GB2138215A - Amorphous wound coil - Google Patents

Amorphous wound coil Download PDF

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Publication number
GB2138215A
GB2138215A GB08409566A GB8409566A GB2138215A GB 2138215 A GB2138215 A GB 2138215A GB 08409566 A GB08409566 A GB 08409566A GB 8409566 A GB8409566 A GB 8409566A GB 2138215 A GB2138215 A GB 2138215A
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United Kingdom
Prior art keywords
wound core
amorphous
gap
core
resin
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB08409566A
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GB2138215B (en
GB8409566D0 (en
Inventor
Yoshihito Yoshizawa
Kiyotaka Yamauchi
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Proterial Ltd
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Hitachi Metals Ltd
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Filing date
Publication date
Priority claimed from JP6493783A external-priority patent/JPS59189610A/en
Priority claimed from JP10561383A external-priority patent/JPS59231806A/en
Application filed by Hitachi Metals Ltd filed Critical Hitachi Metals Ltd
Publication of GB8409566D0 publication Critical patent/GB8409566D0/en
Publication of GB2138215A publication Critical patent/GB2138215A/en
Application granted granted Critical
Publication of GB2138215B publication Critical patent/GB2138215B/en
Expired legal-status Critical Current

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Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00Cores, Yokes, or armatures
    • H01F3/04Cores, Yokes, or armatures made from strips or ribbons
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F3/00Cores, Yokes, or armatures
    • H01F3/10Composite arrangements of magnetic circuits
    • H01F3/14Constrictions; Gaps, e.g. air-gaps

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Soft Magnetic Materials (AREA)
  • Manufacturing Cores, Coils, And Magnets (AREA)

Abstract

An amorphous wound core 1 for use in a normal-mode noise filter or an output smoothing device, comprises a gap 3. The wound core is impregnated with a resin such as an epoxy resin. The wound core has good DC current superimposition characteristics and high complex permeability. It may be produced by the steps of winding an amorphous alloy ribbon, heat-treating the resulting wound core, coating it with resin, providing a gap therein, placing a non-magnetic spacer in the gap, and coating the core surface with insulating resin. <IMAGE>

Description

SPECIFICATION Amorphous wound core Background of the invention (1) Field of the invention The present invention relates to an amorphous wound core with a gap which is suitable for normal-mode noise filtering and output smoothing.
62) Description of the prior art Because of recent development of electronic apparatuses, switching power supplies have been getting more and more widely used. As a result, output smoothing chokes and normal-mode noise filters have become widely used.
Choke magnetic cores are conventionally made of sintered ferrites, silicon steel ribbons, permalloy dust cores, etc. Recently, the use of amorphous magnetic cores for chokes has been proposed. Dust cores do not raise any problem of noise because of no gap, and are relatively good in frequency characteristics. They have, however, low permeability so that they are not necessarily satisfactory when used for chokes because of low impedance.
Ferrite cores have as low as about 5000 G of staturation magnetic flux density Bs, so gaps are needed to provide sufficient saturation magnetic field. This, however, lowers the apparent permeability of the cores, resulting in chokes with poor magnetic characteristics. In addition, ferrite cores are inferior to dust cores in frequency characteristics. Silicon steels suffer from large core loss.
Amorhous cores have higher saturation magnetic flux density Bs than that of ferrite cores. Amorphous cores are also advantageous over silicon steel cores in core loss, though the former has lower Bs than that of the latter.
Japanese patent Laid-Open Nos. 57-82454 and 57-83005 disclose wound cores made of an amorphous Fe-Ni-Si-B alloy and an amorphous Fe-Co-Si-B alloy, respectively. These amorphous wound cores, however, do not have any gap, so their permeabilities drop rapidly as a magnetic field increases. This tendency is not suitable where they are used for normal-mode noise filters and output smoothing devices.
Summary ofthe invention An object of the present invention is to provide an amorphous wound core useful for normal-mode noise filters and output smoothing devices, which has good direct current superimposition characteristics and good frequency characteristics of impedance.
Another object of the present invention is to provide such an amorphous wound core with excellent gap precision. An amorphous wound core according to the present invention comprises at least one gap.
The amorphous wound core is impregnated with a resin so that it may keep its shape and dimension after being provided with a gap. The gap may be filled with a non-magnetic spacer. The resin-impreganted wound core may be further coated with a non-conductive resin to insulate it from a conductive wire wound on the core.
Brief description of the drawings Figure lisa perspective view of an amorphous wound core according to one embodiment of the present invention; Figure 2 is a graph showing the relation between the cutting speed with a grinder and the thickness change of the amorphous wound core after being provided with a gap; Figure 3 is a graph showing the relations between the cutting speed with a grinder and the gap width of the amorphous wound core; Figure 4 is a graph showing the relations between the coating thickness and inductance of the amorphous wound core provided with a gap; Figure 5 is a graph showing complex permeabilities of magnetic cores varying depending on frequency; Figure 6 is a graph showing the absolute values of the magnetic cores' conplex permeabilities varying depending on frequency;; Figure 7 is a graph showing the absolute values of the complex impedance of choke coils varying depending on frequency; Figure 8 is a graph showing the relations between a bias DC magnetic field combined with an AC magnetic field and the incremental permeabilities of magnetic cores; and Figure 9 is a graph showing the frequency dependence of the core loss of magnetic cores.
Description ofthe preferred embodiments Referring to Figure 1, an amorphous wound core 1,which is constituted by an amorphous alloy ribbon 2, comprises a gap 3.
Any amorphous alloy having a high saturation magnetic flux density Bs may be used according to the present invention. Iron-base amorphous alloys are particularly desirable because of a high saturation magnetic flux density Bs. Iron-base amorphous alloys which may be used in the present invention include those defined by the general formula :FedNieTfSigBh wherein T represents one or more elements selected from the group consisting of Be, Mg, Ca, Sr, Ba, Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Ru, Co, Pd, Cu, Zn, Y, Ce, Pr, Nd, Sm, Eu, Gd, Tb and Dy, d + e + f + g + h = 100,72'd+e'85, 0.05e/(d + e) '0.40,0'f~3,7 < g < 16, 7 < h < 10,15~g+h'25.
Specific examples of these iron-base amorphous alloys are Fe70Ni8Si13B9, Fe63Ni15Sj13B9r Fe54Ni24Si3B9, Fe78Ni 5Si8Bg, Fe70Ni8Ti3Si11B8, Fe58Ni7Cr2Sr1Si14B8, etc. See Japanese patent Laid-Open No.5782454.
Another example of Fe-base amorphous alloys which may be used are defined by the general formula: FedCOeTfSigBh wherein T represents one or more elements selected from the group consisting of Be, Mg, Ca, Sr, Ba, Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Ru, Ni, Pd, Cu, Zn, Y, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, d + e+ f+ g + h = 100,72'd + e=85, 0.05e/(d + e)0.70, 0f=3, 7 < g < 16, 7 < h < 10, 15 g + h '25. Specific examples are Fe78Co5Si8B9, Fe70Co8Sin3Bg, Fe63Co15Si13B9, Fe54Co24Si13B9, Fe39Co39-Si13B9, etc.See Japanese Patent Laid-Open No. 57-83005. These Fe-base alloys provided magnetic wound cores having excellent DC current superimposition characteristics because of their high saturation magnetic flux density. Amorphous alloys are used in the form of a ribbon 2. The ribbon 2 is wound until the core thickness reaches a desired level. The amorphous alloy ribbon 2 may be produced by any known method.
The amporphous wound core 1 may be heat-treated to enhance magnetic characteristics thereof. The heat treatment is performed by annealing the wound core 1 at temperatures of about 250"C to about 450 C and cooling it at the rate of less than about 300"C per hour. A magnetic field may be applied in the heat treatment, if necessary. The magnetic wound core 1 is provided with a gap 3. In the embodiment as shown in Figure 1, the gap 3 extends throughout a vertical cross section of the wound core 1. The gap 3, however, may be in any form and dimension in general. It may have a uniform width or may be tapered. The gap 3 is provided by cutting operations with a grinder.The width of the resulting gap is not necessarily equal to the thickness of the grinder used, but tends to be smaller than the latter due to slight deformation of the wound core after cutting. The gap width may vary depending on a cutting speed. The radial thickness of the wound core 1 may also vary depending on the speed of cutting to provide a gap to the core.
The gap 3 may be filled with a non-magnetic spacer to ensure its dimensional stability. The non-magnetic spacer may be made of plastics, aluminium, etc.
The amorphous wound core 1 is solidified with resins so that it may keep its desired dimension and shape after being provided with a gap. The solidification of the wound core with resins may be performed by impregnating it with liquid resins, which may include liquid monomers or oligomers, polymer solutions in organic solvents, molten resins, etc. the resins which may be used include thermoplastic resins and thermosetting resins. When thermosetting resins are employed, they may preferably contain curing agents.
A liquid epoxy resin containing an appropriate curing agent and an inorganic varnish are preferable for the purpose of solidifying the wound core.
When a liquid epoxy resin containing a curing agent is used, the wound core is first immersed in the resin liquid, placed in a vacuum chamberto make the resin liquid infiltrate into the innermost part of the core while removing air bubbles from it, and then heated at temperatures of about 85"C to about 1 OO"C to cure the epoxy resin. Inorganic varnishes are also useful because they can easily infiltrate into the wound core. The wound core is immersed in an inorganic varnish and then heated at temperatures of about 1 OO"C - about 150"C, preferably about 120"C.
The solidification of the wound core 1 with resins may also be achieved by coating the surface of an amorphous ribbon 2 with resins, winding the ribbon 2 to form a core, and then heating the wound core 1.
Resins for coating may also be thermoplastic orthermosetting resins. The amorphous wound core 1 may be further coated with non-conductive resins. The surface coating of the core should be so thick as to ensure the insulating of the core from wires wound thereon. With respect to a space factor, however, the surface coating should have a restricted thickness. Therefore, the insulating resin coating may be generally as thick as about 0.5 mm to about 2 mm.
In the preferred embodiment, the amorphous wound core 1 may be produced by winding the amorphous alloy ribbon 2 into a toroidal shape; subjecting the resulting toroidal wound core to an appropriate heat treatment; impregnating it with resins; providing it with a gap 3; placing a non-magnetic spacer in the gap 3; and coating the core surface with insulating resins.
The present invention will be further explained by the following Examples.
Example 1 An Fez,1 Ni75Si16B9 alloy melt was ejected through a thin nozzle onto a copper roll rotating at a high speed to form a thin amorphous ribbon of about 20 Fm in thickness and about 6.5 mm in width. The amorphous ribbon was wound to form a toroidal core of 20 mm in outer diameter, 12 mm in inner diameter and 6.5 mm in height. The toroidal core was immersed in an EPIKOTE (trade name for epoxy resin) solution containing a curing agent, placed in a vacuum chamber to remove air bubbles and then heat-cured. The epoxy resin-impregnated wound core was cut with a grinder to have a gap, resulting in the wound core as shown in Figure 1.
Example 2 With respect to the wound core 1 produced as in Example 1, measurements were conducted to know how the thickness of the wound core changes by cutting it to provide a gap 3 by means of a grinder having a 0.3-mm thickness at various cutting speeds. Also, to evaluate the effects of resin impregnation on the thickness change of the wound core, the same measurements were carried out on both of the wound core impregnated with EPIKOTE and that not impregnated. The results are shown in Figure 2. Figure 2 shows that at the cutting speed of up to about 10 mm/min., there is substantially no thickness change of the wound core impreganted with the resin. On the other hand, the core not impregnated suffered from a large thickness change at any cutting speed.
Example 3 With respect to the wound core 1 produced as in Example 1, measurements were conducted on the width of the gap 3 provided by a 0.3 mm-thick grinder at various cutting speeds. The results are shown in Figure 3.
It is shown that the gap 3 was narrower than the grinder thickness, and that the gap width gradually increased as the cutting speed increased.
Example 4 The amorphous wound core produced as in Example 1,which is saturated at 100 Oe, was subjected to surface coating with an insulating resin (EPIKOTE), and a conductive wire was wound 10 turns thereon. The inductance of the wound core was measured at various surface coating thickness. The results are shown in Figure 4. The inductance gradually decreases as the coating becomes thicker. To have a good space factor, thus high inductance, the coating should be less than about 2 mm. It is to be noted that the amorphous wound core 1 having a surface coating of less than 2 mm has higher inductance than those of a permalloy dust core without a gap and a ferrite core with a gap.
Example 5 The amorphous wound core 1 having a 0.335-mm gap produced as in Example 1 was measured with respect to complex permeability at various frequencies. The real part'i' and imaginary part i' of the complex permeability are shown in Figure 5 in comparison with those of the Mo permalloy dust core. It is noted that the amorphous wound core of the present invention has a higher imaginary part p-" of the complex permeability, which means that it works well particularly for normal-mode noise filtering.
Figure 6 shows the absolute value of the complex permeability iii of the above amorphous wound core in comparison with that of the Mo permalloy dust core. It is observed that the resin-impregnated amorphous wound core having a 0.335-mm gap has substantially constant lFl over a wide range of frequency, well higher than ll of the Mo permalloy dust core. This means that the permeability of the amorphous wound core of the present invention has very good frequency characteristics.
Example 6 Five turns of a wire of 0.25 4 was wound on the above amorphous wound core to form a choke, and the resulting choke was measured with respect to impedance. Figure 7 shows the absolute value of the complex impedance Iz of the above amorphous wound core over a wide range of frequency, in comparison with that of the Mo permalloy dust core. It is appreciated that the amorphous wound core has higher izl than that of the Mo permalloy dust core throughout the frequency range measured.
Example 7 The effects of a gap width on DC current superimposition characterictics will be evaluated. The following five amorphous wound cores with various gap widths were measured together with the Mo permalloy dust core with respect to incremental permeability pA.
Amorphous Wound Core* Gap Width (mm) A B 0.335 C 0.421 D 0.516 E 0.721 *All of them were produced In the same way as in Example 1.
The incremental permeability > A is defined by the following expression:
wherein AB and AH are respectively incremental magnetic flux density and incremental magneticfield when an AC magnetic field is superimposed on a certain level of a DC magnetic field.
Measurements were conducted using a bias DC magnetic field ranging from 0 to 100 Oe with an AC magnetic field having a one-KHzfrequency. The results are shown in Figure 8.
It is seen that the amorphous wound core with a gap has a incremental permeability pA which is higher than that of the Mo permalloy dust core and does not drop rapidly with the increase of HDC. The amorphous wound core with no gap has a very high incremental permeability ,aA at a low HDC (less than 10 Oe), but is > A drops rapidily as the HDC increases. This fact shows that the amorphous wound core with a gap according to the present invention has good DC current superimposition characteristics which are necessary for a normal-mode noise filter choke and output smoothing device.
Example 8 Core loss was measured on the amorphous wound core B of the present invention as well as on the Mo permalloy dust core. The results are shown in Figure 9. It is found that the amorphous wound core with a gap according to the present invention has as good frequency characteristics of core loss as that of the dust core.
As mentioned above, the amorphous wound core with a gap according to the present invention has good DC current superimposition characteristics and high complex permeability. Therefore, it is highly suitable for normal-mode noise filtering and output smoothing.
The present invention has been described above with reference to the preferred embodiments, but it is to be noted that the present invention is not restricted by them and that it may be modified and changed without departing from the spirit and scope of the present invention.

Claims (15)

1. An amorphous wound core comprising at least one gap.
2. An amorphous wound core according to Claim 1, wherein said core is impregnated with a resin.
3. An amorphous wound core according to Claim 2, wherein said gap is filled with a non-magnetic spacer.
4. An amorphous wound core acording to Claim 1, wherein said core is made of an Fe-base alloy.
5. An amorphous wound core according to Claim 2, wherein said resin-impregnated core is further coated with an insulating resin.
6. An amorphous wound core according to Claim 5, wherein the insulating coating of said resin-impregnated core has a thickness of less than about 2 mm.
7. An amorphous wound core according to Claim 5, wherein said gap is covered with a thin metal sheath.
8. A method of producing an amorphous wound core, comprising the steps of: winding an amorphous alloy ribbon to form a toroidal core; impregnating the wound core with a resin to solidify said wound core; and providing a gap to said resin-impregnated wound core.
9. A method of producing an amorphous wound core according to Claim 8, further comprising the step of heat treatment after the step of winding the amorphous alloy ribbon.
10. A method of producing an amorphous wound core according to Claim 8 or 9, further comprising the step of placing a non-magnetic spacer in the gap after the step of proving the gap.
11. A method of producing an amorphous wound core according to Claim 10, further comprising the step of coating the core surface with an insulating resin.
12. A method of producing an amorphous wound core according to Claim 9, wherein said heat treatment comprises annealing the wound core at temperatures of about 250 C - about 450"C and cooling it at the rate of less than about 300"C per hour.
13. A method of producing an amorphous wound core according to Claim 12, wherein the annealing is conducted in a DC or AC magnetic field.
14. A normal-mode noise filter comprising a resin-impregnated amorphous wound core provided with a gap.
15. An output smoothing device comprising a resin-impregnated amorphous wound core provided with a gap.
GB08409566A 1983-04-13 1984-04-12 Amorphous wound coil Expired GB2138215B (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP6493783A JPS59189610A (en) 1983-04-13 1983-04-13 Amorphous wound magnetic core
JP10561383A JPS59231806A (en) 1983-06-13 1983-06-13 Magnetic core for normal mode noise filter

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GB8409566D0 GB8409566D0 (en) 1984-05-23
GB2138215A true GB2138215A (en) 1984-10-17
GB2138215B GB2138215B (en) 1987-05-20

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GB (1) GB2138215B (en)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1991018404A1 (en) * 1990-05-18 1991-11-28 Allied-Signal Inc. Magnetic cores utilizing metallic glass ribbons and mica paper interlaminar insulation
EP0477936A2 (en) * 1990-09-28 1992-04-01 Mitsui Petrochemical Industries, Ltd. Method of reducing noise in magnetic core
GB2227372B (en) * 1988-11-16 1993-06-23 Hitachi Metals Ltd Magnetic device
WO2001052277A1 (en) * 2000-01-12 2001-07-19 Koninklijke Philips Electronics N.V. Method of manufacturing a substantially closed core, core, and magnetic coil
WO2004025816A2 (en) * 2002-09-11 2004-03-25 Abb Inc. Low harmonic rectifier circuit
EP1563518A2 (en) * 2002-11-01 2005-08-17 Metglas, Inc. Bulk laminated amorphous metal inductive device
US7541909B2 (en) * 2002-02-08 2009-06-02 Metglas, Inc. Filter circuit having an Fe-based core
CN104538159A (en) * 2014-12-12 2015-04-22 杭州凯尔达电焊机有限公司 Magnetic biasing resisting device of inverter welding machine and magnetic biasing resisting transformer
WO2020070316A1 (en) * 2018-10-05 2020-04-09 Abb Schweiz Ag Magnetic core arrangement, inductive device and installation device

Families Citing this family (8)

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JPS6074412A (en) 1983-09-28 1985-04-26 Toshiba Corp Multi-output common choke coil
DE3526047A1 (en) * 1985-07-20 1987-01-22 Vacuumschmelze Gmbh CURRENT COMPENSATING RADIO INTERFERENCE THROTTLE
DE3603473A1 (en) * 1986-02-05 1987-08-06 Flowtec Ag Method and device for producing magnetic annular cores (toroidal cores)
DE3928223C2 (en) * 1988-08-25 1994-08-18 Hitachi Metals Ltd Magnetic device for a high voltage pulse generator device
JPH02123710A (en) * 1988-11-02 1990-05-11 Toshiba Corp Magnetic core and manufacture thereof
DE9411261U1 (en) * 1994-07-12 1994-09-15 Schunk Motorensysteme Radio interference suppression choke
DE19816485C2 (en) * 1998-04-14 2000-05-25 Aloys Wobben Coil for step-up converter
DE19833190A1 (en) * 1998-07-23 2000-01-27 Bayerische Motoren Werke Ag ignition coil

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GB2098403A (en) * 1981-05-13 1982-11-17 Gen Electric Plc An inductive device having a ferromagnetic core

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DE749247C (en) * 1939-06-21 1944-11-20 Winding core made of tape-shaped material for magnetic purposes, especially for choke coils that can be placed on cables, with an air gap separating the core
DE2832731A1 (en) * 1978-07-26 1980-02-07 Vacuumschmelze Gmbh MAGNETIC CORE MADE OF A SOFT MAGNETIC AMORPHOUS ALLOY
DE2913741A1 (en) * 1979-04-05 1980-10-09 Philips Patentverwaltung Toroidal core for LF transformer - consists of amorphous ferromagnetic tape coated in adhesive and wound into desired shape
JPS5782454A (en) 1980-11-11 1982-05-22 Hitachi Metals Ltd Wound iron core
JPS5783005A (en) 1980-11-11 1982-05-24 Hitachi Metals Ltd Wound core

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GB2098403A (en) * 1981-05-13 1982-11-17 Gen Electric Plc An inductive device having a ferromagnetic core

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2227372B (en) * 1988-11-16 1993-06-23 Hitachi Metals Ltd Magnetic device
US5443664A (en) * 1988-11-16 1995-08-22 Hitachi Metals, Ltd. Surge current-suppressing circuit and magnetic device therein
WO1991018404A1 (en) * 1990-05-18 1991-11-28 Allied-Signal Inc. Magnetic cores utilizing metallic glass ribbons and mica paper interlaminar insulation
EP0477936A2 (en) * 1990-09-28 1992-04-01 Mitsui Petrochemical Industries, Ltd. Method of reducing noise in magnetic core
EP0477936A3 (en) * 1990-09-28 1992-11-19 Mitsui Petrochemical Industries, Ltd. Method of reducing noise in magnetic core and magnetic core
WO2001052277A1 (en) * 2000-01-12 2001-07-19 Koninklijke Philips Electronics N.V. Method of manufacturing a substantially closed core, core, and magnetic coil
US7541909B2 (en) * 2002-02-08 2009-06-02 Metglas, Inc. Filter circuit having an Fe-based core
WO2004025816A2 (en) * 2002-09-11 2004-03-25 Abb Inc. Low harmonic rectifier circuit
WO2004025816A3 (en) * 2002-09-11 2005-08-04 Abb Inc Low harmonic rectifier circuit
US6965290B2 (en) 2002-09-11 2005-11-15 Abb Inc. Low harmonic rectifier circuit
US6922883B2 (en) 2002-09-11 2005-08-02 Abb Inc. Method for making a non-linear inductor
EP1563518A2 (en) * 2002-11-01 2005-08-17 Metglas, Inc. Bulk laminated amorphous metal inductive device
EP1563518A4 (en) * 2002-11-01 2011-10-19 Metglas Inc Bulk laminated amorphous metal inductive device
CN104538159A (en) * 2014-12-12 2015-04-22 杭州凯尔达电焊机有限公司 Magnetic biasing resisting device of inverter welding machine and magnetic biasing resisting transformer
WO2020070316A1 (en) * 2018-10-05 2020-04-09 Abb Schweiz Ag Magnetic core arrangement, inductive device and installation device

Also Published As

Publication number Publication date
GB2138215B (en) 1987-05-20
GB8409566D0 (en) 1984-05-23
DE3414056A1 (en) 1984-10-18
DE3414056C2 (en) 1994-06-01

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