capability, an additional air gap is usually required. However, the presence of the air gap weakens the permeability of the ferrite and increases material losses. Furthermore, inductor losses include not only core losses but also copper wire losses. A suitable magnetic core structure can prevent additional losses caused by magnetic lines of force cutting the windings, improving the inductor's efficiency.

[0003] A patent with publication number CN117976376A discloses a composite magnetic core structure consisting of thin-film nanocrystals and sheet ferrites stacked alternately. This structure combines the advantages of both materials: the high saturation magnetic flux density of nanocrystals and the low loss characteristics of ferrites. While the resulting inductor structure exhibits both high saturation magnetic flux density and low core loss, the fabrication process is complex, involving numerous stacking steps. Furthermore, a patent with publication number CN116864275 discloses a composite magnetic core structure for a current transformer. This core structure is formed by sequentially stacking and winding multiple composite magnetic core layers in the same direction. The composite magnetic core layers include: a first magnetic core layer with low permeability; a second magnetic core layer with high permeability sealed and bonded to the outside of the first magnetic core layer, the width of the second magnetic core layer being larger than that of the first magnetic core layer; and multiple composite magnetic core layers sequentially and sealed to form a ring-shaped magnetic core, wherein the magnetic core has at least one air gap cutout in the direction perpendicular to the winding direction. When there is no DC component current in the power grid, the high permeability of the second core layer plays a crucial role, resulting in a small ratio error and phase angle error in the current transformer. Even when there is a DC component current in the power grid, although the second core layer is saturated with magnetization, the first core layer remains unsaturated, allowing for accurate current measurement. While this structure can improve the device's DC resistance and reduce core losses to some extent, it requires the introduction of a significant amount of binder during fabrication, increasing material costs and introducing environmental pollution and reliability issues.

[0004] Bs refers to the saturation magnetic flux density. It is an important parameter of magnetic materials, representing the maximum magnetic flux density that the material can achieve under the influence of an external magnetic field. When a magnetic material reaches its saturation magnetic flux density, its magnetic flux density will not increase further even if the external magnetic field is increased. Generally speaking, the higher the Bs of a material, the better its DC superposition capability. Magnetic powder cores have distributed air gaps and a relatively large Bs, so their anti-saturation capability is greater than that of ferrites. However, magnetic powder cores have higher losses and are more expensive, limiting many applications. Utility Model Content

[0005] The technical problem to be solved by this utility model is to overcome the shortcomings of the prior art. The primary objective is to provide a magnetic core structure with high magnetic permeability, reduced cost, and reduced energy loss.

[0006] The second objective of this invention is to provide an inductor with high permeability, reduced cost, and reduced energy loss.

[0007] The technical solution adopted by this utility model is as follows: the magnetic core structure includes a first magnetic core component and a second magnetic core component. The first magnetic core component includes a high Bs structure on which a coil is wound. The second magnetic core component includes a low Bs structure on which the high Bs structure is disposed.

[0008] Furthermore, the low Bs structure includes an upper cover plate and a lower cover plate, the lower cover plate being located below the upper cover plate, and a side post being provided between the upper cover plate and the lower cover plate. The high Bs structure includes a central post being provided between the upper cover plate and the lower cover plate, and the coil is wound on the central post.

[0009] Furthermore, there are two side pillars and at least one central pillar, with the central pillar located between the two side pillars.

[0010] Furthermore, the high Bs structure includes at least one of FeNi layer, FeSi layer, FeSiAl layer, FeNiMo layer, FeSiCr layer, and amorphous / nanocrystalline layer.

[0011] Furthermore, the low-Bs structure includes at least one of MnZn layer, NiZn layer and MgZn layer.

[0012] Furthermore, the coil is one of flat wire, round wire, Litz wire, and stranded wire.

[0013] Furthermore, the magnetic core structure is shaped as one of the following: EE, EC, EQ, ER, and PQ.

[0014] In addition, this utility model also provides an inductor that includes the aforementioned magnetic core structure.

[0015] The beneficial effects of this utility model are:

[0016] In contrast to the shortcomings of existing technologies, this invention combines a high-Bs structure and a low-Bs structure, with the coil wound on the high-Bs structure. When a DC component exists in the circuit, the low-Bs structure saturates first, followed by the high-Bs structure, effectively improving the anti-saturation capability of the magnetic core structure. Therefore, the magnetic core structure features low loss, high superposition, and high permeability, and is simple to prepare, easy to operate, low in cost, and highly efficient in production. Moreover, no adhesive is needed between different magnetic core components, saving costs and avoiding environmental pollution. It also has relatively high reliability, giving the magnetic core structure the advantages of high permeability, reduced cost, and reduced energy consumption. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0018] Figure 1 This is a plan view of Embodiment 1 of the present utility model;

[0019] Figure 2 This is a plan view of Embodiment 2 of this utility model;

[0020] Figure 3 This is a cross-sectional schematic diagram of Embodiment 2 of this utility model;

[0021] Figure 4 This is a plan view of Embodiment 3 of this utility model.

[0022] The attached figures are labeled as follows:

[0023] 1. High Bs structure; 2. Coil; 3. Low Bs structure; 5. Top cover plate; 6. Bottom cover plate; 7. Side post; 8. Middle post.

[0024] The realization of the purpose, functional features and advantages of this utility model will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0025] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present utility model.

[0026] It should be noted that all directional indicators in this utility model embodiment, such as up, down, left, right, front, back, clockwise, counterclockwise, etc., are only used to explain the relative positional relationship and movement of each component in a specific posture. If the specific posture changes, the directional indicator will also change accordingly.

[0027] Furthermore, the use of terms such as "first" and "second" in this utility model is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. Additionally, the technical solutions of the various embodiments can be combined with each other, but only on the basis of being achievable by those skilled in the art. When the combination of technical solutions is contradictory or impossible to implement, such a combination of technical solutions should be considered non-existent and not within the scope of protection claimed by this utility model.

[0028] like Figures 1 to 4 As shown, in this embodiment, the magnetic core structure includes a first magnetic core component and a second magnetic core component. The first magnetic core component includes a high Bs structure 1, on which a coil 2 is wound. The second magnetic core component includes a low Bs structure 3, on which the high Bs structure 1 is disposed.

[0029] In contrast to the shortcomings of existing technologies, this invention combines a high-Bs structure 1 and a low-Bs structure 3, with the coil 2 wound on the high-Bs structure 1. When a DC component exists in the circuit, the low-Bs structure 3 preferentially reaches saturation, followed by the high-Bs structure 1, effectively improving the anti-saturation capability of the magnetic core structure. Therefore, the magnetic core structure features low loss, high superposition, and high permeability, and is simple to prepare, easy to operate, low in cost, and highly efficient in production. Moreover, no adhesive is needed between different magnetic core components, saving costs and avoiding environmental pollution. It also has relatively high reliability, giving the magnetic core structure the advantages of high permeability, reduced cost, and reduced energy consumption.

[0030] It should be noted that in addition to core losses, copper wire losses also account for a significant portion of inductor losses. A suitable core structure can effectively reduce copper wire losses caused by magnetic lines of force cutting the windings. For example, when copper wire is wound on an open-circuit core such as a rod, the magnetic lines of force cutting the copper wire will cause losses. If the magnetic lines of force are rearranged appropriately, i.e., a suitable core structure is used, direct cutting of the windings can be avoided, thus reducing losses.

[0031] In some embodiments, the low-Bs structure 3 includes an upper cover plate 5 and a lower cover plate 6, with the lower cover plate 6 located below the upper cover plate 5. A side post 7 is disposed between the upper cover plate 5 and the lower cover plate 6. The high-Bs structure 1 includes a central post 8 disposed between the upper cover plate 5 and the lower cover plate 6, with the coil 2 wound on the central post 8. There are two side posts 7 and at least one central post 8, located between two side posts 7. Specifically, by using a high-saturation BS as the central post and other low-Bs components as the upper cover plate 5, lower cover plate 6, and side posts 7, the magnetic field lines are diverted, preventing them from directly cutting the winding and reducing losses. Furthermore, when there is a DC component in the circuit, the low-Bs structure 3 saturates first, and the high-Bs structure 1 saturates last, making it suitable for high-current applications.

[0032] In some embodiments, the high-Bs structure 1 includes at least one of FeNi layer, FeSi layer, FeSiAl layer, FeNiMo layer, FeSiCr layer, and amorphous / nanocrystalline layer; the low-Bs structure 3 includes at least one of MnZn layer, NiZn layer, and MgZn layer; the coil 2 is one of flat wire, round wire, Litz wire, and stranded wire; and the magnetic core structure is shaped as one of EE, EC, EQ, ER, and PQ.

[0033] Furthermore, this utility model also provides an inductor including the aforementioned magnetic core structure. Specifically, the inductor combines the advantages of composite materials, optimizes the magnetic core structure, reduces energy consumption, and improves efficiency. Moreover, the specific structure of the magnetic core is as described in the above embodiments. Since the magnetic core structure adopts all the technical solutions of all the above embodiments, it possesses at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be elaborated further here.

[0034] The above description is only a preferred embodiment of the present utility model and does not limit the patent scope of the present utility model. All equivalent structural transformations made under the inventive concept of the present utility model using the contents of the present utility model specification and drawings, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present utility model.

Claims

1. A magnetic core structure, characterized in that: It includes a first magnetic core component and a second magnetic core component. The first magnetic core component includes a high Bs structure (1) on which a coil (2) is wound. The second magnetic core component includes a low Bs structure (3) on which the high Bs structure (1) is disposed.

2. The magnetic core structure according to claim 1, characterized in that: The low Bs structure (3) includes an upper cover plate (5) and a lower cover plate (6), the lower cover plate (6) being located below the upper cover plate (5), and a side post (7) being provided between the upper cover plate (5) and the lower cover plate (6). The high Bs structure (1) includes a central post (8) being provided between the upper cover plate (5) and the lower cover plate (6), and the coil (2) being wound on the central post (8).

3. The magnetic core structure according to claim 2, characterized in that: The number of side pillars (7) is two, and the number of middle pillars (8) is at least one, with the middle pillar (8) located between the two side pillars (7).

4. The magnetic core structure according to claim 1, characterized in that: The high Bs structure (1) includes at least one of FeNi layer, FeSi layer, FeSiAl layer, FeNiMo layer, FeSiCr layer and amorphous / nanocrystalline layer.

5. The magnetic core structure according to claim 1, characterized in that: The low Bs structure (3) includes at least one of MnZn layer, NiZn layer and MgZn layer.

6. The magnetic core structure according to claim 1, characterized in that: The coil (2) is one of flat wire, round wire, Litz wire, and stranded wire.

7. The magnetic core structure according to claim 1, characterized in that: The magnetic core structure is shaped as one of the following: EE, EC, EQ, ER, and PQ.

8. An inductor, characterized in that: It includes the magnetic core structure as described in any one of claims 1-7.

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