WO2007133399A2 - Ensembles électromagnétiques, segments de noyaux formant de tels ensembles, et leurs procédés de fabrication - Google Patents

Ensembles électromagnétiques, segments de noyaux formant de tels ensembles, et leurs procédés de fabrication Download PDF

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Publication number
WO2007133399A2
WO2007133399A2 PCT/US2007/009904 US2007009904W WO2007133399A2 WO 2007133399 A2 WO2007133399 A2 WO 2007133399A2 US 2007009904 W US2007009904 W US 2007009904W WO 2007133399 A2 WO2007133399 A2 WO 2007133399A2
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Prior art keywords
segment
magnetic core
interlocking
assembly
core assembly
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Ceased
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PCT/US2007/009904
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WO2007133399A3 (fr
Inventor
Joseph F. Huth, Iii
Lowell M. Bosley
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Spang and Co
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Spang and Co
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Priority claimed from US11/430,446 external-priority patent/US20070262839A1/en
Priority claimed from US11/430,409 external-priority patent/US20070261231A1/en
Application filed by Spang and Co filed Critical Spang and Co
Publication of WO2007133399A2 publication Critical patent/WO2007133399A2/fr
Publication of WO2007133399A3 publication Critical patent/WO2007133399A3/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00—Cores, Yokes, or armatures
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00—Cores, Yokes, or armatures
    • H01F3/08—Cores, Yokes, or armatures made from powder

Definitions

  • the invention relates to electromagnetic assemblies, core segments that form the same, and their methods of manufacture.
  • Soft magnetic cores made from ceramic materials such as Mn-Zn ferrite, Ni-Zn ferrite, and other soft magnetic ferrite compositions, and from powdered metallic alloys such as Fe, Fe-Al-Si, Fe-Co, Fe-Co-V, Fe-Mn, Fe-P, Fe- Si, Ni-Fe 1 Ni-Fe-Mo, and other soft magnetic alloys, have been commercially available for decades. More recently, amorphous and nanocrystalline soft magnetic alloys made by a variety of rapid solidification techniques and reduced to powder form by atomization or comminution are becoming commercially available. Single-piece cores such as ring cores (toroids) are available in sizes up to about 150 mm diameter.
  • a 1000-ton press used to compact a powder requiring 150 tsi (2068 MPa) pressure will be limited to a pressing area of 6.67 square inches (43.03 cm 2 ) (i.e., 1000 tons divided by 150 tsi (2068 MPa)). Pressing areas greater than 6.67 square inches (43.03 cm 2 ) will result in lower pressures and degraded core performance.
  • one commercially acceptable soft magnetic core formed with 150 tsi (2068 MPa) pressing area is a toroid of approximately 3.36" (8.53 cm) outside diameter (OD) and 1.68" (4.27 cm) inside diameter (ID), a 2:1 ratio of OD to ID being a common proportion for toroids.
  • a typical powder compacting die to produce this part will consist of a cylindrical die cavity; a center core rod (a solid cylinder) positioned parallel to the axis of the cylindrical opening, and in the center of the opening thus creating an annular cavity; a bottom punch with an annular cross section that closely fits the die cavity; and a top punch with the same annular cross section as the bottom punch.
  • These four pieces of tooling are held in proper alignment by attachment to a common structure, known as a tool set, and the tool set is provided with external attachment points to fit into an appropriate compacting press.
  • the tool set allows the top and bottom punches to move longitudinally within the die cavity and also allows the top punch to travel vertically out of engagement with the die so the empty cavity is exposed and powder can be introduced into the cavity for each pressing cycle.
  • the top punch re-enters the annular cavity and compresses the powder into a solid form. Therefore, to determine the maximum core size that can be produced on a press, one divides the maximum force the press can generate by the cross section of the annular face of the top punch.
  • mated pairs of cores are commonly used, with an E-shaped configuration being typical.
  • Other cores used in mated pairs can be shaped to correspond to the letters U, I and C.
  • E, U, I and C cores are open-ended and as such usually require mating with another core, open end-to-open end, to create a closed magnetic pathway.
  • E-to-E, E-to-l, U-to-U, U-to-l, C-to-C and C-to-l core pairings are also common.
  • an open-ended E, U 1 I or C core used by itself as a magnetic device would also be limited to the same dimensional limits as the mated pairs described above, since each core half, whether used as a mated pair or not, is pressed individually.
  • reducing the pressing pressure to 40 tsi (552 MPa) a typical pressing pressure for more ductile materials such as powdered iron, and continuing to use a 1000-ton press provides a maximum single piece toroid size of about 6.50 inches (16.51 cm) OD and 3.25 inches (8.26cm) ID.
  • a laminar gap that cannot be reduced to zero; known in the trade as a "stacking factor.”
  • a typical stacking factor for a core made from 0.0005" (0.0013 cm) thick ribbon is 60%. Accordingly, a core must be substantially larger than the arithmetic sum of the thicknesses of the wraps, leading magnetic cores that can be up to 50% larger for any given power output.
  • Tape wound cores are also limited to certain metal alloys whose ductility permits fabrication into ribbon form by rolling, or that can be cast to final gauge thickness directly. Ceramic magnetic materials cannot be formed into ribbons, and, thus, cannot be used in tape-wound configurations.
  • Equation 1 the change in effective permeability for a typical inductor material (60 permeability) and a typical transformer material (2500 permeability) are shown in Figures 1 and 2.
  • low permeability material In inductor applications, low permeability material is required. Low permeability materials are created by taking the powder form of soft magnetic metal alloys and coating the particles with a non-magnetic coating. In effect, this creates a large number of very small air gaps between particles after the powder is compressed into a desired shape. Cores selected for inductor applications usually have a permeability of 300 or less. For example, many inductors use 60- perm material, and this material has its effective permeability reduced by nearly 8% if the sum total of all air gaps, created by the glue line thickness, around the magnetic path length is as little as 0.5mm. Following the teachings of International Publication WO 2005/041221 A1 will naturally lead to the introduction of multiple air gaps.
  • inductor cores show a guaranteed inductance value of, typically, +/-8% to +/-12% of nominal values.
  • Magnetics a division of Spang & Company, Pittsburgh, PA 1 discloses +/-8% tolerances for their molypermalloy (Fe-Ni-Mo) and High Flux (Fe-Ni) alloys, and +/-12% for their Kool Mu ® (Fe-Al-Si) 60-perm materials.
  • ferrite In transformer applications where high inductance is required, materials such as ferrite are chosen due to their relatively high permeability ranging from about 500 to about 20,000.
  • the permeability of a material directly affects the inductance of a core assembly, as described in Equation 2, where L is the inductance of the core (in Henries), N is the number of turns of wire on the core, ⁇ 0 is the permeability of the material, A 0 is the effective cross section of the core, and l e is the effective magnetic flux path length in the core.
  • Japanese Publication No. 04-165607 is said to teach improved manufacturing efficiency by adhering segments together in overlapping layers to form larger, useful magnetic assemblies.
  • the teachings of this reference are similar to WO 2005/041221 A1 , and discuss how segments are used as building blocks.
  • Japanese Publication No. 04-165607 teach only simple shapes that have no means of establishing registration between segments, and no means to control inductance of the final assembly. Air gaps created by glue lines that interrupt the magnetic path length are uncontrolled and will lead to an undesirably high degree of variation in inductance from assembly to assembly. Similar teachings are offered in Japanese Publication Nos. 61-071612 and 59-178716, where magnetic materials in strip form are laminated into larger assemblies.
  • a magnetic core segment comprising a first interlocking member configured to form an interlocking portion with a second interlocking member of a second magnetic core segment.
  • a magnetic core assembly comprising a first segment and a second segment, at least a portion of the first segment configured to form an interlocking portion with at least a portion of the second segment.
  • a stacked magnetic core assembly comprising first and second magnetic cores assemblies, the first and second magnetic core assemblies each further comprising an inter-layer interlocking member configured to form an inter-layer interlocking portion therebetween.
  • a method of forming a magnetic core segment comprising forming a magnetic core segment comprising an interlocking member thereon, the interlocking member configured to form an interlocking portion with a second interlocking member of a second magnetic core segment.
  • a method of forming a segmented magnetic core assembly comprising: contacting a first segment to a second segment, the first segment having an interlocking member configured to form an interlocking portion with a second interlocking member of the second magnetic core segment; and interlocking the first segment to the second segment to form the segmented magnetic core assembly.
  • a method of forming a stacked magnetic core assembly comprising: placing a first magnetic core assembly over a second magnetic core assembly, the first and second magnetic core assemblies each comprising an inter-layer interlocking member configured to form an inter-layer interlocking portion therebetween.
  • a method of forming a segmented magnetic core assembly comprising selecting individual interlocking segments based on a selected size and shape of the assembly.
  • Figure 1 is a graph that illustrates the change in effective permeability with the change in the gap between segments, where the initial permeability of each segment is 60, and represents a typical material used in high power inductor applications;
  • Figure 2 is a graph that illustrates the change in effective permeability with the change in the gap between segments, where the initial permeability of each segment is 2500, and represents a typical material used in high power transformer applications;
  • Figure 3 illustrates the improvement in magnetic core loss achieved by pressing core segments to higher pressures
  • Figure 4 illustrates the improvement in core strength with higher pressing force
  • Figure 5 illustrates the effect of pressing force on the final permeability of the core
  • Figure 6 illustrates the improvement in compacted core density with increased pressing force
  • Figures 7-7E are plan views that illustrate embodiments of the invention, wherein interlocking segments using certain primary shapes form a wide variety of larger, more complex assemblies;
  • Figure 8 is a perspective view that illustrates a powder compaction die that may be employed to form the segments shown in Figures 7-7E;
  • Figure 9 is a perspective view that illustrates additional interlocking designs of the invention in the form of toroid assemblies;
  • Figures 10A- 10C are plan views that illustrate adhesive bonding of segments while eliminating glue line thickness variations
  • Figures 11A and 11B are perspective views that illustrates interlocking engagement between segments that can be applied in both radial and circumferential symmetries
  • Figures 12A and 12B are perspective views that illustrate alternative embodiments of the invention with enhanced segment interlocking engagement
  • Figures 13A-13C are plan views that illustrate various assembly configurations, such as oval and triangular shaped toroids, and alternate interlocking geometries;
  • Figures 14A-14C are perspective views that illustrate one method of inserting a pre-wound bobbin onto partially-formed assemblies of the invention
  • Figures 15A and 15B are perspective views that illustrate alternative embodiments of the invention that encompass layer-to-layer interlocking assemblies;
  • Figure 16 illustrates a series of perspective views of large E-cores having round center legs that employ embodiments of the invention
  • Figure 17 illustrate a series (1-5) of perspective views of large core assemblies that employ embodiments of the invention.
  • Figure 18 illustrates a high power inductor design, and provides comparative data listing key parameters of an inductor that employs a conventional stack of toroid cores versus an embodiment of the invention.
  • each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding the fact that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Furthermore, when numerical ranges of varying scope are set forth herein, it is contemplated that any combination of these values inclusive of the recited values may be used.
  • any numerical range recited herein is intended to include all sub-ranges subsumed therein.
  • a range of “1 to 10" is intended to include all sub-ranges between (and including) the recited minimum value of 1 and the recited maximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value of equal to or less than 10.
  • the terms "one,” “a,” or “an” as used herein are intended to include “at least one” or “one or more,” unless otherwise indicated.
  • the terms “registration” or “interlocking engagement” refer to the association between a first and second magnetic core assembly segment, wherein at least a portion of the first segment comprises a first member, such as, for example, a protrusion, complementary to a second member, such as, for example, an indention, of the second segment, such that when the first segment engages the second segment to form an interlocking portion, motion of the first segment relative to the second segment is at least partially constrained when a force is applied.
  • the terms “interlocking portion” or “interlocking interface” refer to the contact region wherein adjacent interlocking members, such as a protrusion and corresponding indentation, are joined.
  • protrusion refers to the portion of a segment that projects beyond what would otherwise be a flat or blunt surface of the segment.
  • indentation 1 refers to the portion of the segment that is recessed from what would otherwise be a flat or blunt surface of the segment.
  • unstacked refers to single-tiered or single-layered magnetic core assemblies, in contrast to “stacked” assemblies having portions of the assembly that overlap or overlay other portions to form regions that are multi-tiered or multi-layered.
  • the invention is directed to electromagnetic cores assemblies, core segments for those assemblies, and their methods of manufacture.
  • the assemblies may be, for example, inductor and transformer cores made for high power applications.
  • Such assemblies can be held together by physically restraining the segments relative to one another by using straps, bands, clamps, pre-forms, molds and other physical devices; or by bonding segments together using a compatible adhesive, paint or other conformal coating.
  • surfaces, such as the proximal surfaces, and some embodiments ends, of the abutting segments may be formed or contoured to provide interlocking engagement therebetween that corresponds to substantially accurate meshing or mating of the segments while substantially eliminating potential variability in inductance caused by inconsistent glue line thickness.
  • the invention provides a soft magnetic core segment comprising a first interlocking member configured to form an interlocking portion with a second interlocking member of a second magnetic core segment.
  • the invention provides a magnetic core assembly comprising a first segment and a second segment, at least a portion of the first segment configured to form an interlocking portion with at least a portion of the second segment.
  • the invention also provides stacked magnetic core assemblies comprising at least one segmented magnetic core assembly as described herein.
  • the segments may be formed into the desired shape by compacting soft magnetic powders at pressures ranging up to 150 tons per square inch into shapes being selected from a family of geometries that all possess commonality in terms of providing mechanical registration of the segments with respect to one another in an assembly.
  • the registration may be uniform, predictable, repeatable and unaffected by operator methodology during assembly of the segments.
  • the resultant assemblies provide sufficient strength to withstand the rigors of being wound with heavy conductors when used as high power components in power supplies, power factor correction circuits, and other circuitry where large magnetic cores are advantageous.
  • methods of forming the magnetic core segments of the invention include forming the magnetic core segment comprising an interlocking member, the interlocking member configured to form an interlocking portion with a second interlocking member of a second magnetic core segment.
  • the invention provides a method of forming a segmented magnetic core, comprising: contacting a first segment to a second segment, the first segment having an interlocking member configured to form an interlocking portion with a second interlocking member of the second magnetic core segment; and interlocking the first segment to the second segment to form the segmented magnetic core.
  • Embodiments of the invention also provide methods of forming a stacked magnetic core assembly, comprising placing a first magnetic core assembly over a second magnetic core assembly, the first and second magnetic core assemblies each comprising an inter-layer interlocking member configured to form an inter-layer interlocking portion therebetween.
  • the segments of the invention may be made from any suitable soft magnetic materials known to those of ordinary skill in the art for compaction and sintering to develop desired magnetic properties. Suitable examples include ferrite powders, such as Ni-Zn or Mn-Zn ferrite powders, and combinations thereof. It is also contemplated that the segments may be made from a variety of insulated soft magnetic metal alloy powders, the powders being formed into a desired shape and further processed to enhance magnetic properties.
  • suitable metal alloy powders include, for example, Fe, Fe-Al-Si, Fe-Co, Fe-Co- V, Fe-Mn, Fe-P, Fe-Si, Ni-Fe, Ni-Fe-Mo, and combinations thereof, as well as amorphous and nanocrystalline alloys of various well known chemistries. Accordingly, one of ordinary skill in the art will recognize that the segments and assemblies of the embodiments set forth herein may be formed of any soft magnetic materials that can be compacted from powders that exhibit useful properties in a wide range of electromagnetic circuits.
  • embodiments of the invention may employ a wide variety of commercially available soft magnetic materials, such as those made from insulated metal alloy powders, as well as pressed and sintered ceramic soft magnetic materials, such as ferrites, and combinations thereof, and should not be construed as being limited to the type of materials employed.
  • segment 1 comprising interlocking portion 1a may be used in a variety of orientations or patterns in interlocking engagement to form magnetic core assemblies 10, such as those illustrated in Figures 7A, 7B, and 7C.
  • additional assemblies such as those illustrated in Figures 7D and 7E, can be formed.
  • the segments 1, 2 may be any suitable cross sectional configuration, such as, for example, square or rectangular, or any shape that lends itself to easily maintaining substantially complete surface-to-surface contact at the intersections of segments.
  • each adjacent segment 1 may comprise a first interlocking member 1a configured to form an interlocking portion 3, identified as the contact region wherein a adjacent segments, such as segment 1 , having interlocking members, such as interlocking member 1a, are joined.
  • Interlocking members 1a may comprise a protrusion and/or a corresponding indentation, as illustrated, such that when adjacent segments 1 are joined, the protrusion and indentation form the interlocking portion 3.
  • any number of protrusions and indentations may be employed in any configuration or pattern (e.g. linear, diagonal, diamond-shaped, and the like) to form the interlocking portion 3.
  • the interlocking members 1a, 2a may have any cross sectional configuration to promote for efficient meshing between an adjacent segment.
  • the protrusion and the indentation may each have a matching or mating cross-sectional configuration, such as, for example, a stepped-pyramidal, a square, a rectangular, a trapezoidal, triangular or conical, or arcuate cross section, and the like, or any combination thereof can be used.
  • a stepped-pyramidal such as, for example, a stepped-pyramidal, a square, a rectangular, a trapezoidal, triangular or conical, or arcuate cross section, and the like, or any combination thereof can be used.
  • additional interlocking configurations other than those illustrated herein may also be employed.
  • other assembly configurations other than those illustrated may be employed.
  • embodiments of the invention that employ the configuration set forth in Figures 7A-7E allow both segment shapes to be pressed using a single compacting die by repositioning some tooling components. This commonality reduces the overall cost of the powder compaction dies. This arrangement offers the additional benefit of reducing tooling costs by allowing one tool to press segments that can form a multitude of assembled shapes.
  • Figure 8 illustrates this tool design concept. By relocating the die inserts, 4, and by using one or more of these inserts 4, several usable shapes, such as segments 1, 2 may be formed. For clarity, the top and bottom punches are not shown in Figure 8.
  • segments having more complex profiles may be formed using dies and inserts having appropriate configurations, as will be appreciated by one of ordinary skill in the art.
  • These more complex profiles may require dies with independently-controlled and adjustable punches, as well as presses that incorporate a more sophisticated series of movements that can be properly timed to create compacted cores with the proper shape and density.
  • Manufacturers of these advanced press types include Dorst America, Inc, Bethlehem PA 1 Osterwalder Inc., Cincinnati, OH, Gasbarre Products, Inc., DuBois, PA, and the like.
  • segments of the invention may be made in a range of sizes, or any number of pieces-per- assembly. From an economic and practical standpoint, one of ordinary skill in the art will recognize that large assemblies can be made from two or more segments. Assemblies composed of a numerous segments may pose alignment and boding difficulties, but for various reasons may be desirable. In certain non-limiting embodiments, for example, it may be desirable to limit the number of segments to about 6, however, in certain embodiments using intricate or extremely large assemblies, higher numbers of segments may be desirable.
  • Figure 9 illustrates embodiments of the invention directed to curved segments 6, and illustrates several methods of achieving registration and a degree of interlocking of the segments 6 to form completed assembly 15.
  • a ring core, or toroid, assembly may be made from two or more separate segments 6, such as, for example, four separate segments, as illustrated. Assemblies with as few as two segments are contemplated.
  • the number of segments per assembly may be at least two, with a maximum that is essentially unlimited.
  • Various considerations, such as practical and economic factors for assembly may affect the number of segments chosen for certain embodiments of the invention.
  • each segment 6 may have, for example, at least one protrusion, such as convex protrusion 8, and at least one indention, such as concave indention 12 that may extend a portion or across the entirety of the segment end, as illustrated, that are designed to provide interlocking engagement between adjoining segments 6 and mesh accurately.
  • Various other configurations such as, for example, a V-shaped or triangular ridge or protrusion 14 and notch 16 orientation, as illustrated, may also be employed.
  • assemblies 15 may have segments with both ends having either a convex or concave cross sectional configuration (i.e.
  • Figures 10A 1 10B, and 10C illustrate additional embodiments of the invention comprising interlocking portions 3 having various profiles that may be engineered to provide segment-to-segment contact along portions of the interfaces 18.
  • the segments may be restrained in a desired or selected shape and size by various mechanisms, such as, for example, by a peripheral restraint, such as, for example, by a band, a strap, a tape, or a clamp.
  • the interlocking portion 3 may be configured to include at least one gap portion 20 to receive a bonding material for attachment, such as an adhesive.
  • the combination of a peripheral restraint and a bonding adhesive may also be employed.
  • Various bonding materials known to those of ordinary skill in the art may be employed.
  • bonding materials include one or two-part epoxies, polyurethanes, polyesters, polyimides, silicones, cyanoacrylates, acrylics, ceramics, curable rubbers, solders, hot melt glues, light-cured adhesives, low melting point glasses, and the like, and combinations thereof.
  • the gap portion 20 may be, for example, an internal cavities, as shown in Figure 10A, or open- ended gaps as shown in Figure 10B, and may be purposefully created to leave room for adhesive even when the segments 19, 21 are in contact with one another.
  • the volume of cured adhesive may be no more than the interstitial volume between segments 19, 21.
  • cross sectional profiles of the protrusion 8 and the indention 12 may include, for example, a stepped pyramid 22, a concave/convex orientation 24 (either over a portion of the surface, as shown in Figure 10A, or over substantially the entirety of the surface, as shown in Figure 10B), and a triangular orientation 26.
  • a stepped pyramid 22 a concave/convex orientation 24 (either over a portion of the surface, as shown in Figure 10A, or over substantially the entirety of the surface, as shown in Figure 10B), and a triangular orientation 26.
  • the use of profiles as shown in Figure 10B, where contact between segments occurs in substantially the center portion of the protrusion and indention, or in substantially the center of the segment width allows any small amount of distortion or misalignment 28 to be accommodated while still providing segment-to-segment contact as shown in Figure 10C.
  • protrusion and indentation arrangements include, for example, a sinusoidal or a saw-tooth arrangement. Other configurations will be well know to those of ordinary skill in the art reading the present disclosure.
  • Figures 11A and 11B illustrate embodiments of the invention wherein the interlocking features on the distal ends of the segments 30, 34 may have either a radial orientation 32 or a circumferential orientation 36. Although various reasons may be present to employ either interlocking engagement 32, 36, those segments with horizontally-oriented profiles 32 may find applicability where a stronger adhesive bond may be required. In addition, those of ordinary skill in the art will recognize that a combination of radial 32 and circumferential 36 interlocking engagements may be employed.
  • Figures 12A and 12B illustrate additional non-limiting embodiments of the invention, and show other variations on the interlocking engagement at the interlocking portion 3 between segments 38, 50, respectively, with these embodiments offering the advantage of registering the segments 38, 50 more securely in the circumferential direction and making relatively effective and efficient engagement between the segments 38, 50 that form assembly 45.
  • the first segment 38 may comprise at least one ridge portion 40 and at least one notch portion 42
  • the second adjacent segment may comprise at least one corresponding ridge portion 40 and at least one notch portion 42 to form a key-type locking engagement.
  • this design also permits inclusion of an interstitial gap portion 20, for retention of a glue line without also creating variation in the spacing between segments 38, 50.
  • the volume of the interstitial gap can be calculated and the proper amount of adhesive can be metered onto one or both faces of the interlocking portions prior to assembly. By controlling the location and amount of adhesive precisely, one can avoid “squeeze-out” or overflow as the segments are brought into full contact.
  • adhesive dispensers are commercially available, one example being the dispensers offered by EFD Dispensing Systems, Inc., East Buffalo, Rl.
  • Figure 12A illustrates the interlocking features with similar orientation, described above, and is an embodiment that requires an even number of segments in order to form a completed assembly 45.
  • Figure 12B illustrates interlocking features in opposition, allowing for either an even or odd number of segments 50 per assembly 45.
  • Figures 13-13C illustrate additional non-limiting embodiments of the invention and provide assemblies 55 wherein a magnetic core combines substantially straight segments 52 and arcuate or curved segments 54, and may employ registered and interlocked ends, as discussed hereinabove.
  • Figure 13A illustrates assembly of a toroid from four substantially equal curved segments 54. By introducing two straight segments 52, positioned as illustrated, an oval toroid assembly 55 may be assembled.
  • Figure 13B illustrates a toroid assembled from three substantially equal arc or curved segments 56. By interspersing or alternating straight segments 58 between each curved segment 56, a triangular-shaped toroid assembly 57 may be formed. Other configurations such as a round-cornered square or a round cornered rectangle may also be formed.
  • interlocking ends of the segments can employ various interlocking portions 3 that vary in profile while still providing the advantages taught in this invention.
  • Figure 14 illustrates a non-limiting assembly procedure employing an oval-shaped toroid 55 (as illustrated in Figure 13A) and a wire coil 59 that illustrates certain advantages that may be obtained by the invention.
  • the toroid 55 may be partially assembled employing straight segments 52 and curved segments 54.
  • a bonding material such as glue, may be applied to interlocking interfaces a in the area of the interstitial gap, as shown in Figure 14A to at least partially restrain the partially completed assembly.
  • glue is not applied to interfaces b at this stage. All segments 52, 54 of the assembly 55 may be held in position and at least partially restrained during the cure of the adhesive to provide proper alignment.
  • Suitable restraining members include peripheral restraints, such as a band, a strap, a tape, or a clamp.
  • the cured segments may then be separated at interface b, and the wire coil 59 may be placed over one of the open ends, as shown in Figure 14B.
  • the wire coil 59 may be, for example, a pre-wound bobbin, as illustrated, or a self- supporting wire coil pre-form.
  • the balance or remainder of the segments may be re-positioned to complete the core assembly 55 and adhesive may be applied to interface b and cured, as shown in Figure 14C, to form the final assembly.
  • all segments 52, 54 may be glued at once after the wire coil 59 is inserted onto the core.
  • embodiments of the invention allow pre-formed coils of wire, such as a pre-wound bobbin, to be inserted onto the semi-assembled segments prior to completed assembly, and thereby reduce the costs normally associated with winding toroids.
  • This is in contrast to conventional toroids, where wire must be wound directly onto the core using specialized winding equipment such as that manufactured by Gorman Machine Corp., Brockton, MA 1 or Jovil Manufacturing Co.. Danbury, CT. Circuit designers most often choose toroid cores for inductor applications, however one drawback of using them is the extra cost associated with applying the winding.
  • a toroid winding machine requires pre- winding the proper length of wire onto a spool before it is transferred to the core, making it slower than the bobbin winding process used with mated cores such as E-E, E-I, U-U, U-I, C-C and C-I configurations.
  • Embodiments of the invention that employ segmented assemblies allow pre-wound wire to be placed over various segments without the need for special winding processes.
  • Figures 15A and 15B illustrate additional embodiments of the invention wherein both intra-layer and inter-layer (i.e. stacked) registration of the segments may be formed, and wherein a stacked magnetic core assembly 60, comprising first core assembly 63 and second magnetic core assembly 65 each comprise an inter-layer interlocking member 62, 64 configured to form an interlocking portion therebetween.
  • a stacked magnetic core assembly 60 comprising first core assembly 63 and second magnetic core assembly 65 each comprise an inter-layer interlocking member 62, 64 configured to form an interlocking portion therebetween.
  • ring cores 63, 65 formed from curved segments are illustrated, it is contemplated that any suitably shaped electromagnetic assembly or magnetic core may be employed.
  • the stacked magnetic core assembly 60 may have segmented cores, as illustrated and described herein, solid, unsegmented cores, or a combination of both segmented an unsegmented cores.
  • Embodiments that employ segmented cores can be used to enlarge the final core assembly even further should the application require it. Careful design and placement of registration profiles make alignment between layers easy to achieve and does so in a repeatable and consistent manner. As illustrated, these profiles may be concave and convex shapes that nest together when stacked.
  • one or more convex protrusions may be pressed onto individual segments that form the magnetic core 65 (or on one face of an unsegmented magnetic core (not shown)) during formation.
  • Mating concave protrusions such as recessed hemispherical curvatures (not shown) may be pressed onto individual segments that form the adjacent magnetic core 63 (or on the opposite face of an unsegmented magnetic core (not shown)) such that the concave protrusions are, for example, aligned directly under the convex protrusions 62 to form an interlocking portion when interlocking engagement between magnetic cores 63, 65 is desired.
  • both faces of the magnetic cores may have protrusions or indentations, or some combination of both, for receipt of magnetic cores on each face thereof.
  • Figure 15B illustrates a second embodiment whereby the protrusions and indentation profiles are illustrated as convex grooves 64 and concave grooves 66, respectively, with, for example, a trapezoidal cross section.
  • the grooves 64, 66 may be positioned in any manner that provides suitable interlocking engagement, such as being formed in a radial orientation, as illustrated. Meshing and registration of segments within a layer is accomplished with the use of various profiles 68, described in detail herein, and illustrated in Figures 9-13.
  • careful placement of the profiles along the top and bottom faces of the segments allow spacing between profiles within each segment 70 that may be equal to the spacing between profiles on adjacent segments 72 that allow the layers to be stacked either directly on top of one another or to overlap those of the layer above and beneath, as illustrated.
  • overlapping segments in this way, additional strength of the assembly can be achieved by the inherently greater interfacial surface on which to apply adhesive. Any variation in glue line thickness in this plane will not affect permeability or other properties of the assembly. This is because the magnetic flux created in the wound and energized core is parallel to the circumference of the assembly. Magnetic flux is not impeded by air gaps that are parallel to it.
  • the stacked segmented magnetic core assembly 60 allows a wire coil, such as a pre-wound bobbin (not shown) to be placed over at least one of a first segment of the magnetic core 65 and a second segment of the magnetic core 63.
  • Figure 16 illustrates an additional embodiments of the invention that combine segments with different cross sectional geometries, and demonstrates the flexibility of the invention to produce a wide variety of complex core assemblies.
  • the general configuration of the assembly in this figure is an E-core with a round center leg 76.
  • the invention can be applied to this shape as shown in the four examples in Figure 16.
  • Example 1 illustrates a 2-segment assembly 100.
  • the U-shape portion 78 that creates the base and two outer legs may be pressed as a single piece separate from the round center leg 76. Interlocking profiles as described above may be pressed into each segment 76, 78, to form the two-piece assembly 100.
  • Example 2 illustrates a 4-piece assembly 110 wherein the base 80 may be separate from each of the outer legs 82 and center leg 76.
  • each piece would require less pressing force due to its smaller pressing area.
  • each of the pieces in Example 2 could be larger, and the resulting assembly 110 would be larger.
  • Examples 3 and 4 illustrate the same progression as Examples 1 and 2, respectively, with a modified base assembly made in two pieces rather than one.
  • Embodiments 120, 130 illustrated in Examples 3 and 4 may extend the size range of the final assembled cores even further than either Examples 1 or 2.
  • Figure 17 illustrates additional embodiments of the invention employing a round leg 76.
  • a round leg 76 such as a center leg as illustrated in Embodiments 1, 2, and 3, instead of a square or rectangular one, is often preferred in high-power applications.
  • the overall efficiency of the wound and assembled unit is affected by the hysteresis, eddy current and residual losses associated with the magnetic material, as well as the resistive losses of the copper windings. Resistance of any conductor increases as its length increases.
  • Example 1 provides a configuration similar to the embodiment illustrated in Example 2 of Figure 16, but with a slightly varied interlocking profile (a single V-shaped triangular profile instead of two stepped pyramid profiles) of the segments.
  • Example 2 provides a configuration similar to Example 1 , but with curved outer legs 84.
  • Example 3 illustrates a center leg 76 that is smaller in diameter than the width of the outer legs. This example illustrates additional design flexibility in assembling segments.
  • Example 3 provides additional electromagnetic shielding of the wire coil, which aids in reducing fringing flux and stray electromagnetic interference.
  • Examples 4 and 5 illustrate round legs 76 that are positioned on an outside portion of the assembly, either in combination with a flat leg, as shown in Example 4, or in combination with a second round leg 76, as shown in Example 5 to create U-shaped core assemblies.
  • Examples 4 and 5 illustrate embodiments of the invention that can be applied to other common core configurations currently available in smaller, single- piece shapes from a variety of manufacturers.
  • the segments of embodiments of the invention may form assemblies that may be useful in a wide range of applications and configurations that employ large, economical cores such as, for example, in switching power supplies, flyback transformers, power factor correction circuits, high power transformers and high power inductors such as inductors for inverters, inductors for solar energy power conversion, inductors for wind energy power conversion, inductors for fuel cell power conversion, inductors for transportation power conversion applications, such as train traction and electric/hybrid vehicles.
  • large, economical cores such as, for example, in switching power supplies, flyback transformers, power factor correction circuits, high power transformers and high power inductors such as inductors for inverters, inductors for solar energy power conversion, inductors for wind energy power conversion, inductors for fuel cell power conversion, inductors for transportation power conversion applications, such as train traction and electric/hybrid vehicles.
  • Figure 18 compares a high power inductor design using a segmented core 86 of the invention with a conventional stack of commercially available toroid cores 88.
  • the sample power inductor design compares a soft magnetic core assembled from segments as described herein with that made from a conventional core made from a stack of smaller toroids.
  • the formulas used to calculate the values are well known to those skilled in the art of inductor design and are not shown in the figure.
  • significant differences in properties, such as the winding area, conductor size. DC copper loss and current density, are shown between the unitary magnetic core assembly of the invention versus the stacked magnetic core in the Figure 18.
  • both core assemblies are made from a 26-perm sendust (Fe-Al-Si) alloy.
  • Both cores have essentially identical volumes of magnetic material (136 cm 3 , 138 cm 3 ) and, therefore, the same energy storage capability when used as an inductor.
  • the physical dimensions of the assemblies are used to calculate the effective core area (A 6 ), magnetic path length (l e ) and core volume (V ⁇ ) according to industry accepted standards published by the International Electrotechnical Commission, Geneva, Switzerland, publication IEC- 205. Inserting these values into Equation 2, the inductance of each assembly is calculated and expressed in terms of nanohenries-per-turns-squared (nH/N 2 ).
  • winding factor The ratio of the cross section of the windings to the winding area of the core is known as the "winding factor,” and a typical winding factor is between 20% and 60%. When multiple strands of wire are wound together, the winding factor is closer to the lower end of this range since keeping the strands parallel and closely aligned is difficult.
  • the winding factor for the stacked toroids in this example is 33% and will prove to be a tight fit.
  • embodiments of the invention require 14 turns of wire, each turn made of 10 strands of #10 AWG wire.
  • the larger Winding Area results in a window fill that is half that of the toroid.
  • the winding factor for this example is 19% and can be easily accomplished.
  • the 14 turns of wire can be pre-wound onto a bobbin pre-form and slid over one of the segments during assembly. Using more strands of wire, the Current Density is much lower in the segmented core than in the toroid stack (190 amps/cm ⁇ s. 480 amps/cm 2 ).
  • the Wire Length per Turn is shorter in the segmented core (16 cm vs. 30 cm) and therefore the DC Copper Loss is less than half of the toroid stack (7.3 watts vs. 15 watts).
  • Embodiments of the invention set forth herein provide designs of magnetic core segments that provides accurate registration of each segment within an assembly.
  • the registration can be both circumferential as well as inter- laminar.
  • the interlocking members can take many profiles, the interlocking portion between the segments can be engineered to provide both interlocking engagement and at least one gap portion for receipt of a bonding material, such as an adhesive.
  • the interlocking members provides the added benefit of restricting adhesive to certain areas of the abutting segment ends so as to provide the necessary strength of the final assembly.
  • the interlocking portions can provide direct segment-to-segment contact in areas adjacent to the cavities so that the adhesive thickness does not affect the inductance of the final assembly.
  • the assembly provides improved uniformity in inductance from assembly to assembly.
  • the assembly can take many forms, including forms that combine different and individual segment cross sections together and form more complex assemblies.
  • the individual interlocking segments may be selected based on a desired or selected size and shape of the assembly.
  • Complex assemblies have the additional benefit of incorporating round cross section segments with rectilinear segments so as to reduce winding losses when the assembly is used in high power applications.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Soft Magnetic Materials (AREA)
  • Coils Or Transformers For Communication (AREA)

Abstract

La présente invention concernent des ensembles électromagnétiques, des segments de noyaux formant de tels ensembles, et leurs procédés de fabrication. Les segments comprennent un engagement de verrouillage, permettant la production d'une variété d'ensembles à partir d'un très petit nombre de segments identiques ou complémentaires d'une manière qui assure une excellente stabilité mécanique. Les articles et procédés de formation permettent une flexibilité de conception et fournissent une grande variété de modèles à partir d'un petit nombre d'ébauches primaires, assurant un procédé de fabrication économique pour des noyaux de transformateur et d'inducteur de grande dimension, et améliorent l'uniformité des propriétés magnétiques des ensembles par rapport aux procédés classiques.
PCT/US2007/009904 2006-05-09 2007-04-23 Ensembles électromagnétiques, segments de noyaux formant de tels ensembles, et leurs procédés de fabrication Ceased WO2007133399A2 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US11/430,446 US20070262839A1 (en) 2006-05-09 2006-05-09 Electromagnetic assemblies, core segments that form the same, and their methods of manufacture
US11/430,409 US20070261231A1 (en) 2006-05-09 2006-05-09 Methods of manufacturing and assembling electromagnetic assemblies and core segments that form the same
US11/430,446 2006-05-09
US11/430,409 2006-05-09

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WO2007133399A2 true WO2007133399A2 (fr) 2007-11-22
WO2007133399A3 WO2007133399A3 (fr) 2008-01-17

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WO2009053534A1 (fr) * 2007-10-24 2009-04-30 Salomaeki Jarkko Procédure de fabrication d'un noyau magnétique et noyau magnétique
WO2009138101A1 (fr) * 2008-05-13 2009-11-19 Abb Technology Ag Noyau toroïdal modulaire
WO2019092014A1 (fr) * 2017-11-10 2019-05-16 Abb Schweiz Ag Transformateur pour l'utilisation dans un véhicule ferroviaire
WO2019097095A1 (fr) * 2017-11-16 2019-05-23 Sp Control Technologies, S.L. Procédé implémenté par ordinateur pour générer un modèle numérique de représentation d'un noyau magnétique pour élément à induction magnétique
CN113470956A (zh) * 2021-06-04 2021-10-01 罗延平 一种正反斜角法对软磁铁氧体烧结前排胶处理装置
CN120594510A (zh) * 2025-06-04 2025-09-05 国家地质实验测试中心 一种黑色岩系Re含量快速准确测定方法

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KR101287355B1 (ko) * 2011-09-07 2013-07-18 (주)창성 연자성 금속 분말을 이용한 코어 제조용 엘립스 형태의 단위블록 및 이를 이용하여 제조된 분말 자성코어
KR20250177970A (ko) 2024-06-18 2025-12-26 신승목 항공드론의 전기모터 부품 연자성 고정자용 합금 조성물 및 이를 이용한 고정자 합금 제조방법

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Publication number Priority date Publication date Assignee Title
WO2009053534A1 (fr) * 2007-10-24 2009-04-30 Salomaeki Jarkko Procédure de fabrication d'un noyau magnétique et noyau magnétique
WO2009138101A1 (fr) * 2008-05-13 2009-11-19 Abb Technology Ag Noyau toroïdal modulaire
WO2019092014A1 (fr) * 2017-11-10 2019-05-16 Abb Schweiz Ag Transformateur pour l'utilisation dans un véhicule ferroviaire
US11984248B2 (en) 2017-11-10 2024-05-14 Hitachi Energy Ltd Transformer for use in a rail vehicle
WO2019097095A1 (fr) * 2017-11-16 2019-05-23 Sp Control Technologies, S.L. Procédé implémenté par ordinateur pour générer un modèle numérique de représentation d'un noyau magnétique pour élément à induction magnétique
CN113470956A (zh) * 2021-06-04 2021-10-01 罗延平 一种正反斜角法对软磁铁氧体烧结前排胶处理装置
CN113470956B (zh) * 2021-06-04 2023-06-30 海宁凌通磁业科技有限公司 一种正反斜角法对软磁铁氧体烧结前排胶处理装置
CN120594510A (zh) * 2025-06-04 2025-09-05 国家地质实验测试中心 一种黑色岩系Re含量快速准确测定方法

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