Special-shaped magnetic core and manufacturing method therefor

Abstract

The present invention relates to the technical field of magnetic components. Provided are a special-shaped magnetic core and a manufacturing method therefor. The special-shaped magnetic core comprises a first magnetic core portion, a second magnetic core portion and a magnetic adhesive layer, wherein the magnetic adhesive layer is bonded between the first magnetic core portion and the second magnetic core portion, and the magnetic adhesive layer contains a plurality of magnetic powder particles, a resin adhesive matrix and at least one spherical particle; the maximum size of any one of the magnetic powder particles is less than the sphere diameter of a spherical particle; a first bonding surface of the first magnetic core portion and a second bonding surface of the second magnetic core portion respectively abut against two radially opposite ends of a spherical particle, so as to form a bonding gap between the first magnetic core portion and the second magnetic core portion; and the sphere diameter of the spherical particle ranges from 1 micron to 20 microns. The special-shaped magnetic core in the present invention has the advantages of a small volume, a high consistency, good magnetic properties and a low production cost, thereby improving the product quality and meeting product miniaturization requirements.

Description

Irregular magnetic cores and their manufacturing methods Technical Field

[0001] This invention relates to the field of magnetic components technology, and in particular to a non-standard magnetic core and a method for manufacturing the non-standard magnetic core. Background Technology

[0002] A magnetic core is an electromagnetic component that changes the current by manipulating the magnetic flux of a device under circuit conditions, thereby changing the output signal.

[0003] Most existing magnetic cores are irregularly shaped, such as those composed of irregular magnetic rods, sheets, or plates. There are two main manufacturing methods for these irregularly shaped cores: First, a special mold is used to integrally form the core. The structure of this mold is very complex, significantly increasing production costs. Furthermore, integral molding of irregularly shaped cores using this mold makes it difficult to ensure consistent density, leading to problems such as hidden cracks and delamination, which affect the magnetic properties. Second, the magnetic material is first pressed into regular magnetic rods, sheets, or plates, and then the corresponding irregular shape is machined. However, this method wastes a lot of magnetic material, and the waste generated during machining pollutes the environment. The manufacturing process is also more complex, significantly increasing production costs.

[0004] To reduce manufacturing costs and simplify production processes, another existing manufacturing method involves using magnetic adhesive to bond irregularly shaped magnetic rods, sheets, plates, and other components together to form irregularly shaped magnetic cores. Technical issues

[0005] However, existing methods for manufacturing irregularly shaped magnetic cores by bonding irregular magnetic rods, sheets, plates, and other components with magnetic adhesive result in inconsistent gaps at the bonding points. This leads to poor consistency in the produced irregularly shaped magnetic cores. Furthermore, the gaps at the bonding points of the irregularly shaped magnetic cores produced by this method are much larger than 50 μm (micrometers), which increases the size of the irregularly shaped magnetic cores, making it difficult to meet the requirements for product miniaturization and affecting the magnetic properties of the products. Solution

[0006] The primary objective of this invention is to provide a non-standard magnetic core that is small in size, has good consistency, good magnetic properties, and low production cost, so as to improve product quality and meet the requirements for product miniaturization.

[0007] A second objective of this invention is to provide a method for manufacturing the aforementioned irregular magnetic core.

[0008] To achieve the first objective of this invention, this invention provides a non-standard magnetic core, comprising a first magnetic core portion, a second magnetic core portion, and a magnetic adhesive layer. The magnetic adhesive layer is bonded between the first magnetic core portion and the second magnetic core portion. The magnetic adhesive layer contains multiple magnetic powder particles, a resin adhesive substrate, and at least one spherical particle. The maximum size of any magnetic powder particle is smaller than the diameter of the spherical particle. The first bonding surface of the first magnetic core portion and the second bonding surface of the second magnetic core portion respectively abut against the radially opposite ends of the spherical particle to form an adhesive bonding gap between the first magnetic core portion and the second magnetic core portion. The diameter of the spherical particle is between 1 micrometer and 20 micrometers.

[0009] A preferred embodiment is that the magnetic adhesive layer contains at least three spherical particles, which are arranged tangentially to the gaps in the adhesive assembly.

[0010] A further proposed approach is to have the total weight of magnetic powder particles in the magnetic adhesive layer account for between 1% and 95% of the total weight of the magnetic adhesive layer.

[0011] A further approach is to use magnetic powder particles with a maximum size between 0.1 micrometers and 1 micrometer.

[0012] A further approach is to use magnetic powder particles made from a soft magnetic material selected from alloys, amorphous materials, nanocrystalline materials, high-entropy alloys, and ferrites.

[0013] A further proposed approach is to use a magnetic adhesive layer with a viscosity between 10,000 and 100,000 centipoise.

[0014] A further proposed solution is that the density of the first magnetic core is greater than 6.8 g / cm³; and / or, the density of the second magnetic core is greater than 6.8 g / cm³.

[0015] A further proposed solution is to use spherical glass beads as the spherical particles.

[0016] To achieve the second objective of this invention, the present invention provides a method for manufacturing an irregularly shaped magnetic core, characterized in that the method for producing the aforementioned irregularly shaped magnetic core includes: applying magnetic adhesive to a first bonding surface of a first magnetic core portion; abutting a second bonding surface of a second magnetic core portion against the side of the magnetic adhesive away from the first magnetic core portion; controlling the first magnetic core portion and the second magnetic core portion to move toward each other in the normal direction of the first magnetic core portion while pressing against the magnetic adhesive, and controlling the first magnetic core portion and the second magnetic core portion to slide relative to each other in the tangential direction of the first magnetic core portion, such that the first bonding surface of the first magnetic core portion and the second bonding surface of the second magnetic core portion abut against the radially opposite ends of a spherical particle of magnetic adhesive water, thereby forming an adhesive combination gap between the first magnetic core portion and the second magnetic core portion; and the cured magnetic adhesive forming a magnetic adhesive layer bonded between the first magnetic core portion and the second magnetic core portion.

[0017] A further approach is to include the following method for manufacturing irregularly shaped magnetic cores: curing the magnetic adhesive using a temperature-controlled method, where the curing temperature is maintained between 40°C and 80°C. Beneficial effects

[0018] In this invention, the first and second magnetic core portions of the irregularly shaped magnetic core are bonded together by a magnetic adhesive layer. This magnetic adhesive layer comprises multiple magnetic powder particles, a resin substrate, and at least one spherical particle. The magnetic powder particles filling the adhesive layer give it superior magnetic properties. Furthermore, since the maximum size of any single magnetic powder particle in the adhesive layer is smaller than the diameter of a spherical particle, the first bonding surface of the first magnetic core portion and the second bonding surface of the second magnetic core portion abut against the radially opposite ends of the spherical particle, forming a bonding gap between the first and second magnetic core portions. Because the diameter of the spherical particle is between 1 micrometer and 20 micrometers, the bonding gap formed by the magnetic adhesive layer between the first and second magnetic core portions is ensured to be between 1 μm and 20 μm, effectively reducing the bonding gap. A smaller bonding gap results in lower permeability loss and reduces the volume of the irregularly shaped magnetic core, thus meeting the requirements for product miniaturization. Furthermore, the bonding gap between the first and second core portions of the irregularly shaped magnetic core of the present invention is stably limited by the spherical particles of the magnetic adhesive layer, resulting in good product consistency and thus improving product quality. In addition, the bonding between the first and second core portions of the irregularly shaped magnetic core of the present invention via a magnetic adhesive layer simplifies the manufacturing process, reduces material waste, thereby lowering production costs and shortening the production cycle.

[0019] Therefore, the irregular magnetic core of the present invention has the advantages of small size, good consistency, good magnetic properties and low production cost, thereby improving product quality and meeting the needs of product miniaturization. Attached Figure Description

[0020] Figure 1 is a cross-sectional view of an embodiment of the irregular magnetic core of the present invention.

[0021] Figure 2 is a structural diagram of an embodiment of the irregular magnetic core of the present invention.

[0022] Figure 3 is a schematic diagram of an embodiment of the irregular magnetic core of the present invention.

[0023] The present invention will be further described below with reference to the accompanying drawings and embodiments. Embodiments of the present invention

[0024] Example of irregular magnetic core:

[0025] Referring to Figures 1 to 3, this embodiment discloses an irregularly shaped magnetic core 10, including a first magnetic core portion 11, a second magnetic core portion 12, and a magnetic adhesive layer 13. The magnetic adhesive layer 13 is bonded between the first magnetic core portion 11 and the second magnetic core portion 12. Specifically, in this embodiment, the magnetic adhesive layer 13 comprises multiple magnetic powder particles 131, a resin adhesive substrate, and at least one spherical particle 132. The maximum size of any magnetic powder particle 131 is smaller than the diameter of the sphere of the spherical particle 132. The first bonding surface of the first magnetic core portion 11 and the second bonding surface of the second magnetic core portion 12 respectively abut against the radially opposite ends of the spherical particle 132 to form an adhesive bonding gap H between the first magnetic core portion 11 and the second magnetic core portion 12. Further, in this embodiment, the diameter of the spherical particle 132 is between 1 micrometer and 20 micrometers. Specifically, the first magnetic core portion 11 and the second magnetic core portion 12 can be irregular magnetic rods, magnetic sheets, magnetic plates, or other components.

[0026] In this embodiment, the first core portion 11 and the second core portion 12 of the irregular magnetic core 10 are bonded together by a magnetic adhesive layer 13. This magnetic adhesive layer 13 comprises multiple magnetic powder particles 131, a resin substrate, and at least one spherical particle 132. As can be seen, the magnetic adhesive layer 13 is filled with magnetic powder particles 131, giving it good magnetic properties. Since the maximum size of any magnetic powder particle 131 in this embodiment is smaller than the diameter of a spherical particle 132, the first bonding surface of the first core portion 11 and the second bonding surface of the second core portion 12 respectively abut against the radially opposite ends of a spherical particle 132 to form a bonding gap H between the first core portion 11 and the second core portion 12. Because the diameter of the spherical particle 132 in this embodiment is between 1 micrometer and 20 micrometers, this ensures that the bonding gap H formed by the magnetic adhesive layer 13 between the first core portion 11 and the second core portion 12 is between 1 μm (micrometer) and 20 μm. The adhesive layer 13 effectively reduces the bonding gap H between the first magnetic core portion 11 and the second magnetic core portion 12 formed by the adhesive layer 13, with a smaller bonding gap H resulting in lower permeability loss and a smaller volume of the irregularly shaped magnetic core 10, thus meeting the requirements for product miniaturization. Furthermore, in this embodiment, the bonding gap H between the first magnetic core portion 11 and the second magnetic core portion 12 of the irregularly shaped magnetic core 10 is stably limited by the spherical particles 132 of the adhesive layer 13, resulting in good product consistency and improved product quality. In addition, the adhesive layer 13 bonds the first magnetic core portion 11 and the second magnetic core portion 12 of the irregularly shaped magnetic core 10, simplifying the manufacturing process, reducing material waste, thereby lowering production costs and shortening the production cycle.

[0027] Therefore, the irregular magnetic core 10 in this embodiment has the advantages of small size, good consistency, good magnetic properties and low production cost, thereby improving product quality and meeting the requirements of product miniaturization.

[0028] To further improve product quality and consistency, the magnetic adhesive layer 13 in this embodiment includes at least three spherical particles 132. These spherical particles 132 are arranged tangentially to the bonding gap H, forming a support array of spherical particles 132 in the tangential direction of the bonding gap H. This array provides stable support between the first magnetic core portion 11 and the second magnetic core portion 12 in the normal direction of the bonding gap H, ensuring the stability of the bonding gap H between the first magnetic core portion 11 and the second magnetic core portion 12 of the irregularly shaped magnetic core 10. Specifically, the spherical particles 132 in this embodiment are spherical glass beads.

[0029] To further improve the magnetic properties, in this embodiment, the total weight of the magnetic powder particles 131 in the magnetic adhesive layer 13 accounts for between 1% and 95% of the total weight of the magnetic adhesive layer 13. Specifically, in this embodiment, the maximum size of the magnetic powder particles 131 is between 0.1 micrometers and 1 micrometer, making the magnetic powder particles 131 reach the submicrometer level, further improving the magnetic properties. Furthermore, in this embodiment, the magnetic powder particles 131 are made of a soft magnetic material selected from alloys, amorphous materials, nanocrystalline materials, high-entropy alloys, and ferrites.

[0030] To further improve the magnetic properties, the density of the first magnetic core 11 in this embodiment is greater than 6.8 g / cm³, and the density of the second magnetic core 12 in this embodiment is greater than 6.8 g / cm³.

[0031] In order to improve the bonding strength of the magnetic adhesive layer 13 and thus improve product quality, the viscosity of the magnetic adhesive layer 13 in this embodiment is between 10,000 centipoise and 100,000 centipoise.

[0032] The first magnetic core 11 and the second magnetic core 12 refer to magnetic objects with the highest density pressed from soft magnetic materials. The soft magnetic materials can be soft magnetic materials such as alloys, amorphous materials, nanocrystalline materials, high-entropy alloys, and ferrites. The outer contours of the first magnetic core 11 and the second magnetic core 12 can be any shape such as square, round, or rhomboid.

[0033] Furthermore, in this embodiment, the resin adhesive substrate of the magnetic adhesive layer 13 is preferably selected from resin adhesive materials with high bonding strength, corrosion resistance, and high temperature resistance.

[0034] Example of a method for fabricating irregularly shaped magnetic cores:

[0035] The method for manufacturing irregularly shaped magnetic cores in this embodiment is used to produce the products of the above-mentioned irregularly shaped magnetic cores 10 embodiments. The manufacturing method includes:

[0036] Apply magnetic adhesive to the first bonding surface of the first magnetic core 11;

[0037] The second adhesive surface of the second magnetic core 12 is placed against the side of the magnetic adhesive away from the first magnetic core 11;

[0038] By controlling the first magnetic core 11 and the second magnetic core 12 to move towards each other in the normal direction of the first magnetic core 11 and press against the magnetic adhesive, and by controlling the first magnetic core 11 and the second magnetic core 12 to slide relative to each other in the tangential direction of the first magnetic core 11, it is ensured that there are no more than two overlapping spherical particles 132 in the magnetic adhesive in the normal direction of the first magnetic core 11, and there are no magnetic powder particles 131 between the normal direction of the first magnetic core 11 and the bonding surface in the normal direction of the first magnetic core 11. This makes the first bonding surface of the first magnetic core 11 and the second bonding surface of the second magnetic core 12 respectively abut against the radially opposite ends of a spherical particle 132 of the magnetic adhesive, so as to form a bonding combination gap H between the first magnetic core 11 and the second magnetic core 12.

[0039] The cured magnetic adhesive forms a magnetic adhesive layer 13 bonded between the first magnetic core 11 and the second magnetic core 12.

[0040] Specifically, the first magnetic core 11 and the second magnetic core 12 can be irregular magnetic rods, magnetic sheets, magnetic plates, or other components.

[0041] In this embodiment, the method for manufacturing the irregular magnetic core involves bonding a first magnetic core portion 11 and a second magnetic core portion 12 together with magnetic adhesive. While the first and second magnetic core portions 11 and 12 are pressed against the magnetic adhesive in the normal direction of the first magnetic core portion 11 using a pressing machine, the pressing machine also controls the first and second magnetic core portions 11 to slide relative to each other in the tangential direction of the first magnetic core portion 11. This causes the first bonding surface of the first magnetic core portion 11 and the second bonding surface of the second magnetic core portion 12 to respectively abut against the radially opposite ends of a spherical particle 132 of the magnetic adhesive, forming a bonding gap H between the first and second magnetic core portions 11 and 12. The magnetic adhesive is then cured to form a magnetic adhesive layer 13 bonded between the first and second magnetic core portions 11 and 12. Because the diameter of the spherical particles 132 in the magnetic adhesive layer 13 is between 1 micrometer and 20 micrometers, the bonding gap H of the produced irregular magnetic core 10 is ensured to be between 1 μm (micrometer) and 20 μm. The bonding gap H between the micrometer (µm) and the magnetic core 10 is effectively reduced. A smaller bonding gap H results in lower magnetic permeability loss and a smaller volume of the shaped magnetic core 10, thus meeting the miniaturization requirements. Since the magnetic adhesive layer 13 in this embodiment is filled with magnetic powder particles 131, the magnetic adhesive layer 13 of the produced shaped magnetic core 10 has good magnetic properties. Furthermore, the bonding gap H between the first core portion 11 and the second core portion 12 of the shaped magnetic core 10 produced by the method of this embodiment is stably limited by the spherical particles 132 of the magnetic adhesive (which, after curing, becomes the magnetic adhesive layer 13), resulting in good product consistency and improved product quality. In addition, the method of producing the shaped magnetic core in this embodiment is simple and quick, effectively shortening the production cycle and reducing material waste, thereby reducing production costs.

[0042] To improve the curing stability of the magnetic adhesive (which cures into magnetic adhesive layer 13), the fabrication method of the irregular magnetic core in this embodiment further includes curing the magnetic adhesive using a temperature-stabilized method. This temperature-stabilized method maintains the curing temperature between 40°C and 80°C, thereby ensuring the stability of the bonding gap H between the first magnetic core portion 11 and the second magnetic core portion 12. Specifically, the temperature-stabilized method in this embodiment includes water baths, heating platforms, heating ovens, constant temperature rooms, and hot air blowing, which can achieve a stable temperature curing effect for the magnetic adhesive (which cures into magnetic adhesive layer 13).

[0043] Specifically, the "I"-shaped magnetic core manufactured by the irregular magnetic core manufacturing method of this embodiment includes a columnar first magnetic core portion 11 and two plate-shaped second magnetic core portions 12 located on both ends of the first magnetic core portion 11. Therefore, the irregular magnetic core manufacturing method includes:

[0044] First, a columnar first magnetic core 11 is pressed using iron-silicon-chromium alloy, and the density of the columnar first magnetic core 11 is greater than 6.8 g / cm³. Then, two plate-shaped second magnetic cores 12 are pressed using iron-silicon-chromium alloy, and the density of the plate-shaped second magnetic cores 12 is greater than 6.8 g / cm³. Finally, the pressed columnar first magnetic core 11 and plate-shaped second magnetic cores 12 are sintered.

[0045] Next, magnetic adhesive is applied to the bonding surfaces at both ends of the columnar first magnetic core 11. The magnetic adhesive contains multiple magnetic powder particles 131, a resin substrate, and at least one spherical particle 132. Preferably, the magnetic powder particles 131 are selected as 0.1-1 μm fine iron-silicon-chromium particles, the resin substrate is selected as modified high-temperature resistant epoxy resin, and the total weight of the magnetic powder particles 131 in the magnetic adhesive accounts for no less than 80% of the total weight of the magnetic adhesive.

[0046] Subsequently, the two plate-shaped second magnetic core portions 12 are controlled by a pressing machine to move and press against the magnetic adhesive at both ends in the direction normal to the first magnetic core portion 11. The pressing machine also controls the two plate-shaped second magnetic core portions 12 to slide relative to the columnar first magnetic core portion 11 in the tangential direction, ensuring that no more than two spherical particles 132 in the magnetic adhesive overlap in the direction normal to the first magnetic core portion 11, and that no magnetic powder particles 131 exist between the first magnetic core portion 11 and the bonding surface in the direction normal to the first magnetic core portion 11. This ensures that... A second adhesive surface of a plate-shaped second magnetic core portion 12 and a first adhesive surface on one side of a columnar first magnetic core portion 11 respectively abut against the radially opposite ends of a spherical particle 132 of magnetic adhesive water on one side, to form an adhesive combination gap H between the first magnetic core portion 11 and the second magnetic core portion 12, and such that the second adhesive surface of another plate-shaped second magnetic core portion 12 and the first adhesive surface on the other side of a columnar first magnetic core portion 11 respectively abut against the radially opposite ends of a spherical particle 132 of magnetic adhesive water on the other side, to form another adhesive combination gap H between the first magnetic core portion 11 and the second magnetic core portion 12;

[0047] Then, the magnetic adhesive is cured at a constant temperature. The cured magnetic adhesive forms a magnetic adhesive layer 13 bonded between the first magnetic core 11 and the second magnetic core 12, thereby assembling an "I"-shaped magnetic core. The bonding gap H of the "I"-shaped magnetic core is between 1 μm (micrometer) and 20 μm (micrometer), effectively reducing the bonding gap H of the irregular magnetic core 10 product. A smaller bonding gap H results in lower magnetic permeability loss and reduces the volume of the irregular magnetic core 10, thus meeting the miniaturization requirements. Furthermore, the core density and inductance of the "I"-shaped magnetic core product produced by the irregular magnetic core manufacturing method of this embodiment are comparable to those of the "I"-shaped magnetic core product produced by machining. Moreover, the core density and inductance of the "I"-shaped magnetic core product produced by the irregular magnetic core manufacturing method of this embodiment are about 7% higher than those of the "I"-shaped magnetic core product produced by mold-integrated molding, as shown in Table 1 below. Therefore, the I-shaped magnetic core products produced by the irregular magnetic core manufacturing method of this embodiment have good magnetic properties and good consistency. Moreover, the irregular magnetic core manufacturing method of this embodiment is simple and quick, effectively shortens the production cycle, and reduces material waste, thereby reducing production costs.

[0048] Table 1 Comparison of Effects

[0049]

[0050] The method for manufacturing irregular magnetic cores in this embodiment involves decomposing the irregular magnetic core 10 into multiple regularly shaped rods, sheets, or plates, which are then pressed separately to ensure that each decomposed irregular component has a consistent density and reaches the maximum density level. The pressed irregular components are then bonded together using submicron magnetic adhesive. By adding spherical particles 132 to the magnetic adhesive, the bonding gap H at the bonding joint is ensured to be between 1 μm (micrometer) and 20 μm (micrometer). This method produces irregular magnetic cores 10 that are small in size, have good consistency, good magnetic properties, and low production cost, thereby improving product quality, meeting the requirements for product miniaturization, and providing a simple and quick manufacturing method that effectively shortens the production cycle and reduces material waste, thus lowering production costs.

[0051] The above embodiments are merely preferred examples of the present invention and are not intended to limit the scope of the present invention. Therefore, all equivalent changes or modifications made to the structure, features and principles of the present invention in accordance with the claims of the present invention should be included in the scope of the present invention patent application. Industrial application

[0052] In this invention, the first and second magnetic core portions of the irregularly shaped magnetic core are bonded together by a magnetic adhesive layer. This magnetic adhesive layer comprises multiple magnetic powder particles, a resin substrate, and at least one spherical particle. The magnetic powder particles filling the adhesive layer give it superior magnetic properties. Furthermore, since the maximum size of any single magnetic powder particle in the adhesive layer is smaller than the diameter of a spherical particle, the first bonding surface of the first magnetic core portion and the second bonding surface of the second magnetic core portion abut against the radially opposite ends of the spherical particle, forming a bonding gap between the first and second magnetic core portions. Because the diameter of the spherical particle is between 1 micrometer and 20 micrometers, the bonding gap formed by the magnetic adhesive layer between the first and second magnetic core portions is ensured to be between 1 μm and 20 μm, effectively reducing the bonding gap. A smaller bonding gap results in lower permeability loss and reduces the volume of the irregularly shaped magnetic core, thus meeting the requirements for product miniaturization. Furthermore, the bonding gap between the first and second core portions of the irregularly shaped magnetic core of this invention is stably limited by the spherical particles of the magnetic adhesive layer, resulting in good product consistency and thus improving product quality. In addition, the bonding between the first and second core portions of the irregularly shaped magnetic core of this invention via a magnetic adhesive layer simplifies the manufacturing process, reduces material waste, thereby lowering production costs and shortening the production cycle. Therefore, the irregularly shaped magnetic core of this invention has advantages such as small size, good consistency, good magnetic properties, and low production cost, thereby improving product quality and meeting the requirements for product miniaturization.

[0053] Meanwhile, the method for manufacturing irregular magnetic cores of the present invention uses magnetic adhesive to bond the first magnetic core portion and the second magnetic core portion. While controlling the first magnetic core portion and the second magnetic core portion to move towards each other in the normal direction of the first magnetic core portion and press against the magnetic adhesive, the first magnetic core portion and the second magnetic core portion are controlled to slide relative to each other in the tangential direction of the first magnetic core portion. This allows the first bonding surface of the first magnetic core portion and the second bonding surface of the second magnetic core portion to abut against the radially opposite ends of a spherical particle of the magnetic adhesive water, thereby forming a bonding gap between the first magnetic core portion and the second magnetic core portion. After that, the magnetic adhesive is cured to form a magnetic adhesive layer bonded between the first magnetic core portion and the second magnetic core portion. Since the diameter of the spherical particle of the magnetic adhesive layer is between 1 micrometer and 20 micrometers, the bonding gap H of the produced irregular magnetic core is ensured to be between 1 μm (micrometer) and 20 μm (micrometer), effectively reducing the bonding gap of the irregular magnetic core product. A small bonding gap results in low magnetic permeability loss and can reduce the volume of the irregular magnetic core, thereby meeting the requirements for product miniaturization. Because the magnetic adhesive layer of this invention is filled with magnetic powder particles, the magnetic adhesive layer of the produced irregularly shaped magnetic core has good magnetic properties. Furthermore, the bonding gap between the first and second magnetic core parts of the irregularly shaped magnetic core product produced by the method of this invention is stably limited by the spherical particles of the magnetic adhesive (which, after curing, forms a magnetic adhesive layer), resulting in good product consistency and improved product quality. In addition, the industrial manufacturing method of the irregularly shaped magnetic core of this invention is simple and quick, effectively shortening the production cycle for industrial applications and reducing material waste, thereby lowering the production cost for industrial applications.

Claims

1. An irregularly shaped magnetic core, comprising a first magnetic core portion, a second magnetic core portion, and a magnetic adhesive layer, wherein the magnetic adhesive layer is bonded between the first magnetic core portion and the second magnetic core portion, characterized in that: The magnetic adhesive layer comprises multiple magnetic powder particles, a resin adhesive substrate, and at least one spherical particle. The maximum size of any one of the magnetic powder particles is smaller than the diameter of the sphere of the spherical particle. The first bonding surface of the first magnetic core and the second bonding surface of the second magnetic core respectively abut against the radially opposite ends of the spherical particle to form a bonding gap between the first magnetic core and the second magnetic core. The diameter of the spherical particles is between 1 micrometer and 20 micrometers.

2. The irregularly shaped magnetic core according to claim 1, characterized in that: The magnetic adhesive layer contains at least three of the spherical particles, and the plurality of the spherical particles are arranged in the tangential direction of the gap in the adhesive assembly.

3. The irregular magnetic core according to claim 1 or 2, characterized in that: The total weight of the magnetic powder particles in the magnetic adhesive layer accounts for between 1% and 95% of the total weight of the magnetic adhesive layer.

4. The irregularly shaped magnetic core according to any one of claims 1 to 3, characterized in that: The maximum size of the magnetic powder particles is between 0.1 micrometers and 1 micrometer.

5. The irregularly shaped magnetic core according to any one of claims 1 to 4, characterized in that: The magnetic powder particles are made of a soft magnetic material selected from alloys, amorphous materials, nanocrystalline materials, high-entropy alloys, and ferrites.

6. The irregularly shaped magnetic core according to any one of claims 1 to 5, characterized in that: The viscosity of the magnetic adhesive layer is between 10,000 centipoise and 100,000 centipoise.

7. The irregularly shaped magnetic core according to any one of claims 1 to 6, characterized in that: The density of the first magnetic core is greater than 6.8 g / cm³; And / or, the density of the second magnetic core portion is greater than 6.8 g / cm³.

8. The irregularly shaped magnetic core according to any one of claims 1 to 7, characterized in that: The spherical particles are spherical glass beads.

9. A method for manufacturing irregularly shaped magnetic cores, characterized in that, For producing the irregular magnetic core according to any one of claims 1 to 8, comprising: Apply magnetic adhesive to the first bonding surface of the first magnetic core; The second adhesive surface of the second magnetic core is placed against the side of the magnetic adhesive away from the first magnetic core. The first magnetic core and the second magnetic core are controlled to move toward each other in the normal direction of the first magnetic core and press against the magnetic adhesive, and the first magnetic core and the second magnetic core are controlled to slide relative to each other in the tangential direction of the first magnetic core, so that the first adhesive surface of the first magnetic core and the second adhesive surface of the second magnetic core respectively abut against the radially opposite ends of a spherical particle of the magnetic adhesive water to form an adhesive combination gap between the first magnetic core and the second magnetic core; The cured magnetic adhesive forms a magnetic adhesive layer that bonds between the first magnetic core and the second magnetic core.

10. The method for manufacturing an irregularly shaped magnetic core according to claim 9, characterized in that: The method for manufacturing the irregular magnetic core further includes: curing the magnetic adhesive by means of a temperature stabilization method, wherein the temperature stabilization method maintains the curing temperature between 40°C and 80°C.

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