Patent Grant
11631519
This application claims priority under 35 U.S.C. § 119 to Korean Patent Application No. 10-2019-0087300, filed in Korea on Jul. 19, 2019 and No. 10-2020-0074176, filed in Korea on Jun. 18, 2020, which are hereby incorporated in its entirety by reference as if fully set forth herein.
Embodiments relate to a magnetic core having improved reliability.
In recent years, research on vehicles equipped with electric motors has been actively conducted in accordance with continued interest in, and legislation pertaining to, the environment, and the market thereof is also expanding. Therefore, the importance of the vehicle power electronics (PE) field is also increasing.
A typical vehicle power electronic component is a DC-DC converter. Vehicles using an electric motor as a power source are generally provided with a high-voltage battery for driving the electric motor in combination with an auxiliary battery for supplying power to the electric load, and the auxiliary battery can be charged through the power of the high-voltage battery. In order to charge the auxiliary battery, it is necessary to convert the DC power of the high voltage battery into DC power corresponding to the voltage of the auxiliary battery. For this purpose, a DC converter may be used.
The DC converter converts DC power into AC power, and then transforms the same through a transformer, rectifies the result again, and outputs DC power with a desired output voltage. Thus, the DC converter includes a passive element such as an inductor operating at a high frequency.
However, in general, a magnetic core constituting an inductor or transformer has a problem of the difficulty of satisfying reliability such as low-temperature characteristics or thermal shock required for a vehicle environment.
In addition, the trend toward slimming of parts has recently been applied to magnetic elements, but slimmed magnetic elements have relatively small size and surface area, which are disadvantageous from the aspects of heat capacity and heat dissipation. Thus, it is also necessary to consider a method of reducing heat generation in an attempt to reduce loss.
Embodiments provide a magnetic core having improved reliability.
Further, embodiments provide a magnetic core having superior low-temperature characteristics or thermal shock characteristics.
The objects to be accomplished therein are not limited to those described above, and other objects not described herein will be obvious to those skilled in the art from the following description.
In one embodiment, a magnetic core includes 37 to 44 mol % of manganese (Mn), 9 to 16 mol % of zinc (Zn), 42 to 52 mol % of iron (Fe), a magnetic additive and a non-magnetic additive, and has a permeability of 2,900 or more and a core loss of 500 mW/cm3 or less.
For example, the magnetic core may have a permeability decrease of 4 to 9% and a core loss increase of 0.5 to 7% at −40 to 125° C. during 1,000 cycles for 30 minutes in each cycle.
For example, the magnetic core may have a permeability decrease of 2 to 5% and a core loss increase of 0.05 to 3.00% under an impact caused by an impact acceleration of a semi-sinusoidal wave of 100G in each of the ±directions in the x, y, and z axes for 6 ms.
For example, the magnetic core may have a permeability decrease of 1 to 3% and a core loss increase of 0.2 to 1.0% after vibration is maintained for 4 hours in each of the x, y and z axes at a vibration frequency of 10↔2000 Hz, a vibration acceleration of 5G for a sweep time of 20 minutes.
For example, the magnetic core may have a toroidal shape, and the magnetic core has an average breaking load of 800 N or more after applying a load at a speed of 30 mm/min 5 times under a limit load of 1,000 N vertically downwards along the height direction of the toroidal shape.
For example, the magnetic additive may include cobalt (Co) and nickel (Ni).
For example, the cobalt may be present in an amount of 0.1 to 1 mol %, and the nickel may be present in an amount of 0.1 to 0.5 mol %.
For example, the non-magnetic additive may include at least one of silicon (Si), calcium (Ca), tantalum (Ta), vanadium (V) or zirconium (Zr).
For example, the silicon may be present in an amount of 50 to 200 ppm, the calcium may be present in an amount of 200 to 700 ppm, the tantalum may be present in an amount of 200 to 900 ppm, the vanadium may be present in an amount of 50 to 500 ppm, and the zirconium may be present in an amount of 50 to 500 ppm.
In another embodiment, a magnetic core includes a magnetic compound containing 37 to 44 mol % of manganese (Mn), 9 to 16 mol % of zinc (Zn), 42 to 52 mol % of iron (Fe), 0.1 to 1 mol % of cobalt (Co), 0.1 to 0.5 mol % of nickel (Ni) and an additive, wherein the magnetic compound includes a plurality of grains and a grain boundary between the corresponding grains, wherein the ratio of the content of the cobalt at the center of a first grain among the plurality of grains to the content of the cobalt at the center of a first grain boundary, located between the first grain and a second grain adjacent thereto, may be 0.4 or more.
For example, the content of cobalt may gradually decrease from the first grain to the first grain boundary.
For example, the ratio of the content of cobalt at the center of a third grain among the plurality of grains to the content of cobalt at the center of a second grain boundary, located between the third grain and a fourth grain adjacent thereto, may be 0.4 or more.
For example, the additive may include a nonmagnetic material.
For example, the nonmagnetic material may include at least four of silicon (Si), calcium (Ca), tantalum (Ta), vanadium (V), niobium (Nb), or zirconium (Zr).
For example, the silicon may be present in an amount of 50 to 200 ppm, the calcium may be present in an amount of 200 to 700 ppm, the tantalum may be present in an amount of 200 to 900 ppm, the vanadium may be present in an amount of 50 to 500 ppm, and the zirconium may be present in an amount of 50 to 500 ppm.
In another embodiment, a magnetic core includes a magnetic compound containing 37 to 44 mol % of manganese (Mn), 9 to 16 mol % of zinc (Zn), 42 to 52 mol % of iron (Fe) and a non-magnetic additive, wherein the non-magnetic additive includes 50 to 200 ppm of SiO2, 200 to 700 ppm of CaO, 200 to 900 ppm of Ta2O5, 50 to 500 ppm of ZrO2, and 50 to 500 ppm of V2O5, wherein the magnetic compound includes a plurality of grains and a grain boundary between the corresponding grains, wherein the content of at least one of the non-magnetic additive gradually increases in a first direction from the center of the first grain to the second grain adjacent to the first grain, and the ratio of the total content of at least one of the non-magnetic additive in the first grain to the total content of at least one of the non-magnetic additive in the first grain boundary between the first grain and the second grain may be 0.1 or more.
For example, the magnetic core may further include a magnetic additive of at least one of cobalt (Co) or nickel (Ni).
For example, the cobalt may be present in an amount of 0.1 to 1 mol %, and the nickel may be present in an amount of 0.1 to 0.5 mol %.
For example, the ratio of the content of cobalt at the center of the first grain to the content of cobalt at the center of the first grain boundary may be 0.4 or more.
For example, the ratio of the content of nickel at the center of the first grain to the content of nickel at the center of the first grain boundary may be 0.4 or more.
In another embodiment, a magnetic core includes a compound containing 37 to 44 mol % of manganese (Mn), 9 to 16 mol % of zinc (Zn), 42 to 52 mol % of iron (Fe) and an additive, wherein the additive includes at least three elements in Groups 4 and 5 of the periodic table.
For example, the element in Group 5 may include at least two of tantalum (Ta), vanadium (V), or niobium (Nb).
For example, the element in Group 4 may include at least one of zirconium (Zr) or titanium (Ti).
For example, the total content of elements in Groups 4 and 5 may be 1,500 ppm or less.
For example, the additive may further include at least three of cobalt (Co), nickel (Ni), silicon (Si), or calcium (Ca).
For example, the additive may include oxide.
For example, the additive may include 50 to 200 ppm of SiO2, 200 to 700 ppm of CaO, 200 to 900 ppm of Ta2O5, 50 to 500 ppm of ZrO2, and 50 to 500 ppm of V2O5.
For example, the magnetic compound includes a plurality of grains and a grain boundary between the corresponding grains, wherein the compound includes at least one non-magnetic material and the content of the at least one non-magnetic additive gradually increases in a first direction from the center of the first grain to a second grain adjacent to the first grain, and the ratio of the total content of the at least one non-magnetic additive in the first grain to the total content of the at least one non-magnetic additive in the first grain boundary between the first grain and the second grain may be 0.1 or more.
Arrangements and embodiments may be described in detail with reference to the following drawings, in which like reference numerals refer to like elements, and wherein:
It should be understood that numerous other modifications and embodiments will fall within the spirit and scope of the principles of this disclosure, and certain embodiments will be exemplified and described with reference to the attached drawings. However, it should be construed that these embodiments do not limit the scope of this disclosure and include all possible variations, equivalents and substitutions which fall within the scope of this disclosure.
It will be understood that, although terms including ordinal numbers such as “second” or “first” may be used herein to describe various elements, these elements should not be construed as being limited by these terms which are used only to distinguish one element from another. For example, within the scope defined by the disclosure, a second element may be referred to as a first element, and similarly, a first element may be referred to as a second element. The term “and/or” includes a combination of a plurality of the related described items or any one of the plurality of related described items.
It will be understood that when an element is referred to as being “bound” or “connected” to another element, it may be directly bound or connected to the element, or one or more intervening elements may also be present therebetween. On the other hand, it will be understood that when an element is referred to as being “directly bound” or “directly connected” to another element, there is no intervening element therebetween.
It will be understood that when an element such as a layer (film), region, pattern or structure is referred to as being “on” or “under” another element such as a substrate, each layer (film), region, pad or pattern, it may be directly on/under the element, or one or more intervening elements may also be present. When an element is referred to as being “on” or “under”, “under the element” as well as “on the element” can be included based on the element. In addition, in the drawings, the thickness or size of a layer (film), region, pattern or structure may be exaggerated for clarity and convenience, and may thus be different from the actual thickness or size thereof.
In addition, terms herein used are provided only for illustration of certain embodiments and should not be construed as limiting the scope of the disclosure. Singular forms are intended to include plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “has” herein used specify the presence of stated features, numbers, steps, operations, elements, components or combinations thereof, but do not preclude the presence or addition of one or more other features, numbers, steps, operations, elements, components, or combinations thereof.
Unless differently defined, all terms used herein including technical or scientific terms have the same meanings as generally understood by those skilled in the art. In addition, terms identical to those defined in generally used dictionaries should be interpreted as having meanings identical to contextual meanings in the related art, and are not to be interpreted as having abnormally or excessively formal meanings unless they are definitely defined herein.
According to one embodiment, the proportion of a specific metal element at a grain boundary can be increased so that the magnetic core can exhibit better reliability.
Referring to
For this purpose, unlike a general core-manufacturing process, in which an additive is mixed with the main composition material at an initial stage, in this embodiment, at least a part of additives may be mixed after mixing of the main composition materials and then calcination.
Hereinafter, the main composition materials and additives according to the present embodiment will be first described and then the manufacturing process will be described.
The main composition of the magnetic core according to an embodiment may have the content ratio shown in Table 1 below.
Referring to Table 1, the magnetic core according to an embodiment includes manganese (Mn), zinc (Zn) and iron (Fe) as main composition materials, and includes cobalt oxide (CoO) and nickel oxide (NiO) as magnetic additives. The content ratio of Table 1 is based on a molar ratio (mol %), and the results of experimentation of combination properties based on weight ratio (wt %) are shown in Table 2 below.
Table 2 shows the results of experiments in which the content of Fe is fixed to about 71% in Samples 1 to 4 and about 67% in samples 5 to 8, respectively, under the same sintering conditions, excluding additives to be described later.
First, in the case of Samples 1 to 4, the composition is changed by decreasing the Zn content while increasing the Mn content from Sample 1 to Sample 4, and Sample 3 is determined to be optimal from the aspect of loss. That is, the performance is improved when the content of Mn is 20 wt % or more and the content of Zn is 8.56 wt % or less.
In addition, in the case of Samples 5 to 8, the composition is changed by decreasing the Zn content while increasing the Mn content from Sample 5 to Sample 8. Performance with respect to loss is excellent when the content of Zn is 4.3 to 12.83 wt %, and Sample 6, having a Zn content of 8.56% is determined to be optimal from the aspect of loss. The Zn ratio is excessively reduced when the content of Mn is 28.2 wt % or more, thus causing deterioration in performance.
In conclusion, when Fe2O3 is present in an amount of about 70 wt %, as shown in Table 3 above, the optimal content of Zn is 6 wt % or more in consideration of loss.
Next, the non-magnetic additives will be described with reference to Table 4 below.
As can be seen from Table 4, in addition to the above-described main composition materials, the magnetic core according to the embodiment includes at least one of non-magnetic additives including silicon oxide (SiO2), calcium oxide (CaO), tantalum pentoxide (Ta2O5), zirconium dioxide (ZrO2) and vanadium pentoxide (V2O5). Such a non-magnetic additive may serve to maintain bonding strength between main components after heat treatment (that is, sintering) to be described later.
A method for manufacturing a magnetic core using respective materials shown in Tables 1 to 4 according to an embodiment will be described with reference to
Referring to
Next, the mixed raw material powder may be calcined to increase the density of the spherical grains (S220) in a spray-drying (S250) process, which will be described later. For example, the process may be performed by elevating the temperature to a maximum of 950° C. at a heating rate of 3.5° C./min and maintaining the temperature for 4 hours, but the disclosure is not limited thereto.
Next, in general, since the calcined powder particles are often aggregated (entangled) with one another, a disintegration process to minimize the particle size may be performed (S230). At this time, components other than the raw material, that is, non-magnetic additives such as SiO, CaO, Ta2O5, ZrO2 and V2O5, may be mixed in this process. The process may also be carried out using a ball mill, but the disclosure is not limited thereto.
Next, slurry to be sprayed in the spray-drying (S250) process described below may be prepared (S240). This process may be performed by stirring a solvent, a binder, and a binder dispersant along with the resulting product of S230. For example, the solvent may be distilled water, the binder may be polyvinyl alcohol present in an amount of 1 wt % of the result of S230, and the binder dispersant may be present in an amount of 0.1 to 0.3 wt % of the resulting product of S230. The stirring time may be 10 hours or more, but the disclosure is not necessarily limited thereto.
The prepared slurry may be granulated in a spherical shape through the spray-drying process (S250). This process improves the flowability of the powder through granulation of particles, thereby enabling high-pressure molding in the subsequent molding step (S260). This is because, as the pressure increases during molding, the density of the resulting product increases and magnetic properties are thus improved.
The spray-dried granulated particles may be molded into a desired shape at a high pressure (S260). For example, the desired shape includes a toroidal type, an E type, an EPC type, an I type or the like, depending on the application, and the pressure may be 3 to 5 tons/unit area, but the disclosure is not limited thereto.
When the molding is completed, a sintering process for securing desired core performance may be performed (S270). For example, the process may be performed by maintaining a maximum temperature of 1,360° C. for 4 hours, but the disclosure is not limited thereto.
After sintering, a surface-polishing process for component application may be performed (S280).
The process described so far has the greatest difference from a general process in terms of the time of mixing of the non-magnetic additives rather than the main components. In other words, in the general process, the main components and the non-magnetic additives are initially mixed together, whereas, in the process according to the present embodiment, the non-magnetic additives may be mixed and incorporated after mixing, calcining and disintegration of the raw materials. The process according to this embodiment may be referred to as a “post-addition process”.
Further, according to another embodiment, the post-addition process may be performed in two steps. For example, as described above, after mixing, calcining and disintegration of the raw materials, 92% to 96% of the nonmagnetic additive is added, and the remaining amount of nonmagnetic additive (i.e., 4% to 8% of the previously added amount) is added during the spray drying (S250). In this case, a higher amount of additives may be distributed at the grain boundary.
The effect of the post-addition process will be described with reference to
In
The sintering conditions and the main composition ratio (i.e., Fe 69.75 wt %, Mn 22.94 wt %, Zn 6.97 wt %), and additive contents (Si 100 ppm, Ca 500 ppm, Ta 500 ppm, Zr 100 ppm, V 100 ppm, Co 2,000 ppm, Ni 200 ppm) are fixed in both the post-addition process and the conventional process. However, in the post-addition process, Co and Ni, added after mixing, calcining and disintegration of the raw materials, account for 10% of the amount of the corresponding additive.
The loss and permeability at 25° C. and −30° C., shown in
As can be seen from
Meanwhile, the function of each component in the described process is as follows.
First, SiO2 can cause excessive grain growth by inducing flow through the grain boundary when SiO2 is present in an amount of 200 ppm or more.
Non-magnetic additives (such as SiO2, CaO, Ta2O5, Nb2O5 and ZrO2) can commonly contribute to reducing hysteresis loss. For example, Ta2O5 can help CaO to be distributed well at grain boundaries. Here, Ta2O5 may be replaced with Nb2O5 or ZrO2 (i.e., (SiO2+CaO)+(Ta2O5, Nb2O5, ZrO2)).
In addition, non-magnetic additives also contribute to reducing eddy current loss. Specifically, since there is a high possibility that CaO is present at the grain boundary, it precipitates on the grain boundary, thus increasing the resistivity of the grain boundary. In addition, V2O5 can form a liquid film on the grain boundary, thereby suppressing grain growth. In addition, Ta2O5 can function to suppress excessive grain growth due to the increase in specific resistance and addition of SiO2.
Meanwhile, Co enables Fe2+ to be substituted with Co2+ to improve the temperature dependence of permeability, thereby contributing to the control of anisotropy.
In addition, NiO, which replaces ZnO, can increase the relative content of Fe2O3, thereby shifting a core loss minimum expression temperature to a high temperature.
In addition, CaO, which is present at the grain boundary, has effects of reducing hysteresis loss, as described above, and of improving high-frequency response.
The effects of the addition of additives such as Si, Zr and Ta described above will be described with reference to
In
Referring to
The loss and permeability at 25° C. in
As can be seen from
Hereinafter, the optimal content of the components according to an embodiment will be described.
First, the experimental conditions related to the content of Ni are as follows.
The content of Ni was changed to 200 ppm, 400 ppm and 600 ppm, but the sintering process was the same in each case, and the main components were fixed at Fe of 71.13 wt %, Mn of 21.76 wt % and Zn of 7.11 wt %, and the additives were fixed at 3000 ppm of Co, 100 ppm of Si, 300 ppm of Ca and 500 ppm of Ta. The experimental results under these conditions are as shown in
Referring to
Next, the experimental conditions related to the content of Co are as follows.
The content of Co was changed to each of 500 ppm and 1500 ppm, and in both cases, Co was mixed together with 200 ppm of Ni through the post-addition process described above, the sintering process was the same, the main composition included Fe 69.75 wt %, Mn 22.94 wt % and Zn 6.97 wt %, and the additive contents were fixed at 100 ppm of Si, 500 ppm of Ca, 500 ppm of Ta, 100 ppm of Zr, and 100 ppm of V. The experimental results under these conditions are as shown in
As can be seen from
In order to determine the optimum content of the components according to the present embodiment, the contents of some main components were fixed and the contents of other main components and non-magnetic additives were varied, the characteristics were measured under conditions of 100 kHz and 200 mT, and the results are shown in Table 7.
In Table 7, in the main composition, the content of manganese (Mn) was 22.94 wt %, the content of zinc (Zn) was 6.97 wt % and the content of iron (Fe) was 69.75 wt %, and the content (ppm) of each of SiO, CaO, Ta2O5, ZrO2 and V2O5, excluding some additives, was also fixed. As a result of experiments performed while changing the content of CoO and NiO under these conditions, when the content of CoO was 3,000 ppm and the content of NiO was 400 ppm, permeability of 3349 and loss of 349 were obtained. These contents correspond to 0.3 wt % of CoO and 0.004 wt % of NiO on a weight-ratio basis, and both the highest permeability and the lowest loss were obtained compared to other cases, and it can be seen that there is a critical significance in the corresponding content ratio.
Hereinafter, the performance of the magnetic core manufactured according to the process of
Specifically, the test was conducted on items such as thermal shock, impact resistance, vibration and strength.
First, the thermal shock test was conducted for 1,000 cycles of 30 minutes each at −40/+125° C., corresponding to Grade 1 of AEC-Q200. The temperature change applied in this test is as shown in
temperature change was conducted linearly for 5 minutes.
The test results are shown in Table 8 below.
As shown in Table 8, the test results showed that the permeability decrease was 5.0 to 8.2% and the core loss (@ 100° C.) increase was 0.8 to 6.7%, without cracks or breakage, thus satisfying AEC-Q200 pass conditions (i.e., within ±15%).
Next, an impact resistance test was performed at an impact acceleration of 100G or less with regard to an impact waveform of a semi-sinusoidal wave, a total of 18 times 3 times in each of the +/−directions of each of x, y, and z axes for a time of 6 ms. The test results are shown in Table 9 below.
As shown in Table 9, the test results showed that the permeability decrease was 2.3 to 4.5% and the core loss (@ 100° C.) increase was up to 2.4% without cracking or breakage, thus satisfying the AEC-Q200 Pass conditions.
Next, a vibration test was conducted under conditions including a vibration frequency of 10 ↔2000 Hz, a vibration acceleration of 5G, a sweep time of 20 minutes/sweep, a test time of 4 hours for each of x, y, and z axes, and a total time of 12 hours. The test results are shown in Table 10 below.
As shown in Table 10, the test results showed that the permeability decrease was 1.0 to 2.7% and the core loss (@ 100° C.) increase was up to 0.9% without cracking or breakage, thus satisfying the AEC-Q200 Pass conditions.
Meanwhile, a strength test was conducted by applying a load vertically downward along a height direction of the toroidal core using a UTM LS1 device capable of applying a maximum load of 1 kN (i.e., direction: compression). At this time, the applied speed was 30 mm/min and the applied limit load was 1,000 N. In addition, the specifications of the magnetic core used in the test are shown in Table 11 below.
The results of strength test for the core under the conditions shown in Table 11 are shown in Table 12 below.
Referring to Table 12, in a total of 5 tests, the load causing breakage was within the range from 670 to 960 N, and the mean thereof was 824 N. Among these results, raw data of the results of the fourth test are shown in
The excellent performance of the magnetic core according to the embodiments described so far, that is, excellent performance in items such as thermal shock, impact resistance, vibration and strength, is caused by the distribution of the components of the grain boundary resulting from post-addition of components, unlike the raw materials. This will be described with reference to
Respective graphs in
First, referring to
In conclusion, in the magnetic core according to the embodiment, even at the grain boundary, a considerable amount of cobalt and nickel, corresponding to 0.4 wt % or more, is distributed, so that excellent thermal shock and low-temperature characteristics can be obtained. Meanwhile, as shown in
The description of each of the embodiments may be applied to the other embodiments, as long as the contents do not conflict with each other.
As is apparent from the above description, the magnetic core according to the embodiment has an improved composition ratio at grain boundaries, thus exhibiting excellent low-temperature characteristics and thermal shock characteristics.
The effects that can be accomplished herein are not limited to those described above, and other effects not described herein will be obvious to those skilled in the art from the description given above.
Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.
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