CN1759007A - 使用具有绝缘体覆层的磁性金属条带的磁性装置 - Google Patents

使用具有绝缘体覆层的磁性金属条带的磁性装置 Download PDF

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CN1759007A
CN1759007A CNA2003801102233A CN200380110223A CN1759007A CN 1759007 A CN1759007 A CN 1759007A CN A2003801102233 A CNA2003801102233 A CN A2003801102233A CN 200380110223 A CN200380110223 A CN 200380110223A CN 1759007 A CN1759007 A CN 1759007A
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R·哈赛加瓦
J·P·韦布
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METGRAS CO
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    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
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Abstract

在形成磁性装置之前在磁性条带或薄片上涂覆绝缘体。在一个单一的工序中完成磁性装置的制造而无需将磁性条带与绝缘体条带共同卷绕。在热处理期间，利用磁性材料和绝缘体之间的热特性的差异来提高装置的磁性特性的改良。

Description

使用具有绝缘体覆层的磁性金属条带的磁性装置
技术领域
本发明涉及用于变压器和电感器的磁芯的磁性装置；尤其涉及适用于高频工作的变压器和电感器的磁芯的磁性装置，该磁性装置具有金属合金条带，该金属合金条带上涂覆有绝缘体涂层。
技术背景
磁芯广泛地用于低频输送电流的电力变压器；所述低频是典型地低于500Hz的频率。当变压器工作在某一频率时，将损失能量，部份是由于磁损失。磁损失有二个来源：与频率成比例的磁滞损失，和与频率的N次方成比例的涡流损失，其中n的范围为从约1.3到2。通常，涡流损失的比例系数与磁芯材料的厚度的平方成比例。这样，较薄的电绝缘磁性材料产生较低的涡流的损失。一种相似的情形为由AC激励而工作的电感器。当这种变压器和电感器的工作频率较低时，例如在电力变压器通常所工作的50或60Hz的情况下，与磁滞损失相比，因涡流造成的磁损失相对较低，因而在磁性材料表面的某些薄氧化涂层就足以使材料绝缘。镁氧化物广泛地用于涂层材料。然而，这种氧化物对磁性材料的表面的附着程度较差，这是因为它以一种粉末形式存在，而粉末在磁芯制造期间通常会从表面脱落。
磁性材料通常以条带状或薄片状的形式用作磁芯材料，以便于形成带绕磁芯或层叠磁芯。在形成磁性条带和磁性薄片的方面新的进展包括无定形材料。这些材料可根据美国再颂专利RE32925的教导而方便地生产。
当磁芯用于高频时，必须具有更好或更可靠的表面涂层，以确保在磁性材料之间的有效的电绝缘。
薄的、非导电性的绝缘体，例如纸，聚合物薄膜和类似材料已经普遍用于上述目的。为使绝缘最大化，绝缘体材料必须具有充分的介电特性。通常优选低介电常数和高介电击穿电压。当磁性元件工作于高频高压下时，这些特征变得越发重要。虽然上述磁性金属-绝缘体-磁性金属的结构被广泛应用，但是制造上述结构的工艺充满问题。上述制造工艺需要一套特别的装置，在其中条带状或薄片状的磁性金属和绝缘体被共同卷绕以形成具有卷绕磁芯形式的磁性元件。磁性金属-绝缘体-磁性金属结构也可通过一套装置生产，其中磁性金属和绝缘体被交替地并置形成一个层叠磁芯。上述类型的共同卷绕工艺时常会由于锋利的磁性金属条带或薄片而破坏或撕裂绝缘体。
现有技术还需要用于制造适用于高频工作的变压器和电感器的磁芯的磁性装置的方法和装置。尤其需要用于制造包括无定形金属条带或薄片的磁性装置的工艺，以避免在共同卷绕中破坏或撕裂绝缘体。更进一步需要具有通过热处理改良的磁性特性组合的绝热的磁性装置。
发明内容
本发明提供一种具有改良的磁性特性组合的绝热的磁性装置。在形成磁性装置之前，在铁磁条带或薄片上涂覆绝缘体层。磁性装置的制造是在单一工艺中完成的，无需将磁性条带和绝缘体条带进行共同卷绕。在热处理期间，磁性材料和绝缘体之间的热特性差异被用于该装置的磁特性的改良。
一方面，本发明提供一种制造磁性装置的方法，以在金属磁性材料之间可靠地并置电绝缘，同时调整装置磁特性以达到所需的磁性性能。在磁性装置的制造过程中施加于磁性材料表面的电绝缘材料可以容易地以液态的形式获得。它是通过在磁性材料上刷涂液态绝缘体或使磁性材料通过液态绝缘体浴来在磁性材料上进行涂敷的。在绝缘材料干燥之后，通过卷绕或堆叠材料将所涂覆的磁性材料制成磁性装置。所制成的装置随后被热处理以修正或改良其磁特性。制成后，磁性装置包括磁芯，所述磁芯包含由涂覆有电绝缘体的磁性条带或薄片，所述电绝缘体具有不同的介电特性和厚度。
在本发明的另一个方面，在制造期间，根据装置所要求的性能规格选择条带或薄片形式的金属磁性材料。随后确定电绝缘材料的电绝缘特性，例如介电特性和击穿电压。选出候选的绝缘材料并应用于磁性材料的表面。磁性金属和候选的绝缘材料的选择由特定的标准决定，包括金属与绝缘材料间的热膨胀系数差。这种热膨胀系数差对经热处理的装置的磁性性能有显著的影响。如此制造的磁性装置尤其适用于脉冲变压器、信号或电流计量变压器、电扼流圈、和高频率电变压器。
附图说明
参考以下详细说明以及附图，可更完整地理解发明并且本发明的其它优点也变得清晰。
图1所示是说明依据本发明构成的磁芯的磁化行为的图，所示的磁通量为施加于某磁芯的磁场的函数，该磁芯包括一个钴基METGLAS2705M条带，该芯具有OD×ID×HT＝102×58×25mm的尺寸，并且在沿磁芯的轴向施加1kOe的DC(直流)磁场的条件下，以335℃热处理2小时。
图2所示是说明含有未涂覆的METGLAS2705M条带的现有磁芯在DC条件下的BH磁化行为的图，磁芯尺寸和热处理条件与图1所示的磁芯基本相同。
图3所示是说明图1所示的磁芯和图2所示的现有磁芯的磁芯损失的图，所示磁芯损失是在0.1T的感应强度下所测量的，是关于频率的函数。
图4所示是说明2个包含铁基METGLAS2605S3A条带的本发明的磁芯在DC条件下的BH磁化行为，磁芯具有OD×ID×HT＝104×40×12.7mm的尺寸，并且分别在没有施加任何磁场(曲线A)以及沿磁芯的圆周方向施加20Oe(1.6kA/m)的磁场(曲线B)的条件下，以390℃热处理1小时。
图5所示是说明含有METGLAS2605S3A条带的现有磁芯在DC条件下的BH磁化行为的图，磁芯热处理条件与图4A所示的磁芯基本相同。
图6所示是说明图4A所示磁芯的电感值和直流偏置电压的函数的图。
图7所示是说明图4A所示磁芯的电感值和频率的函数。
发明详述
由新泽西Molecu公司在市售的无定形金属条带METGLAS2705M上涂覆聚酰亚胺。涂层厚度为约2μm～约4μm。所涂覆的绝缘体的介电常数约为3.9。将宽度约25mm的具有涂层的无定形金属条带卷绕形成环形的磁芯，该磁芯的尺寸为OD＝100～125mm，ID＝58mm，HT＝25mm。卷绕后，磁芯以约300℃～350℃的温度热处理1～5小时。选择该热处理温度范围是因为合金的居里温度为约350℃。在热处理时，沿着磁芯轴向施加约1kOe(80kA/m)的直流磁场以获得线性的BH行为。图1所示为由以335℃热处理2小时的OD＝102mm的磁芯所获得的结果。该图显示了直到约0.7Oe(56A/m)的施加磁场和约30mOe(2.4A/m)的矫顽力Hc都相对恒定的约为5700的直流导磁率μde。为了评价该磁芯的高频特性，5圈的铜线圈被放置在磁芯上。在800kHz，可获得约88μH的电感，表明在该频率下磁芯的AC导磁率为约1800。这些特征表明该磁芯可用于脉冲变压器、信号变压器和电扼流圈。与图1所示磁芯的情况相同，将条带上没有聚酰亚胺表面涂层的相似磁芯沿着磁芯轴向施加约1kOe的直流磁场，以335℃热处理2小时。图2所示为在可达约1Oe(80A/m)的磁场下由该磁芯获得的直流BH回线的结果。相同的磁芯被重新卷绕，以在金属之间插入聚脂薄膜，并获得与图2大致相同直流BH回线。如图2所示，磁芯的相对线性的BH行为仅限于约0.05Oe(4A/m)的低施加磁场下，此时顽磁Br为约1.5kG(0.15T)、矫顽力Hc为60mOe(4.8A/m)。图2所示的BH特性适用于某些类型的电扼流圈，但不适合脉冲膊和信号变压器。比较图1和图2可以发现，条带表面上的聚酰亚胺涂层有助于沿着磁芯的轴向提高磁性的各向异性，从而获得图1所示的线性BH行为。因此，在磁芯制造之前进行绝缘体的涂覆在实现所需磁特性方面是有效的。电绝缘也有助于减少磁芯的涡流损失。此外，聚酰亚胺绝缘体约为3.9的低介电常数可以减小在高频时的元件损失，从而在800kHz获得约为1800的较高的AC导磁率。图3中的数据显示了本发明的磁芯(如图1所示)与现有磁芯(如图2所示)之间的磁芯损失的与频率的关系的直接比较。显然，与利用相同的材料制做成的现有磁芯相比，本发明的磁芯在约50kHz以上具有较低的磁芯损失。
图1和图2所示的磁芯数据是针对近零磁致伸缩的合金的，上述合金趋向于不易受热处理期间产生的应力的影响。当磁性条带是正磁致伸缩的时，因条带和绝缘体之间热膨胀系数的不同而在条带和绝缘体的界面各处产生的应力在磁芯的最后磁性状态中起重要作用。
图4所示为示例的BH回线，在示例中，制造具有聚酰亚胺涂层的正磁致伸缩的、市售的METGLAS2605S3A无定形合金条带。磁芯具有OD×ID×HT＝104×40×12.7mm的物理尺寸。磁芯是分别在没有磁场(曲线A)和沿磁芯圆周方向施加20Oe(1.6kA/m)磁场的(曲线B)条件下以390℃热处理1小时。由无聚酰亚胺涂层的大致相同的条带制备具有大致相同尺寸的磁芯并在与图4A所示磁芯大致相同的条件下进行热处理。图5所示为直流激励下的现有磁芯的BH磁化行为。比较图4和图5得到的数据可以看出，条带磁性的各向异性在热处理期间显著地被聚酰亚胺涂层所修正。修正的磁性向异性产生一个沿磁芯轴向的感应各向异性。随之，沿磁芯轴向的较大的感应磁性各向异性导致在施加场下的磁芯材料的导磁率发生逐渐的改变。这一结果示于图6，其中显示了具有图4A所示的磁芯、有10圈绕组的电感器的感应值相对于施加场的关系。图6所示的数据表明本发明的电感器磁芯适用于电扼流圈。相同的电感器的感应值的频率依赖关系显示于图7。在所用条带的表面涂覆聚酰亚胺涂层可获得对于高达1MHz的频率的相对恒定的感应系数；该绝缘体可减少磁芯材料的涡流损失。这表明该电感器可作为扼流圈用于高达约1MHz的频率。另一方面，具有图4B所示的BH行为的磁芯适用于高频电变压器，例如开关模式电源中的主变压器。
下列实施例提供了对本发明的更全面的理解。所表示的特定的技术、条件、材料、比例以及数据用于原理性的说明，而且本发明的实施例是典型例，而非对本发明范围的限制。
实施例
样品制备
在市售的约25mm宽的无定形材料条带METGLAS2705M和2605S3A上涂覆聚酰亚胺。无定形条带的厚度为16～25μm，而聚酰亚胺层的厚度是2～4μm。各个条带被卷绕形成环形的磁芯，磁芯具有OD＝100～125mm，ID＝40～60mm，HT＝10～30mm的尺寸。在沿环形的轴向(横向)和圆周方向(纵向)施加磁场或不施加磁场的条件下，以300～400℃对磁芯热处理1～5小时。在横向和纵向的磁场的情况下，磁场强度分别为约1kOe(80kA/m)和约20Oe(1.6kA/m)。同样地制备使用无涂层的条带的磁芯。其中一些磁芯是与聚脂薄膜一起缠绕的。
磁性测量
对于直流磁滞现象的测量，每个磁芯的初级线圈和次级线圈分别为具有20圈的铜绕组。一个市售的BH磁滞回线记录仪用来产生磁芯上的直流磁滞回线。图1、2、4、和5是所取的BH回线的图示。
在高频时，初级和次级铜绕组的圈数被减少到5圈或10圈以避免绕组之间的电容。选择测量频率为1kHz～10MHz，因为这是实际装置的工作频率范围。一个市售的电感桥用于上述目的。如此产生的数据示于图6和7中。利用遵循IEEE标准393-1991的指导方针的标准技术对图3所示的磁芯损失进行测量。
根据对本发明的上述详细说明可知，并不一定严格地遵循上述细节，本领域的技术人员可以进行进一步的变更和改良，这些变更和改良都落于本发明由所附的权利要求所规定的全部范围中。

Claims (17)

1.一种磁性装置，包括涂覆有电绝缘体的磁性条带，其中，所述磁性条带的磁力学特性和所述绝缘体的热特性在热处理期间可用以提高所述磁性装置的磁性性能。
2.如要求1所述的磁性装置，其中，所述条带包含无定形的金属磁性合金。
3.如要求1所述的磁性装置，其中，所述条带是晶体磁性合金。
4.如要求1所述的磁性装置，其中，所述电绝缘体的介电常数低于10，且在高于100℃的温度是稳定的。
5.如要求1所述的磁性装置，所述磁性装置经过热处理以改良其磁性性能。
6.如要求1所述的磁性装置，其中，所述装置是高频电感器。
7.如要求1所述的磁性装置，其中，所述装置是高频变压器。
8.如要求5所述的磁性装置，其中，所述装置具有磁激励方向，而且所述热处理是在沿着所述磁激励方向施加场的条件下进行的。
9.如要求5所述的磁性装置，其中，所述装置具有磁激励方向，而且所述热处理是在沿着与所述磁激励方向垂直的方向上施加场的条件下进行的。
10.如要求5所述的磁性装置，其中，所述热处理是在无施加场的条件下进行的。
11.如要求6所述的磁性装置，其中，所述磁性电感器是脉冲压缩器。
12.如要求6所述的磁性装置，其中，所述磁性电感器是电扼流圈。
13.如要求7所述的磁性装置，其中，所述变压器是脉冲变压器。
14.如要求7所述的磁性装置，其中，所述变压器是信号变压器。
15.如要求7所述的磁性装置，其中，所述变压器是电流计量变压器。
16.如要求7所述的磁性装置，其中，所述变压器是高频电变压器。
17.一种磁性装置，包括涂覆有电绝缘体的磁性薄片，其中，所述磁性薄片的磁力学特性和所述绝缘体的热特性在热处理期间可用以提高所述磁性装置的磁性性能。
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