阅读说明：本技术 一种非晶磁性材料高频变压器铁芯及其制造方法 (Amorphous magnetic material high-frequency transformer iron core and manufacturing method thereof ) 是由 沈军 魏宇 余得贵 谢顺德 于 2021-05-26 设计创作，主要内容包括：本发明涉及高频变压器技术领域,尤其涉及一种非晶磁性材料高频变压器铁芯及其制造方法。非晶磁性材料高频变压器铁芯包括多个相同的非晶磁性材料片,所述非晶磁性材料片堆叠成非晶磁性材料块,相邻两张所述的非晶磁性材料片的接触面上涂覆有热固性树脂组合物。制造过程包括带材剪切、铁芯成型、加热固化、切割、研磨、成型等工序,本发明提供的非晶磁性材料高频变压器铁芯一方面能提高应用于10kHz-200kHz的高频变压器的工作磁通密度,显著提高高频变压器的功率密度,且有利于设备小型化,另一方面非晶材料有比铁氧体更好的韧性,在运输和使用过程中不易损坏,提高设备的可靠性。(The invention relates to the technical field of high-frequency transformers, in particular to an amorphous magnetic material high-frequency transformer iron core and a manufacturing method thereof. The amorphous magnetic material high-frequency transformer iron core comprises a plurality of same amorphous magnetic material sheets, the amorphous magnetic material sheets are stacked into amorphous magnetic material blocks, and the contact surfaces of two adjacent amorphous magnetic material sheets are coated with thermosetting resin compositions. The manufacturing process comprises the working procedures of strip shearing, iron core forming, heating and curing, cutting, grinding, forming and the like, on one hand, the amorphous magnetic material high-frequency transformer iron core provided by the invention can improve the working magnetic flux density of a high-frequency transformer applied to 10kHz-200kHz, obviously improve the power density of the high-frequency transformer and is beneficial to equipment miniaturization, on the other hand, the amorphous material has better toughness than ferrite, is not easy to damage in the transportation and use processes and improves the reliability of equipment.)

1. The amorphous magnetic material high-frequency transformer core is characterized by comprising a plurality of same amorphous magnetic material sheets, wherein the amorphous magnetic material sheets are stacked into amorphous magnetic material blocks, and the contact surfaces of two adjacent amorphous magnetic material sheets are coated with thermosetting resin compositions.

2. The amorphous magnetic material high-frequency transformer core according to claim 1, wherein the amorphous magnetic material block is composed of 2E-type amorphous magnetic material blocks, the E-type amorphous magnetic material block includes a smooth portion and a concavo-convex portion, and the concavo-convex portion includes a convex portion and concave portions provided on both sides of the convex portion.

3. The amorphous magnetic material high-frequency transformer core as claimed in claim 1, wherein the blocks of E-shaped amorphous magnetic material are fitted together through end faces of the convex portions.

4. The amorphous magnetic material high-frequency transformer core as claimed in claim 1, wherein the stacking thickness of the amorphous magnetic material sheets is 600-2000 sheets.

5. The amorphous magnetic material high-frequency transformer core according to claim 1, wherein the thermosetting resin composition comprises bisphenol a type epoxy resin, butyl glycidyl ether, 3-aminopropyltriethoxysilane, and diethyltetramethylimidazole.

6. The method for manufacturing a high-frequency transformer core of amorphous magnetic material according to any one of claims 1 to 5, comprising the steps of:

firstly, transversely cutting an amorphous strip into a single amorphous material sheet;

secondly, stacking single amorphous material sheets in order, and pressing thermosetting resin into gaps among the single amorphous material sheets by a vacuum impregnation technology; heating and curing the amorphous material into an amorphous material block;

thirdly, cutting the amorphous material block into an E-shaped iron core by adopting a linear cutting method;

fourthly, grinding the end face of the convex part of the E-shaped iron core;

and fifthly, matching the two ground E-shaped iron cores together through the end surfaces of the convex parts to form the high-frequency transformer iron core.

7. The manufacturing method according to claim 6, wherein the wire-cut filament has a diameter of 180 μm and a cutting speed of 100mm²/min。

8. The manufacturing method according to claim 6, wherein the roughness after polishing the end face of the convex portion is Ra <5 μm.

9. Use of the amorphous magnetic material high frequency transformer core according to any one of claims 1 to 5 in a high frequency transformer.

10. A high frequency transformer comprising the amorphous magnetic material high frequency transformer core as claimed in any one of claims 1 to 4, wherein the frequency of said high frequency transformer is 10kHz to 200 kHz.

Technical Field

The invention relates to the technical field of high-frequency transformers, in particular to an amorphous magnetic material high-frequency transformer iron core and a manufacturing method thereof.

Background

The amorphous soft magnetic alloy has excellent soft magnetic performance due to the characteristic of short-range ordered and long-range disordered microstructure. The amorphous soft magnetic alloy strip is an amorphous alloy material with the largest global production and application scale at present, and is widely applied to industries such as power frequency transformers, mutual inductors, motors and the like. The rotor unmanned aerial vehicle has good market application prospect in the fields of distribution transformers, rotor unmanned aerial vehicles and the like.

The existing high-frequency transformer generally adopts ferrite magnetic materials, and the ferrite has the main advantage that the resistivity is far greater than that of a metal magnetic material, so that the generation of eddy current is inhibited by the characteristic, and the ferrite can be applied to the high-frequency field; the ceramic technology is easy to be made into various shapes and sizes; stable chemical property and no rust; lower manufacturing cost. The main disadvantages of soft ferrite cores are their brittle and fragile texture and their low saturation flux density. When the magnetic flux is applied to a high-frequency power supply of 10kHz-200kHz, the saturation magnetic flux density is low, and the volume specific power density is low, so that the miniaturization of equipment is not facilitated. The high-frequency transformer made of ferrite materials is easy to damage in transportation due to the characteristics of crisp texture and frangibility, a better protective material needs to be used for devices, and the use cost is improved.

The high-power switching power supply generally adopts IGBT as a power device, is limited by the prior art, and has the frequency of 5kHz-40kHz when working in a hard switching mode and the frequency of 40kHz-150kHz when working in a soft switching mode; power ranges from a few kilowatts to hundreds of kilowatts.

When the ferrite is applied to a high-frequency power supply of 1kHz-200kHz, the saturation magnetic flux density is low, and the volume specific power density is low, so that the ferrite is not beneficial to the miniaturization of equipment. The high-frequency transformer made of ferrite materials is easy to damage in transportation due to the characteristics of crisp texture and frangibility, a better protective material needs to be used for devices, and the use cost is improved.

The amorphous soft magnetic alloy has higher saturation magnetic density and much lower specific loss than silicon steel. In terms of saturation magnetic density, the saturation magnetic density of the iron-based amorphous soft magnetic alloy is generally above 1.56T, and the saturation magnetic density of the ferrite is generally not more than 0.5T. In terms of specific loss, the P10/400Hz of the iron-based amorphous soft magnetic alloy is 1.5W/kg, and the P10/400Hz of the 0.2mm non-oriented silicon steel sheet is 11W/kg. Therefore, the amorphous soft magnetic alloy has the characteristics of high saturation magnetic density and low loss. The method is very suitable for being applied to high-frequency transformers.

Disclosure of Invention

In view of the above technical problems, an object of the present invention is to provide an amorphous magnetic material high frequency transformer core, which can be used for a switching power supply with a working frequency up to a range of 10kHz to 200 kHz.

In order to achieve the purpose, the invention adopts the technical scheme that:

the invention provides an amorphous magnetic material high-frequency transformer iron core which comprises a plurality of same amorphous magnetic material sheets, wherein the amorphous magnetic material sheets are stacked into amorphous magnetic material blocks, and the contact surfaces of two adjacent amorphous magnetic material sheets are coated with thermosetting resin compositions.

In the technical scheme of the invention, the amorphous magnetic material block is composed of 2E-type amorphous magnetic material blocks, each E-type amorphous magnetic material block comprises a smooth part and a concave-convex part, and each concave-convex part comprises a convex part and concave parts arranged on two sides of the convex part.

In the technical scheme of the invention, the E-type amorphous magnetic material blocks are matched together through the end faces of the convex parts.

In the technical scheme of the invention, the stacking thickness of the amorphous magnetic material sheet is 600-2000 sheets.

In an embodiment of the present invention, the thermosetting resin composition comprises bisphenol a epoxy resin, butyl glycidyl ether, 3-aminopropyltriethoxysilane, and diethyltetramethylimidazole.

The second aspect of the present invention provides a method for manufacturing the amorphous magnetic material high-frequency transformer core, including the following steps:

firstly, transversely cutting an iron-based amorphous strip into a single amorphous material sheet;

secondly, stacking single amorphous material sheets in order, and pressing thermosetting resin into gaps among the single amorphous material sheets through a vacuum impregnation technology; heating and curing the mixture into an amorphous material block;

thirdly, cutting the amorphous material block into an E-shaped iron core by adopting a linear cutting method;

fourthly, grinding the cross section of the convex part of the E-shaped iron core;

and fifthly, matching the two ground E-shaped iron cores together through the end surfaces of the convex parts to form the high-frequency transformer iron core.

In the technical scheme of the invention, the diameter of the wire-electrode cutting wire is 180 mu m, and the cutting speed is 100mm 2/min.

In the invention, the roughness of the end face of the projection after polishing is Ra <5 μm.

The third aspect of the invention provides the application of the amorphous magnetic material high-frequency transformer iron core in a high-frequency transformer.

The fourth aspect of the invention provides a high-frequency transformer, which comprises the amorphous magnetic material high-frequency transformer iron core, wherein the frequency of the high-frequency transformer is 10kHz to 200 kHz.

The technical scheme has the following advantages or beneficial effects:

the invention provides an amorphous magnetic material high-frequency transformer iron core, a manufacturing method thereof and a transformer comprising the iron core. The manufacturing process comprises the working procedures of strip shearing, iron core forming, heating and curing, cutting, grinding, forming and the like, on one hand, the amorphous magnetic material high-frequency transformer iron core provided by the invention can improve the working magnetic flux density of a high-frequency transformer applied to 10kHz-200kHz, obviously improve the power density of the high-frequency transformer and is beneficial to equipment miniaturization, on the other hand, the amorphous material has better toughness than ferrite, is not easy to damage in the transportation and use processes and improves the reliability of equipment.

Drawings

FIG. 1 is a graph comparing the saturation magnetic densities of amorphous materials and ferrites.

Fig. 2 is a flow chart of a manufacturing process of the amorphous magnetic material high-frequency transformer core in example 1.

Fig. 3 is a schematic structural view and a bottom view of the block of amorphous magnetic material in example 1.

FIG. 4 is a diagram of a method for testing the performance of the amorphous magnetic material high-frequency transformer in example 1.

Detailed Description

The following examples are only a part of the present invention, and not all of them. Thus, the detailed description of the embodiments of the present invention provided below is not intended to limit the scope of the invention as claimed, but is merely representative of selected embodiments of the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments of the invention without making creative efforts, belong to the protection scope of the invention.

Example 1:

an amorphous strip with the original width of 142mm is transversely cut into square single amorphous material sheets with the length of 142 mm. The cut 600-2000 single amorphous strips are laminated together, and the thermosetting resin is pressed into the gaps among the single amorphous strips through a vacuum impregnation technology.

The thermosetting resin consists of the following components: 84 parts of bisphenol A epoxy resin, 12 parts of butyl glycidyl ether, 1 part of 3-aminopropyltriethoxysilane and 3 parts of diethyl tetramethylimidazole; bisphenol A epoxy resin, butyl glycidyl ether and 3-aminopropyltriethoxysilane are mixed and stirred uniformly, diethyl tetramethyl imidazole is heated to 50 ℃, and the mixture is stirred uniformly and defoamed in vacuum.

The amorphous material block is cut into an E-shaped iron core by wire cutting, as shown in fig. 3, wherein 1 is a concave-convex portion, 2 is a smooth portion, 3 is a convex portion, 4 is a concave portion, the diameter of the wire-cut molybdenum wire is 180um, and the cutting speed is 100mm 2/min.

Grinding the end face of the convex part 2 of the E-shaped iron core by a grinding machine until Ra is less than 5um, wherein the linear velocity of a grinding wheel of the grinding machine is 20-30m/s, and the mesh number of the grinding wheel is 600-1200 meshes.

The iron core is fixed with an upper E-shaped iron core and a lower E-shaped iron core through an adhesive tape or a steel belt to manufacture a transformer, and the performance of the transformer is tested when the maximum magnetic density is 1T under different frequencies, and the results are shown in Table 1.

TABLE 1

As can be seen from table 1, the core loss value and the excitation power of the amorphous transformer core high-frequency transformer provided by the present invention are much smaller than those of the common silicon steel at different high frequencies, so that the amorphous transformer core high-frequency transformer can be applied to high-frequency transformers.

The test method is shown in fig. 4, during the measurement process, the respective deviation of the output end voltage and the frequency of the alternating current power supply should exceed the set value by plus or minus 0.2%, and the accuracy of the frequency meter is plus or minus 0.1% or better. The variable frequency power supply should be coupled to a power analyzer with an accuracy of + -1.0% or better to measure the magnetizing current. In order to obtain comparable measurements, it is necessary to keep the secondary voltage sinusoidal. The secondary voltage waveform can be observed by an oscilloscope. The form factor of the secondary voltage can be determined by a power analyzer connected to the secondary winding. The power analyzer can directly calculate the form factor. And calculating the total loss and the reactive power under the maximum magnetic field density through a power analyzer, and comparing the total loss and the reactive power with a standard value to determine the performance of the transformer.

The above description is only for the preferred embodiment of the present invention and is not intended to limit the scope of the present invention, and all equivalent modifications made by the contents of the present specification and the drawings, or applied directly or indirectly to other related technical fields, are included in the scope of the present invention.