Flexible soft magnetic core, antenna with flexible soft magnetic core and method for producing a flexible soft magnetic core

Abstract

The flexible soft magnetic core (1) includes parallel continuous ferromagnetic wires (4) embedded in a core body (2) made of the polymeric medium (3). The continuous ferromagnetic wires (4) extend from one end to another end of said core body (2), are spaced apart from each other and are electrically isolated from each other by the polymeric medium (3). The method for producing the flexible soft magnetic core (1) comprises embedding continuous ferromagnetic wires (4) into an uncured polymeric medium (3) by means of a continuous extrusion process, curing the polymeric medium (3) with the continuous ferromagnetic wires (4) embedded therein to form a continuous core precursor (10), and cutting said continuous core precursor (10) into discrete magnetic cores (1).

Claims

1. Flexible soft magnetic core including a ferromagnetic material arranged to form parallel magnetic paths within a core body that is made of a cured polymeric medium, said parallel magnetic paths being electrically insulated from each other by said polymeric medium, wherein said ferromagnetic material comprises a plurality of parallel, continuous, ferromagnetic elements embedded in said core body made of said polymeric medium, wherein said continuous ferromagnetic elements are spaced apart from each other and extend from one end to another end of said core body and characterized in that: said core is elongated along a longitudinal axis and flexible in at least two orthogonal directions; and said continuous, ferromagnetic elements are flexible wires; whereby said core allowing a flexion with respect to said longitudinal axis parallel to said wires and also with respect to a transversal axis perpendicular to said wires.

2. (canceled)

3. The flexible soft magnetic core according to claim 1, wherein said cured polymeric medium including the plurality of ferromagnetic wires is an extruded part, elongated along an axis, being twistable and flexible along two orthogonal planes which intersect defining said axis.

4. The flexible soft magnetic core according to claim 3, wherein said core has a length longer than 15 cm and the core body is of a prismatic or cylindrical shape.

5. The flexible soft magnetic core according to claim 1 wherein said cured polymeric medium is a polymer-bonded soft magnetic material PBSM.

6. The flexible soft magnetic core according to claim 1 wherein said cured polymeric medium further includes microfibers, microparticles or nanoparticles of a soft ferromagnetic material that are present alone or in any combination thereof, within the polymeric matrix of said polymeric medium.

7. The flexible soft magnetic core according to claim 6, wherein said microfibers, microparticles or nanoparticles of a soft ferromagnetic material represent a weight content up to 85% of the total weight of the core and wherein said microfibers, microparticles or nanoparticles of soft magnetic material are homogeneously distributed and electrically insulated within a polymeric matrix of said polymeric medium by means of one or more dispersant agents incorporated to the uncured liquid polymeric medium along with said microfibers, microparticles or nanoparticles.

8. The flexible soft magnetic core according to claim 6, wherein said one or more dispersant agents are present in an amount of around 4-5% of the liquid polymer providing said core body and wherein said dispersant agents comprises Solsperse from Lubrizol or a liquid monomer or a hyperdispersant providing to said microfibers, microparticles or nanoparticles a surface treatment involving an electric insulation in addition to the dispersing action.

9-11. (canceled)

12. The flexible soft magnetic core according to claim 6 wherein said microfibers, microparticles or nanoparticles are of a metal alloy of a very high relative permeability of less than 600.000, and based on a composition of FeNi, Mo—FeNi, Co—Si, or Fe—NiZn with a weight content of the Ni from 30 to 80% and with additional components including Mo, Co or Si with a weight content less than 10%.

13. The flexible soft magnetic core according to claim 6, wherein said microfibers, microparticles or nanoparticles are selected from the group consisting of pure Fe.sup.3+, Fe carbonyl, Ni carbonyl, Mn Zn ferrite, Mn Ni ferrite and a Mollypermalloy powder.

14. The flexible soft magnetic core according to claim 6 wherein said microparticles or nanoparticles of soft ferromagnetic material that are of a crystalline structure comprise an amorphous, nanocrystalline or macro crystalline with enlarged grains in an annealing process.

15. The flexible soft magnetic core according to claim 6 wherein said microfibers, microparticles or nanoparticles have a low magnetic coercitivity of less than 0.1 A/m, and are electrically insolated within the polymeric matrix with a resistivity (ρ) of less than 10.sup.6Ω.Math.m.

16. The flexible soft magnetic core according to claim 1 wherein said polymeric medium is a polymeric matrix obtained from epoxy or urethane or polyurethanes or polyamide derivatives.

17. The flexible soft magnetic core according to claim 1, wherein each of said continuous ferromagnetic wires has a constant cross section along its whole length, said constant cross section being circular and having an area in the range of 0.002 to 0.8 square millimetres.

18. (canceled)

19. The flexible soft magnetic core according to claim 17, wherein said continuous ferromagnetic wires are arranged in several equidistant parallel geometric planes, wherein the continuous ferromagnetic wires arranged in one geometric plane are staggered with respect to the ferromagnetic wires arranged in another adjacent parallel geometric plane.

20. The flexible soft magnetic core according to claim 1, wherein the continuous ferromagnetic wires are made of a ferromagnetic material having a very high permeability in the range of 22.5 to 438 μm/mH.Math.m.sup.−1, and wherein said very high permeability ferromagnetic material is an alloy of iron and one or more of nickel, cobalt, molybdenum, and manganese.

21. (canceled)

22. The flexible soft magnetic core according to claim 16, wherein said continuous ferromagnetic wires are electrically insulated by a coating of a glaze or enamel.

23. (canceled)

24. An antenna, comprising a flexible soft magnetic core according to claim 6 and at least one winding wound around the flexible soft magnetic core.

25. A method for producing a flexible soft magnetic core, the method comprising: embedding continuous ferromagnetic wires into an uncured polymeric medium by means of a continuous extrusion process, curing the polymeric medium with the continuous ferromagnetic wires embedded therein to form a continuous core precursor, and cutting said continuous core precursor into discrete magnetic soft cores, wherein said continuous extrusion process comprises passing the continuous ferromagnetic wires through an extrusion chamber while the polymeric medium is extruded through said extrusion chamber.

26. (canceled)

27. The method according to claim 25, wherein the continuous ferromagnetic wires are kept aligned with the extrusion chamber and arranged according to a predetermined pattern while passing through said extrusion chamber by making the continuous ferromagnetic wires pass through several holes and/or including an axial magnetic induction on the cured polymer, said several holes being arranged according to said predetermined pattern in a wire feed-in plate located at one end of the extrusion chamber opposite to an outlet end thereof and wherein the continuous ferromagnetic wires are made to pass through said holes of the wire feed-in plate and through the extrusion chamber towards said outlet end by pulling the continuous ferromagnetic wires with the uncured polymeric medium, loaded with dispersed ferromagnetic microfibers, microparticles or nanoparticles, being injected in viscous form into the extrusion chamber from a polymer feed-in passage located in a side wall of the extrusion chamber and wherein each of the continuous ferromagnetic wires is pushed by a pushing device located upstream of the wire feed-in plate.

28. (canceled)

29. The method according to claim 25, wherein former ends of the continuous ferromagnetic wires are connected to a plunger slidably arranged within the extrusion chamber and located downstream of said polymer feed-in passage, said plunger keeping the continuous ferromagnetic wires aligned with the extrusion chamber and arranged according to said predetermined pattern while pulling the continuous ferromagnetic wires along the extrusion chamber at the start of an extrusion operation, said plunger being then eliminated by cutting at least a former end of the continuous core precursor and wherein the continuous core precursor is cooled by means of a cooling device outside the extrusion chamber before cutting and the continuous core precursor is pooled by a pooling device located downstream of the cooling device before cutting.

30-33. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0043] The previous and other advantages and features will be better understood from the following detailed description of embodiments, with reference to the attached drawing, which must be considered in an illustrative and non-limiting manner, in which:

[0044] FIG. 1 is a perspective view of a flexible soft magnetic core according to an embodiment of the present invention;

[0045] FIG. 1a is a perspective view of a flexible soft magnetic core according to an embodiment of the present invention including nanoparticles embedded on the ferromagnetic core;

[0046] FIG. 2 is a perspective view of a coil for an antenna according to an embodiment of the present invention, including the flexible soft magnetic core; and

[0047] FIGS. 3, 4, 5 and 6 are side sectional views illustrating successive stages of a possible method for producing continuously a flexible soft magnetic core according to an embodiment of the present invention;

[0048] FIG. 7 is a perspective view of a flexible soft magnetic core according to an embodiment including nanoparticles and without wires on said core.

[0049] FIGS. 8 and 9 are perspective views showing flexion and torsion of the proposed soft magnetic core according to the invention.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0050] Referring first to FIG. 1, a flexible soft magnetic core 1 according to an embodiment of the first aspect of the present invention is shown. The core body 2 can have a prismatic or cylindrical outer shape.

[0051] According to an embodiment the cured polymeric medium 3 including the plurality of ferromagnetic wires is an extruded part, elongated along an axis, being twistable and flexible along two orthogonal planes which intersect defining said axis.

[0052] The flexible soft magnetic core 1 comprises parallel continuous ferromagnetic wires 4 that are flexible wires, embedded in a core body 2 made of a polymeric medium 3, such as a polymeric matrix. Said continuous ferromagnetic wires 4 are spaced apart from each other and extend from one end to another of said core body 2, so that the continuous ferromagnetic wires 4 are electrically insulated from each other by the polymeric medium 3.

[0053] The soft magnetic core has a length longer than 15 cm and preferably longer than 25 cm (for example 30 cm and more) so that in the case of the core being applicable to an antenna for a vehicle a reduction of number of antennas per vehicle from 5 to 2 can be achieved with up to 4 times longer thinner antennas.

[0054] In an embodiment the cured polymeric medium (3) is a polymer-bonded soft magnetic material PBSM.

[0055] In another embodiment the polymeric medium is a polymeric matrix obtained from epoxy or urethane or polyurethanes or polyamide derivatives.

[0056] Each of said continuous ferromagnetic wires 4 has a constant cross section 5 along its whole length, wherein said constant cross section is a circular cross section having an area in the range of 0.002 to 0.8 square millimetres. Alternatively, the constant cross section is a polygonal cross section having an area within the same range.

[0057] The flexible soft magnetic core 1 shown in FIG. 1 comprises twenty continuous ferromagnetic wires 4, although at least eight continuous ferromagnetic wires 4 per core is considered enough.

[0058] As per one embodiment a flexible magnetic core comprises at least eight ferromagnetic wires (4) comprised by high/low aspect ratio preferably of less than 1000 (having the wires a diameter of 20 microns and a length of 20 cm).

[0059] In the disclosed embodiment the continuous ferromagnetic wires 4 are arranged within the core body 2 made of the polymeric medium 3 in several equidistant parallel geometric planes, wherein the continuous ferromagnetic wires 4 arranged in one geometric plane are staggered with respect to the ferromagnetic wires 4 arranged in another adjacent parallel geometric plane. This provides regular and uniform distances between the continuous ferromagnetic wires 4.

[0060] The continuous ferromagnetic wires 4 are made of a very high permeability (values are in the range from 22.5 to 438 μm/mH.Math.m.sup.−1) ferromagnetic material, such as, for example, an alloy of Nickel, Cobalt and Manganese. In the embodiment shown in FIG. 1, the continuous ferromagnetic wires 4 are bare ferromagnetic wires. However, in an alternative embodiment (not shown) the continuous ferromagnetic wires 4 are wires coated by respective electrically isolating sheaths. In the embodiment shown in FIG. 1, the core body 2 has a prismatic or parallelepiped outer shape. However, in an alternative embodiment (not shown) the core body 2 has a cylindrical outer shape.

[0061] The continuous ferromagnetic wires 4 used have a constant cross section 5 along its whole length, said constant cross section being circular having an area in the range of 0.002 to 0.8 square millimetres.

[0062] As per another embodiment the continuous ferromagnetic wires 4 are arranged in several equidistant parallel geometric planes, wherein the continuous ferromagnetic wires 4 arranged in one geometric plane are staggered with respect to the ferromagnetic wires 4 arranged in another adjacent parallel geometric plane.

[0063] In an example the continuous ferromagnetic wires (4) are made of a ferromagnetic material having a very high permeability in the range of 22.5 to 438 μm/mH.Math.m.sup.−1, such an alloy of iron and one or more of Nickel, Cobalt, Molybdenum, and Manganese

[0064] As per one embodiment the continuous ferromagnetic wires can be also electrically insulated by a coating of a glaze or enamel

[0065] Referring now to FIG. 2, a coil for an antenna 7 according to an embodiment of the third aspect of the present invention is shown. The antenna coil 7 comprises a flexible soft magnetic core 1 as the one described above with reference to FIG. 1 and at least one winding 21 wound about the flexible soft magnetic core 1. The winding 21 is made of a conductor material and is either coated with an isolating layer or the winding 21 of the coil 7 are spaced apart from each other in order to avoid contact therebetween. When an electric current is applied to the winding 21 a magnetic flow is induced along the continuous ferromagnetic wires 4 in the flexible soft magnetic core 1.

[0066] FIGS. 3, 4, 5 and 6 illustrate a method for producing a flexible soft magnetic core 1 according to an embodiment of the third aspect of the present invention.

[0067] Therefore the cured polymeric medium 3 including the plurality of ferromagnetic wires is an extruded part, elongated along an axis, being twistable and flexible (see FIGS. 8 and 9) along two orthogonal planes which intersect defining said axis.

[0068] With regard to the method In a first stage shown is FIG. 3, the method comprises making a plurality continuous ferromagnetic wires 4, which are unwound from respective reels 22, pass through several holes 9 arranged according to a predetermined pattern in a wire feed-in plate 8 located at one end of an extrusion chamber 20. The extrusion chamber 20 has an elongated straight stretch having a constant cross-section with an outlet end 16 opposite to the wire feed-in plate 8. Each of the continuous ferromagnetic wires 4 is pushed into the extrusion chamber 20 by a corresponding pushing device 19 located upstream of the wire feed-in plate 8.

[0069] A polymer feed-in passage 17 is located in a side wall of the extrusion chamber 20. Said polymer feed-in passage 17 is connected to an outlet of a hopper 23 with controlled heating, containing uncured polymeric medium 3 in a fused state and a worm 24 in the hopper 23 is arranged to thrust the uncured fused polymeric medium 3 into the extrusion chamber 20 (thermally isolated) through polymer feed-in passage 17.

[0070] At the start of an extrusion operation, the former ends of the continuous ferromagnetic wires 4 are connected to a plunger 18 slidably arranged within the extrusion chamber 20 and located downstream of said polymer feed-in passage 17. The former ends of the continuous ferromagnetic wires 4 are connected to the plunger 18 at locations thereof arranged according to same predetermined pattern as the holes 9 in the wire feed-in plate 8.

[0071] Thus, the wire feed-in plate 8 and the plunger 18 keep the continuous ferromagnetic wires 4 aligned with the extrusion chamber 20 and arranged according to the predetermined pattern while the plunger 8 pulls the continuous ferromagnetic wires 4 along the extrusion chamber 20 under the pressure exerted by the uncured polymeric medium 3 being injected in viscous form through the polymer feed-in passage 17 into the extrusion chamber 20 between the feed-in plate 8 and the plunger 18, with the uncured polymeric medium 3 embedding the continuous ferromagnetic wires 4.

[0072] By continuously feeding the uncured polymeric medium 3 into the extrusion chamber, the plunger 18 is moved to the outlet end 16 pulling the continuous ferromagnetic wires 4 so that a continuous core precursor 10 begins to be formed. The holes 9 of the wire feed-in plate 8 are configured and arranged to fit to the continuous ferromagnetic wires 4 and to avoid the polymeric medium 3 passing back therethrough.

[0073] FIG. 4 illustrates a second stage of the method in which the former end of the continuous core precursor 10 with the plunger 18 attached thereto has come out the extrusion chamber 20 through the outlet end 16 and the continuous core precursor 10 is cooled 1 by means of a cooling device 13 located outside the extrusion chamber adjacent to the outlet end 16. In the illustrated embodiment, the cooling device 13 comprises a coiled duct along which a cooled heat transfer fluid flows. However, the cooling device 13 can alternatively comprise other cooling means.

[0074] The continuous core precursor 10 is additionally pooled by a pooling device 15 located outside the extrusion chamber 20 downstream of the cooling device 13 and adjacent thereto. In the FIGS. 3, 4, 5 and 6, the polymeric medium 3 is shown shaded by parallel hatch lines representing the level of curing, with distances between the parallel hatch lines being narrower as the polymeric medium 3 becomes more and more cooled and solidified.

[0075] FIG. 5 illustrates a third stage of the method in which the former end of the continuous core precursor 10 with the plunger 18 attached thereto has been passed through a cutting device 24. In the illustrated embodiment, the cutting device 24 comprises an anvil 25 having an opening through which the continuous core precursor 10 passes, and a cutting blade 26 actuated to severe the continuous core precursor 10 adjacent the anvil 25. However, the cutting device 24 can alternatively comprise other cutting means such a laser or a water jet cutting.

[0076] FIG. 6 illustrates a fourth and last stage of the method in which the former end of the continuous core precursor 10 with the plunger 18 attached thereto has been severed from the continuous core precursor 10 by means of the cutting device 24 and then successive flexible soft magnetic cores 1 are formed by repeatedly cutting the continuous core precursor 10 with the cutting device 24 as the continuous core precursor 10 comes out the extrusion chamber 20. The former end of the continuous core precursor 10 with the plunger 18 attached thereto is rejected. The obtained subsequent flexible soft magnetic cores 1 are as described above with reference to FIG. 1.

[0077] Thus, the method of the present invention comprises embedding continuous ferromagnetic wires 4 into an uncured and fluid (fused) polymeric medium 3 by means of a continuous extrusion process, curing the polymeric medium 3 with the continuous ferromagnetic wires 4 embedded therein to form a continuous core precursor 10, and cutting said continuous core precursor 10 into discrete soft magnetic cores 1. The continuous ferromagnetic wires 4 are through an extrusion chamber while the polymeric medium 3 is extruded through said extrusion chamber 20.

[0078] The present invention proposes a core that has the same effectively cross sectional area than the laminations stack that, as claimed in the US2006022886A1 and US2009265916A1 patents can be as much as 80% smaller due to the higher flux density B that these alloys can withstand. Typically ferrite Bsat is 0.3 T while Ni based alloys can withstand 5 fold Bsat up to 1.5 T and other materials like Permalloy 79Ni4MoFe can be 2×Bsat as per below table:

TABLE-US-00001 TABLE 1 Initial Max Saturation Coercive Perme- Perme- induction Rs CurieTemp force ability ability Resistivity Chemical Grade Bs/T Br/Bm Tc/° C. Hc/A .Math. m.sup.−1 mH .Math. m.sup.−1 μm/mH .Math. m.sup.−1 μΩ .Math. cm 46NiFe ≧1.50 0.75 400 ≦12 2.5-4.5 22.5-45   45 50NiFe ≧1.50 0.72 500 ≦8.8 2.8-5.9 31-65 45 65Ni2.5MoFe ≧1.20 ≧0.9 530 ≦6.4 — 200-438 45 76Ni5Cu2CrFe ≧0.75 — 400 ≦4.8 18.8-31.3  75-225 55 77Ni4Mo5CuFe ≧0.60 — 350 ≦2.0 37.5-75.0 175-312 55 79Ni4MoFe 79 ≧0.75 — 450 ≦4.8 15-32 87.5-275  55 Permalloy 80Ni3CrFe ≧0.65 — 330 ≦4.8 17.5-44    75-200 62 80Ni5MoFe ≧0.70 — 400 ≦4.8 20-75 87.5-325  56 81Ni6MoFe ≧0.60 — — ≦4.0 12.5-62.5 100-250 60

[0079] For a given current I the magnetic field intensity H is proportional to the cross sectional area S of the core and the number of turns. The maximum H is limited by saturation Bsat. As Bsat is from 2 folds to 5 folds larger for the same H, cross sectional area of the core S can be reduced proportionally or, if kept the same, less winding turns are needed for the same magnetic induction thus helping to have either smaller antennae or with less windings.

[0080] According an additional embodiment shown in FIG. 1a and 7, the flexible soft magnetic core of the present invention include nanoparticles embedded on the ferromagnetic core in order to increase the magnetic properties of the soft magnetic core. The features, composition and capacities of said nanoparticles have been above exposed, for example regarding to the nanoparticles size, permeability, alloy composition, etc.

[0081] According to a preferred embodiment the cured polymeric medium 3 further includes microfibers, microparticles or nanoparticles of a soft ferromagnetic material that are present alone or in any combination among them within the polymeric matrix of said polymeric medium 3.

[0082] The microfibers, microparticles or nanoparticles of a soft ferromagnetic material used represent weight content up to 85% of the total weight of the core. The microfibers, microparticles or nanoparticles of soft magnetic material are homogeneously distributed and electrically insulated within the polymeric matrix of said polymeric medium (3) by means of one or more dispersant agents incorporated to the uncured liquid polymeric medium along with said microfibers, microparticles or nanoparticles.

[0083] In an embodiment the cited dispersant is present in an amount of around 4-5% of the liquid polymer providing said core body.

[0084] Moreover said one or more dispersant agents comprises Solsperse from Lubrizol.

[0085] As per one embodiment one or more dispersant agents comprises a liquid monomer or a hyperdispersant providing to said microfibers, microparticles or nanoparticles a surface treatment involving an electric insulation in addition to the dispersing action.

[0086] The microfibers, microparticles or nanoparticles are of a metal alloy of a very high relative permeability, preferably of less than 600.000, and based on a composition selected among FeNi or Mo—FeNi, or Co—Si, or Fe—NiZn with a weight content of the Ni from 30 to 80% and with the additional components including Mo, Co or Si with a weight content less than 10%.

[0087] The microfibers, microparticles or nanoparticles are selected from pure Fe, pure Fe.sup.3+, or Fe carbonyl or Ni carbonyl or Mn Zn ferrite or Mn Ni ferrite or from a Mollypermalloy powder.

[0088] Besides, the microparticles or nanoparticles of soft ferromagnetic material that are of a crystalline structure selected among an amorphous, nanocrystalline or macro crystalline with enlarged grains in an annealing process.

[0089] And the cited microfibers, microparticles or nanoparticles have a low magnetic coercitivity, preferably of less than 0.1 A/m, and are electrically insolated within the polymeric matrix with a resistivity (ρ) preferably of less than 10.sup.6

[0090] In the embodiment of the FIG. 1a, a plurality of parallel continuous ferromagnetic wires made of a very high permeability value ferromagnetic material are embedded on said ferromagnetic core, instead in the FIG. 7 embodiment the ferromagnetic core lacks of said continuous ferromagnetic wires, being their functionality supplied by nanoparticles embedded on the ferromagnetic core.