FERRITE CORES AND DEVICES USING SUCH CORES

Abstract: A ferrite core for use in a power transformer or a choke coil comprises a pair of identical core halves, and each of which comprises a circular centre boss (6), a pair of outer walls (7, 8) at both sides of the boss, a pair of base plates (9, 10) coupling the centre boss and the outer walls, with each of the outer walls being substantially rectangular with a flat outer face (7c, 8c) and a curved inner face (7b, 8b). The core half is sym­ metrical with respect to a first plane including a central axis of the boss and extending parallel to the flat outer faces (7c, 8c) of the outer walls (7, 8) and assymetrical with regard to a sec­ ond plane including the central axis of the boss and perpendi­ cular to the first plane. Edges of the outer walls (7, 8) are flush with the side of the core (6) on one side of the second plane and the base plates (9, 10) being absent from a region on the other side of the second plane to provide an opening (R) which extends to the side of the core (6).

Description: FERRITE CORES A3ÇD DEVICES USING SUCH CORES The present invention relates to the structure of ferrite core half and, in particular, relates to such core halves for use in forming the cores of a transformer or a choke coil in a power supply circuit. The example of ferrite core disclosed subsequently is intended to be used in a transformer or a choke coil in a power supply circuit capable of handling up to 1 kW. When used as a power transformer, it may form part of a DC-AC converter and, in this case, a primary power supply is applied to the transformer through a switching circuit to apply an alternate current input to the transformer, and then the required secondary voltage is obtained at the output of the transformer. A ferrite core for such purposes must satisfy the following conditions: a) The core must not magnetically saturate, and preferably, the cross section along the magnetic path is constant along the whole magnetic path in the core. b) The core is preferably closed to improve the shield effect so that it does not disturb an external circuit. c) The shape of a core is preferably simple and enables a bobbin containing a winding coil or coils to be mounted on it and enable lead wires of the windings to extend outside the core. d) The core must comply with the lawful safety standards for a power supply circuit. The safety standard, amongst other things prescribes the minimum separation between pins to which the windings are connected and the minImum spacing between the core and each pin. e) The core is preferably as small and as light in weight as possible. Also, the power handling capacity to weight ratio should be as large as possible. f) Preferably, the external shape of the core is rectangular to enable it to be fitted easily onto a printed circuit board, and the shape of the central part of the core is preferably circular to ease the fabrication of the winding coil or coils. g) The manufacturing process of the core should be simple, and a core mechanically strong. Any sharp edged portion of the core will be broken easily. The most popular conventional ferrite core is an E-shape having a constant cross section throughout. Alternatively, a combination of an E-shaped and an I-shaped core is used. However, that core has the disadvantages that it is large in size, its shielding effect is not perfect and further, a bobbin to fit over the core and carry the coil windings must be rectangular in cross section. Thus the windings are bent sharply at the corners of the bobbin and the normal insulation is often not sufficient, further, automatic winding is impossible. Another conventional ferrite core is a pot core which has a closed circular outer wall and a central cylindrical portion mounted at the centre. Although a pot core is excellently shielded, it has the disadvantage that it is difficult to take the leads of windings outside. A slit is often provided for accommodating the leads but this is often too small. Another prior ferrite core is shown in UK Patent Specification No 1 506 597 which discloses a core with a pair of thick diametrically opposed outer legs. This core is intended to be used in a high frequency filter, but is not suitable for use in a power supply, since its shielding is poor,4 its size large and its supply leads cross one another. Another prior ferrite core is shown in UK Patent Specification No 1 169 742 which discloses a core having four legs and a centre portion arranged at the centre of the legs. Although the leads are readily accommodated in the wide window between the legs, that core has the disadvantage that the core is apt to magnetically saturate in the legs as the legs are rather thin. Therefore, that core has advantages for high output voltage applications, but is not suitable for use in a power supply. Another prior ferrite core is a modification of the pot core in which the pot core is separated into two substantially U-shaped portions. This shape has good shielding, but has the disadvantage that it is difficult to connect leads to a winding associated with it. A further prior ferrite core has the wide disc between the centre core and the outer walls. However, in this core, the structure of a bobbin to hold the winding is rather complicated and, the core is apt to saturate, thus, that core is also not suitable for use in a high power power supply. Bearirgin mind the requirements given above the applicants for this invention designed a magnetic core half which is described and illustrated in their published European Patent Specification No 26104. This core half is illustrated in Figure 1 of this case and will be described in detail subsequently. This earlier core half comprises a cylindrical central boss, a pair of outer walls positioned on opposite sides of the boss, and a pair of base plates coupling the boss and the outer walls so that together they form a subs can tially Reshaped structure with equal length limbs, each of the outer walls having a flat outer face and a cylindrical inner face coaxial with the boss, the length of the external outer face being larger than the diameter of the boss, the area through which the base plates are coupled to the outer walls being larger than half the cross-sectional area of the boss, the area through which the boss is coupled to the base plates being substantially equal to half the cross-sectional area of the boss, the cross sectional area of each of the outer walls being substantially equal to half the cross-sectional area of the boss. and the core half being symmetrical about a first plane including the central axis of the boss and extending parallel to the flat outer faces of the outer walls. In this earlier core half, each of the base plates is substantially sector-shaped with the sides of the sectDr diverging towards the outer walls. A core is made up of two such halves coupled together with the free ends of the outer walls and the boss of the two core halves in contact with one another. Usually, a bobbin carrying one or more windings is mounted in the space between the bosses and the side walls to form a transformer or inductor. The completed transformer or inductor is usually mounted on a printed circuit board with the axis of the bosses in the core halves perpendicular to the printed circuit board. The overall height of the resulting transformer or inductor is rather large which makes it awkward to mount the transformer or inductor since it is so much higher than the other components. Even if attempts are made to mount the inductor or transformer "sidewaysR with the axis of the core halves parallel to the printed circuit board there is no substantial saving in height because the transformer is substantially cubical. Thus the present invention sets out firstly to overcome the problems and limitations of the prior art core halves which faced the applicants before they developed their earlier core half described in European Patent Application No 26104, and secondly to provide a core half that will overcome these problems whilst also being smaller in size and particularly much shorter. According to this invention a magnetic core half as described above is assymetrical about a second plane including the central axis of the boss and extending perpendicularly to the first plane, edges of the outer walls to one side of the first plane are flush with the side of the core, and the base plates are absent from a region on the other side of the boss to provide an opening which extends to the side of the core. Particular examples of core halves, cores and transformers and inductors in accordance with this invention will now be described and contrasted with our prior core halves with reference to the accompanying drawings; in which: Figure 1 is a perspective view of a previously developed core half; Figure 2 is a perspective view of a first example of core half in accordance with the present invention; Figure 3(A) is a front elevation of the first example; Figure 3(B) is a front elevation of a modification of the first example; Figure 4 is a plan of the first example; Figure 5 is an under plan of the first example; Figure 6 is a longitudinal sectional elevation taken along the line A-A shown in Figure 4; Figure 7 is a cross sectional elevation taken along the line B-B shown in Figure 4; ; Figure 8 is an exploded perspective view of a transformer including a pair of the first example of core halves;, Figure 9(A) is a plan of a second example of core half in accordance with the present invention; Figure 9(B) is a front elevation of the second example; Figure 9(C) is a rear elevation of the second example; and, Figure 9(D) is a cross sectional elevation taken along the line A-A shown in Figure 9(A). Figure 1 shows a ferrite core half which is described and claimed in European Patent Application No 26104. This ferrite core has a centre boss I, a pair of outer walls 2 and 3, and a pair of sector shaped base plates 4 and 5 which couple the centre boss 1 to the outer walls 2 and 3. The width B of the outer walls 2 and 3, and the diameter of the circle (2a, 3a) of the outer walls are larger than the diameter dl of the centre boss 1 so that the outer walls 2 and 3 substantially enclose the centre boss 1 and a coil wound on the boss 1. Therefore, this core has excellent magnetic shielding properties, and a thick lead wire can go out through the opening between the base plates. However, this core has the disadvantage that the width B of the core is rather large, and that width B determines substantially the height of the transformer when the transformer using this core is mounted on a printed circuit board with the axis of the boss 1 parallel to the board. Therefore, when this core is used, the height of the transformer is rather high, and the mounting arrangement of components on a printed circuit board is considerably restricted by the presence of the transformer. The transformer utilizing the present ferrite core utilizes two substantially identical core halves of magnetic material butting together, and a core half is shown in the figures 2 through 8. The core half is formed integrally with a circular boss 6, a pair of outer walls 7 and 8, and a pair of base plates 9 and 10 coupling said boss 6 with said outer walls 7 and 8. The inner faces 7b and 8b of the two outer walls 7 and 8 are inwardly curved so that when a core half is formed by assembling two core halves with their outer portions and boss butting together a cylindrical space is left around the boss and between the outer walls for accommodating a bobbin and one or more coils wound on the bobbin The boss 6 is in the shape of a circular post as shown in each of the drawings. Each of the outer walls 7 and 8 are a substantially rectangular plate but the inner surface of the same is curved. The height (H) of the outer walls is the same as the height of the boss 6. The extreme end 6a of the center boss 6, the extreme ends of the outer walls 7 and 8 are positioned on a single plane which is parallel to the base plates. At the end of boss 6 and the outer walls 7 and 8, a pair of arc shaped base plates 9 and 10 are provided, and as apparent from each of the drawings, the inner surface of those base plates coincides with the outer surface of the boss 6, and the outer surface of those base plates coincides with the inner curved surface of the outer walls 7 and 8. It should be appreciated that each of outer walls 7 and 8 are positioned so that they are symmetrical with regard to the first plane which includes the center axis of the center boss 6 and is parallel to the external linear walls of the outer walls 7 and 8. The reference plane is defined so that said reference plane is perpendicular to said first plane, and the reference plane includes the center axis of the boss 6 and the line A-A of Fig.4. It should be noted in Fig.4 that a core half is asymmetrical with regard to the reference plane, but the length B1 in the first side is longer than the length B2 in the second side. The curved inner surfaces of those outer walls 7 and 8 are coaxial with the center boss 6. The external wall of the first outer wall 7 is parallel to that of the second outer wall 8, so that the external appearance of the present core half is almost rectangular. The core half is produced by for instance Mn-Zn ferrite through molding process, sintering process and finish process. In the first side of the reference plane, the width B which is the length between the end of the outer walls 7 and 8, and the reference plane, is longer than the length a 1 which is the radius of the center boss 6. In said first side, the radius a2 of the inner surface of the walls 7 and 8 is longer than the radius a 1 of the boss, and preferably1 a1 is in the range between 15 % and 70 % of a2, and still preferably, a1 is 50 % of a2. With the above dimension, the outer walls 7 and 8 may substantially enclose the center boss 6 and windings around the boss 6, and then, the excellent magnetic shield effect is obtained. The first side has a concaved opening R at the center of the two outer walls. That concaved opening R reaches the surface of the center boss 6, and lead wires of the coils may pass through that concaved opening R. In the second side which is the opposite side in view of said reference plane, the width B2 which is the length between the reference plane and the end of the outer walls 7 and 8, is the same as the radium a2, and of course, that width B2 is shorter than the width B1 of the first side. Preferably, the length B2 is shorter than half of B1. The inner surface of the outer walls in the second side may be either flat as shown in Fig.4, or circular with the radius a2. Due to the short length B2, the height of the transformer is low when the transformer is mounted on a printed circuit board, and then, an electronic component with small size is obtained. When a pair of said core halves compose a transformer, the end 6a of the boss 6, and the ends 7a and 8a of the outer walls 7 and 8 of the first core half abut with the corrensponding ends of the second core half through a bobbin. Thus, a magnetic circuit from the boss of the first core half through the base plates and the outer walls of the first core half, the outer walls and the base plates of the second core half, to the center boss to the second core half is provided. In order to assure the reasonable distribution of the magnetic flux in the cores, and prevent the partial saturation of the magnetic flux in the cores, the size of the core is selected as follows. Assuming that the cross sectional area of the center 2 boss 6 is Ss awl2), the area for coupling said center boss 6 with the base plates 9 and 10 is S2 (=S3), the area for coupling said base plates with the outer walls 7 and 8 is S6 (=S7), and the cross sectional area of the outer walls 7 and 8 is 54 (=S5), then, the following relationship is satisfied: S S2+S3 = S4+S5 (1) With the above relationship, each portion of the cores does not partially saturate magnetically, and therefore, a core may be relatively small in size and light in weight, and thus, the capacity of the transfurr:icr for each weight of the transformer becomes large. Further, when the width of the base plates 9 and 10 is not uniform, but said width is thick at the coupling portion with the center boss, and is thin at the coupling portion with the outer walls, it is possible to satisfy the following equation: i= S2+S3 54 +S5 = S6+S7 (2) In that case, the thickness of the base plates reduces linearly from the center boss to the outer walls (see Fig.3(B)). When the equation (2) is satisfied, the capacity for each weight of the transformer is further improved. When the base plates are the same as each other, and the outer walls are the same as each other, the relations S2=S3, S4=S5, and S6=S7 are satisfied, and said equations 4 5' 6 7 (1) and (2) are expressed as follows. S1 = 2S2 = 2S4, and S1 = 252 = 2S4 = 2S6 It should be noted that as far as said equation (1) or (2) is satisfied, a partial saturation of flux is prevented even when base plates and/or outer walls are not symmetrical with each other. Preferably, each corner or the end portions of the base plates and the outer walls are curved but are not sharp so tat those end portions do not injure a lead wire of a transformer, and a core itself is not broken. It should be appreciated that the present core half has a large opening R, which facilitates the passing of a lead wire for coupling a coil with an external circuit. That opening can pass a thick lead wire of even 1. 5 mm of diameter, which is used in a large current transformer. Further, it should be appreciated in each of the drawings that the shape of each portion of a core half is designed to be pleasing to the eye. Further, it should be appreciated that the present core half has three openings around the center boss 6, and those openings facilitate the ventilation, for cooling the transformer. Fig.8 shows a disassembled view of a transformer which uses the present cores. In Fig.8, a bobbin 11 has a cylindrical hollow portion 11a, a pair of flanges 11b and 11c at both the ends of the cylindrical portion 1lea, and a pair of terminals 11d and 11e coupled with said flanges. The terminals 11d and 11e have a plurality of conductive pins 11p, which facilitate to couple the transformer with an external circuit on a printed circuit board. The flanges 11b and 11c are almost circular, and have a concaved recess R relating to the concaved opening cf the core halves as shown in Fig.8. After a coil (not shown) is wound on the bobbin, a pair of core halves are mounted on the bobbin so that the end 6a of the boss 6 of the first core half abuts to the corresponding portion of the second core half, and the first sides are positioned upside and the second sides are positioned lowerside as shown in the figure. The assembled bobbin together with a coil, and the core halves are mounted on a printed circuit board by using the pins 11p. It should be noted, therefore, that the height of the present transformer on a printed circuit board is low as compared with a prior transformer since the width B2 of the-second side of the core half is shorter than the width B1 of the first side. In one embodiment, the transformer with the longest side 19 mm with the structure of the present invention can provide the output power 100 watts when the frequency is 100 kHz, and that transformer is used, for instance, in a power supply circuit in a portable battery operated video tape recorder. Figs.9(A) through 9(D) show the modification of the present core half, in which the reference numeral 6 is the center boss, 7 t and 8' are outer walls, 9 and 10 are base plates, R' is the recess corresponding to the concaved opening R. The features of the embodiment of Figs.9(A) through 9(D) are that the recess R' extends up to the outer walls 7' and 8', said recess R' touches directly with the center boss 6, and the corner 20 of the outer walls 7' and 8' is not curved, but that corner 20 is flat with the angle of approximately 450 with the adjacent planes

Claims: CLAIMS 1. A ferrite core half for use in a transformer or an inductor comprising a cylindrical central boss (6), a pair of outer walls (7, 8) positioned on opposite sides of the boss (6), a pair of base plates (9, 10) coupling the boss (6) and the outer walls (7, 8) so that together they form a substantially E-shaped structure with equal length limbs, each of the outer walls (7, 8) having a flat outer face (7c, 8c) and a curved inner face (7b, 8b) substantially coaxial with the boss (6), the length ( and B2) of the external outer faces (7c, 8c) being larger than the diameter (2al) of the boss (6), the area (S6,S7) ) through which the base plates (9, 10) are coupled to the outer walls (7, 8) being at least half the cross-sectional area (awl2) of the boss (6), the area (S2S3) through which the boss (6) is coupled to the base plates (9, 10) being substantially equal to half the cross sectional area (awl2) of the boss (6), the cross sectional area (54, S5) of each of the outer walls (7, 8) being at least half the cross sectional area (sal2) of the boss (6), and the core half being symmetrical with regard to a first plane including a central axis of the boss (6) and extending parallel to the flat outer faces (7c,8c) of the outer walls (7,8), characterised in that the core half is assymetrical about a second plane including the central axis of the boss (6) and extending perpendicularly to the first plane, in that edges of the outer walls (7, 8) to one side of the first plane are flush with the side of the core (6), and in that the base plates (9, 10) are absent from a region on the other side of the boss (6) to provide an opening (R) which extends to the side of the core (6). 2. A ferrite core half according to claim 1, wherein the thickness of each of the base plates (9, 10) is tapered so that the coupling portion with the centre boss (6) is thicker than the coupling portion with the outer walls (7, 8) the cross-sectional area of the base plates being substantially constant. 3. A ferrite core half according to claim 1 or 2, wherein the radius al of the center boss (6) is in the range from 15% to 70% of the radius a2 of the curved surface (7b, 8b) of the outer walls (7, 8). 4. A ferrite core half according to any one of the preceding claims, wherein the opening (R) is semicircular in shape. 5. A ferrite core half according to any one of claims 1 to 3, wherein the opening (R) is substantially rectangular in shape, opposite edges of the base plates (9, 10) being parallel. 6. A ferrite core half according to any one of the preceding claims, wherein corners of the outer walls (7, 8) are rounded. 7. A ferrite core half according to any one of claims 1 to 5, wherein corners of the outer walls (7, 8) are chamfered. 8. A ferrite core half for use in a power supply circuit comprising: (a) a circular center boss (6), (b) a pair o! outer walls (7, 8) positioned at both the sides of said boss for mounting a coil, (c) a pair of base plates (9, 10) coupling a portion of said boss with said outer walls, said base plates extending from the periphery of said boss to the side surface of said walls wherein said boss, walls and base plates form an E-shaped structure and wherein the end portion of said boss, end portions of said walls and said base plates are all aligned in a single plane, (d) each of the outer walls is substantially rectangular with an external linear wall and an inner curved wall which is substantially coaxial with said circular boss and the width of said external linear wall is larger than the diameter (2a1) of the circular boss, (e) each of said base plates being substantially in an arc shape, and the portions of said boss which are coupled to said base plates being less than the whole of the periphery of said boss such that a space is formed between said base, plates along the periphery of said boss, (f) the area (S6 S7) coupling said base plates with said outer walls being equal to or larger than the half of the cross-sectional area (S1 = sa2) of said boss, (g) the area tr (S2,S3) coupling said boss with the base plates being substantially the same as half of the cross-sectional area (S #a2) of said boss, (h) the area (S4,S5) of the cross-section of each of said outer walls being equal to or larger than the half of the cross-sectional area (#a1) of said boss, (i) the core half being symmetrical with regard to the first plane including a center axis of said boss and being parallel with the external linear walls of said outer walls, (j) a concaved opening (R) being provided between said base plates in first side of the core half with regard to the reference plane which includes a center axis of said boss and s perpendicular to said first plane, and said opening (R) extending to the surface of the centre boss, (k) the length (Bl) between said reference plane to the end of the first side of the core half in the first side which includes said concaved opening being longer than the length (B2) between said reference plane to the end of the second side of the core half, and (1) said length (B2) ) being the same as the radius al of the center boss. 9. A ferrite core for a transformer or an inductor comprising two ferrite core halves in accordance with any one of the preceding claims, coupled together with the free ends of their outer walls (7, 8) and their bosses (6) in contact with one another. 10. A power transformer or an inductor including a core in accordance with claim 9, which further comprises a bobbin carrying at least one winding in the space betweenthebosses (6) and the curved inner faces (7c,8c) of the outer walls (7, 8).

Inventors: HIRAKU, IMAIZUMI, TADASHI, MITSUI
Applicants: TDK CORPORATION
Application year: 1982
Main classification: H01F3
IPC codes: H01F27, A45D20