Arc-shaped high-frequency E-type magnetic core for high-frequency transformer

Abstract

The utility model discloses an arc high frequency E type magnetic core for high frequency transformer, is provided with E type, including a base, two side columns and a middle column, two side columns are respectively vertically arranged in the left and right sides of base, and the middle column is vertically arranged in the middle part of base, the left and right sides of middle column are respectively symmetrically equipped with a winding slot, the winding slot is arc setting, the outside of two side columns is respectively symmetrically equipped with a recess, and the recess is arc setting. The utility model discloses a recess of arc is arranged on the outside of side column, thereby realizes distributed air gap, reduces local magnetic field concentration, reduces magnetic flux leakage and eddy current loss, disperses mechanical stress, promotes the anti -impact and anti -vibration ability, is provided with winding slot on the left and right sides of middle column, thereby can provide smooth winding path, improves winding density and uniformity, reduces leakage inductance, and the overall surface area of magnetic core increases, thereby can promote the heat dissipation efficiency, is suitable for high temperature, high power density application scene.

Description

Technical Field

[0001] This invention belongs to the field of magnetic core technology, and particularly relates to an arc-shaped high-frequency E-type magnetic core for high-frequency transformers. Background Technology

[0002] With the rapid development of high-frequency electronic devices such as 5G communications, new energy vehicles, and high-frequency power modules, the performance requirements for high-frequency transformers are increasing. Traditional ferrite cores, due to their limited permeability, high high-frequency losses, and poor temperature stability, struggle to meet the demands of modern electronic devices for high efficiency, miniaturization, and high reliability. Especially under high-frequency operating conditions, traditional E-type cores suffer from concentrated magnetic fields at the air gap, significant eddy current losses, low mechanical strength, and poor heat dissipation, leading to decreased overall transformer efficiency, excessive temperature rise, and shortened lifespan. Therefore, a novel core structure is urgently needed to overcome these technical bottlenecks. Utility Model Content

[0003] To address the aforementioned technical problems, the purpose of this invention is to provide an arc-shaped high-frequency E-type magnetic core for high-frequency transformers. Based on the E-type magnetic core, improvements are made to the center column and side columns, thereby effectively reducing local magnetic field concentration in the magnetic core and decreasing eddy current losses and leakage inductance.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] An arc-shaped high-frequency E-type magnetic core for high-frequency transformers is arranged in an E-shape and includes a base, two side posts and a central post. The two side posts are vertically arranged on the left and right sides of the base, and the central post is vertically arranged in the middle of the base. A winding groove is symmetrically arranged on the left and right sides of the central post, and the winding groove is arc-shaped. A groove is symmetrically arranged on the outer side of the two side posts, and the groove is arc-shaped.

[0006] Preferably, the width ratio between the central column and the side columns is 2:1.

[0007] Preferably, the groove width w2 of the winding groove is 1 / 2 of the height h2 of the central column.

[0008] Preferably, the lower end of the winding groove opening is located at the base, and the upper end of the winding groove opening is located at 1 / 2 of the height h2 of the central column.

[0009] Preferably, the groove opening width w1 is greater than the winding groove opening width w2, and the groove opening width w1 is less than the side post height h1.

[0010] Preferably, the lower end of the groove is located at the base.

[0011] Preferably, the radius of the groove is not less than half the thickness of the magnetic core, and the radius of the winding groove is equal to the radius of the groove.

[0012] Preferably, the upper and lower ends of the groove are respectively connected to the side arc transition of the side post, and the upper and lower ends of the winding groove are respectively connected to the side arc transition of the middle post.

[0013] This utility model, by adopting the above technical solutions, has the following beneficial effects: Based on the E-type magnetic core, this utility model achieves a distributed air gap by setting an arc-shaped groove on the outer side of the side post, thereby reducing local magnetic field concentration, reducing magnetic flux leakage and eddy current loss, and also dispersing mechanical stress, improving impact and vibration resistance. By setting winding grooves on the left and right sides of the central post, a smooth winding path can be provided, improving winding density and uniformity, reducing leakage inductance, and increasing the overall surface area of ​​the magnetic core, thereby improving heat dissipation efficiency, making it suitable for high-temperature and high-power-density application scenarios. Attached Figure Description

[0014] The accompanying drawings, which form part of this application, are used to provide a further understanding of this application. The illustrative embodiments of this application and their descriptions are used to explain this application and do not constitute a limitation thereof.

[0015] Figure 1 This is a schematic diagram of the structure of a traditional E-type magnetic core;

[0016] Figure 2 This is a schematic diagram of the structure of this utility model;

[0017] Figure 3 This is a structural schematic diagram of the present invention from another angle.

[0018] in,

[0019] 1. Base; 2. Side post; 21. Groove; 3. Center post; 31. Winding groove; Detailed Implementation

[0020] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0021] It should be noted that the following detailed descriptions are illustrative and intended to provide further explanation of this application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0022] The embodiments of this utility model are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this utility model, and should not be construed as limiting this utility model.

[0023] In the description of this utility model, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0024] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "clockwise", "counterclockwise", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0025] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, unless otherwise stated, "a plurality of" means two or more, unless otherwise expressly defined.

[0026] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0027] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0028] Traditional E-type magnetic cores, such as Figure 1 As shown, the magnetic field is concentrated at the air gap of traditional magnetic cores, leading to edge flux leakage and causing copper loss, eddy current loss, and EMI noise. Furthermore, at high frequencies, the large cross-sectional area of ​​traditional E-type magnetic cores results in significant eddy current loss, especially near the air gap. Traditional E-type magnetic cores are often made of ferrite, a brittle material prone to cracking during assembly or vibration. They also experience severe localized heating near the air gap, with a single heat dissipation path. Additionally, the right-angled edge of the central post used for winding on traditional E-type magnetic cores easily leads to winding damage. Multi-layer winding increases leakage inductance, and dense winding exacerbates conductor loss due to the skin effect.

[0029] This utility model discloses, as follows: Figure 2 and Figure 3 The diagram shows an arc-shaped high-frequency E-type magnetic core for a high-frequency transformer. The core is E-shaped and includes a base 1, two side posts 2, and a central post 3. The base 1 is horizontal to ensure structural stability. The two side posts 2 are vertically symmetrically arranged on the left and right sides of the base 1, with their outer surfaces flush with the outer surfaces of the base 1. The central post 3 is vertically arranged in the middle of the base 1. A winding groove 31 is symmetrically provided on the left and right sides of the central post 3, and the winding groove 31 is arc-shaped. A groove 21 is symmetrically provided on the outer surfaces of the two side posts 2, and the groove 21 is arc-shaped.

[0030] This invention is based on an E-type magnetic core. By setting an arc-shaped groove 21 on the outer side of the side post 2 and opening an arc-shaped winding groove 31 on the left and right sides of the central post 3, the magnetic circuit symmetry is optimized, the magnetic field is guided to distribute along the curved surface, the local magnetic field concentration is reduced, and leakage magnetic field is reduced. If the groove 21 is opened on the inner side of the side post, it will cause an increase in leakage magnetic field. Moreover, unlike the traditional E-type magnetic core, which has a large cross-sectional area and therefore significant eddy current loss, this solution opens an arc-shaped groove 21 and an arc-shaped winding groove 31 on the E-type magnetic core. By replacing a single air gap with multiple arc-shaped air gaps, the air gap distribution is more uniform, the magnetic field energy is dispersed, high-frequency eddy current loss is reduced, the magnetic flux density distribution is optimized, and the high-frequency skin effect is suppressed. The arc-shaped groove 21 and the arc-shaped winding groove 31 can transfer the mechanical stress of the E-type magnetic core from the right-angle edge to the arc surface, improving its impact resistance and vibration resistance. The arc-shaped winding groove 31 can provide a smooth winding path, release more window area, reduce wire bending stress, improve winding density and uniformity, reduce leakage inductance, and increase the overall surface area of ​​the magnetic core. Combined with more window space, this can improve heat dissipation efficiency and make it suitable for high-temperature and high-power-density applications.

[0031] like Figure 3 As shown, to balance the requirements of magnetic flux density and winding space, the width ratio between the central post 3 and the side post 2 is 2:1. The slot width w2 of the winding groove 31 is half the height h2 of the central post 3. The lower end of the slot opening of the winding groove 31 is located at the base 1, and the upper end of the slot opening of the winding groove 31 is located at half the height h2 of the central post 3. The slot width w1 of the groove 21 is greater than the slot width w2 of the winding groove 31, and the slot width w1 of the groove 21 is less than the height h1 of the side post 2. The lower end of the slot opening of the groove 21 is located at the base 1, thereby optimizing the winding path and reducing wire damage.

[0032] The radius of the arc of the groove 21 is not less than half the thickness of the magnetic core; the radius of the arc of the winding groove 31 is equal to the radius of the arc of the groove 21, thereby ensuring process consistency and magnetic circuit symmetry.

[0033] The upper and lower ends of the groove 21 are respectively connected to the side arc transition of the side post 2, and the upper and lower ends of the winding groove 31 are respectively connected to the side arc transition of the middle post 3, thereby further optimizing the winding path and reducing wire damage.

[0034] In this invention, the arc-shaped high-frequency E-type magnetic core is integrally sintered from nickel-based ferrite. Compared to ordinary ferrite, nickel-based ferrite can significantly improve the magnetic permeability of the core, reduce losses, and increase high-temperature stability. The nickel-based ferrite mentioned here includes, but is not limited to, nickel-zinc ferrite.

[0035] Example 1:

[0036] In this embodiment, the arc-shaped high-frequency E-type magnetic core is integrally sintered from nickel-zinc ferrite, with the following specific parameters: the overall thickness of the magnetic core is 10mm; the length L0 of the base 1 is 55mm, and the height w0 of the base 1 is 10mm; the height h1 of the side post 2 is 14mm, the length L1 of the side post 2 is 10mm, the groove width w1 of the groove 21 is 9mm, and the arc radius of the groove 21 is 10mm; the height h2 of the middle post 3 is 14mm, the length L2 of the middle post 3 is 20mm, the groove width w2 of the winding groove 31 is 7mm, and the arc radius of the winding groove 31 is 10mm.

[0037] Comparative Example 1:

[0038] The only difference between the E-type magnetic core in this comparative example and the arc-shaped high-frequency E-type magnetic core in Example 1 is that the E-type magnetic core in this comparative example does not have the winding groove 31 and the recess 21.

[0039] The performance of the magnetic cores in Example 1 and Comparative Example 1 was tested. Each magnetic core provided in Example 1 and Comparative Example 1 was wound with 10 turns and tested under the conditions of a 200kHz LLC resonant topology, an input voltage of 400VDC, and an output power of 1kW. The test results are shown in Table 1 below:

[0040] Table 1: Performance test results of the magnetic cores provided in Example 1 and Comparative Example 1:

[0041] Total loss (W) 17.2 21.7 Temperature rise (°C) 32 48 Coupling efficiency (%) 98.5 93.2 Leakage inductance (μH) 10.03 12.6

[0042] As shown in Table 1 above, under the same number of winding turns, compared with the traditional E-type magnetic core of Comparative Example 1, the arc-shaped high-frequency E-type magnetic core provided in this embodiment 1 has a 20% reduction in total loss, a 16°C reduction in temperature rise, a 33% improvement in heat dissipation efficiency, a 5% improvement in coupling efficiency, and a 20% reduction in leakage inductance. It is superior to the traditional E-type magnetic core in terms of total loss, temperature rise, coupling efficiency, and leakage inductance, and is suitable for high-frequency transformer scenarios.

[0043] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention without departing from the principles and spirit of the present invention.

Claims

1. An arc-shaped high-frequency E-type magnetic core for a high-frequency transformer, arranged in an E-shape, comprising a base (1), two side posts (2) and a central post (3), wherein the two side posts (2) are vertically arranged on the left and right sides of the base (1) respectively, and the central post (3) is vertically arranged in the middle of the base (1), characterized in that, The left and right sides of the central column (3) are respectively provided with a winding groove (31), which is arc-shaped. The outer sides of the two side columns (2) are respectively provided with a groove (21), which is arc-shaped.

2. The arc-shaped high-frequency E-type magnetic core for high-frequency transformers according to claim 1, characterized in that, The width ratio between the central column (3) and the side column (2) is 2:

1.

3. The arc-shaped high-frequency E-type magnetic core for a high-frequency transformer according to claim 1, characterized in that, The slot width w2 of the winding groove (31) is 1 / 2 of the height h2 of the central column (3).

4. The arc-shaped high-frequency E-type magnetic core for a high-frequency transformer according to claim 3, characterized in that, The lower end of the opening of the winding groove (31) is located at the base (1), and the upper end of the opening of the winding groove (31) is located at 1 / 2 of the height h2 of the central column (3).

5. The arc-shaped high-frequency E-type magnetic core for a high-frequency transformer according to claim 1, characterized in that, The groove width w1 of the groove (21) is greater than the groove width w2 of the winding groove (31), and the groove width w1 of the groove (21) is less than the height h1 of the side post (2).

6. The arc-shaped high-frequency E-type magnetic core for a high-frequency transformer according to claim 5, characterized in that, The lower end of the groove (21) is located at the base (1).

7. The arc-shaped high-frequency E-type magnetic core for a high-frequency transformer according to claim 1, characterized in that, The radius of the arc of the groove (21) is not less than half the thickness of the magnetic core; the radius of the arc of the winding groove (31) is equal to the radius of the arc of the groove (21).

8. The arc-shaped high-frequency E-type magnetic core for a high-frequency transformer according to claim 1, characterized in that, The upper and lower ends of the groove (21) are respectively connected to the side arc transition of the side column (2), and the upper and lower ends of the winding groove (31) are respectively connected to the side arc transition of the middle column (3).

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