WO2018127252A2

WO2018127252A2 - Assembly-type inductor and manufacturing method therefor

Info

Publication number: WO2018127252A2
Application number: PCT/CN2018/083646
Authority: WO
Inventors: 苏雨坡; 李有云; 何海根; 黄敬新; 侯勤田
Original assignee: 深圳顺络电子股份有限公司
Priority date: 2018-04-19
Filing date: 2018-04-19
Publication date: 2018-07-12
Also published as: CN108701531A; WO2018127252A3

Abstract

An assembly-type inductor and a manufacturing method therefor. The assembly-type inductor comprises a cap magnetic core, a T-shaped magnetic core, a conductive winding and a pair of hardware assembly pieces. The inside of the cap magnetic core is formed with a recess, the conductive winding is wound on a central column of the T-shaped magnetic core, the central column of the T-shaped magnetic core and the conductive winding are arranged within the recess inside the cap magnetic core, a gap having a preset distance is arranged between the central column of the T-shaped magnetic core and the bottom of the recess of the cap magnetic core so as to form an air gap, the hardware assembly pieces are fixed on the cap magnetic core and form an electrical connection with the conductive winding, the cap magnetic core and the T-shaped magnetic core are fixed by a binder at least filled in a bottom area of the recess inside the cap magnetic core, and the binder filled in the bottom area of the recess inside the cap magnetic core fills the air gap. Also provided is the manufacturing method for the assembly-type inductor. The assembly-type inductor and the manufacturing method therefor are capable of implementing batch automated production and maintain high performance stability.

Description

Assembly inductor and manufacturing method thereof

Technical field

The present invention relates to magnetic electronic components, and more particularly to an assembled inductor and a method of fabricating the same.

Background technique

With the rapid development of industrial and automotive electronics, the requirements for inductors are becoming more and more demanding. The main problems of the existing assembled inductors are as follows:

First, the assembled inductor needs to be centered to control the air gap to keep the inductance stable;

Second, the dimensional tolerance of the magnetic core material has a great influence on the electrical properties and needs to be strictly controlled;

Third, the automatic centering control air gap is more difficult, mainly in a semi-automatic way.

The above problems are problems that need to be solved in the prior art.

Summary of the invention

The main object of the present invention is to provide an assembled inductor and a manufacturing method thereof for solving the deficiencies of the prior art, and to solve the problem that the existing assembled inductor air gap is difficult to control.

To achieve the above object, the present invention adopts the following technical solutions:

An assembled inductor comprising a hat core, a T-shaped core, a conductive winding and a pair of hardware assemblies, wherein the inside of the hat core is formed with a groove, and the conductive winding is wound around the T-shaped core a middle pillar of the T-shaped magnetic core and the conductive coil inserted into the recess inside the hat core, a center pillar of the T-shaped magnetic core and a body of the hat core a gap having a predetermined separation distance between the bottoms of the grooves, forming an air gap, the hardware assembly being fixed to the hat core and electrically connected to the conductive winding, the hat core and the The T-shaped magnetic cores are fixed by an adhesive at least filled in a bottom region of the recess inside the cap core, the filling of the bottom region of the recess inside the cap core The binder fills the air gap.

Further, the hardware assembly is fixed to the hat core by an adhesive.

Further, the material of the T-shaped magnetic core and the hat magnetic core is NiZn ferrite, the relative magnetic permeability is 350-500, and the interval of the air gap is 0.25 mm-0.45 mm.

Further, the material of the T-shaped magnetic core is alloy powder, the relative magnetic permeability is 45-60, the material of the hat magnetic core is NiZn ferrite, and the relative magnetic permeability is 350-500, the air gap The interval ranges from 0.15 mm to 0.25 mm.

Further, the material of the T-shaped magnetic core is MnZn ferrite, the relative magnetic permeability is 2000-3500, the material of the hat magnetic core is NiZn ferrite, the relative magnetic permeability is 350-500, and the air gap is The interval ranges from 0.30 mm to 0.50 mm.

Further, the material of the T-shaped magnetic core and the hat core is an alloy powder, the relative magnetic permeability is 45-60, and the width of the air gap is not more than 0.20 mm.

Further, the binder filled in the bottom region of the groove inside the cap core is an epoxy system adhesive having a relative magnetic permeability of 1.

Further, spherical or nearly spherical soft magnetic powder particles are mixed in the binder filled in the bottom region of the groove inside the cap core.

Further, the binder having a bottom region of the groove filled inside the cap core has a relative magnetic permeability of 1.5 to 6.0.

A method of fabricating the assembled inductor includes the following steps:

Winding the conductive winding onto the center pillar of the T-shaped core;

In the inner groove of the hat core, at least the bottom region of the groove is filled with an adhesive;

Assembling the T-shaped core and the cap core, placing the center pillar of the T-shaped core and the conductive winding into the recess of the cap core, thereby forming the T-shaped magnetic An inner portion of the core, an air gap filled by the adhesive is formed between the T-shaped core and the cap core;

Fixing a pair of hardware assemblies to the hat core and electrically connecting the hardware assembly to the conductive winding; preferably, the inner side of the pair of hardware assemblies and the hat core The outer side is bonded and fixed together by an adhesive;

The obtained semi-finished product is baked to solidify the binder to obtain a final product, that is, an assembled inductor.

Further, the winding manner of winding the conductive winding onto the center pillar of the T-shaped core is α winding.

The invention has the following beneficial effects:

The present invention provides an assembled inductor that can achieve mass automated production and maintain high performance stability and a method of manufacturing the same. In the present invention, the magnet adopts a combination of a hat core having a groove and a T-shaped core to move the position of the air gap to the inside of the core, thereby eliminating the need for centering control; and greatly changing the structure of the core The influence of the structure of the assembled inductor on the air gap is reduced, and the tolerance requirement for the magnetic core is expanded from ±0.05 mm to ±0.1 mm, which is advantageous for mass automated production. By adopting the technical scheme of the invention, the batch-automatic production of the assembled inductor can be realized, and the deviation of the electrical fluctuation of the inductor caused by the fluctuation of the assembly gap can be effectively reduced.

With the technical solution of the present invention, specific advantages in the following aspects can be obtained:

(1) The core adopts a combination of a hat core and a T-shaped core to move the air gap position to the inside of the assembly, so that the product performance maintains high stability;

(2) The influence factors of air gap include two aspects of structural control precision and core tolerance of inductive equipment. The technical solution of the invention greatly reduces the influence of the structure of the inductive device on the air gap, and reduces the requirement for the core tolerance;

(3) The invention is advantageous for realizing automatic mass production of assembled inductors while ensuring high stability of product quality.

The features and technical advantages of the present invention are set forth in the <RTIgt; Other features and advantages of the invention will be described below.

DRAWINGS

1 is an exploded view of an assembled inductor according to a first embodiment of the present invention;

2(a) is a schematic view of the assembled inductor product of the first embodiment of the present invention;

Figure 2 (b) is a cross-sectional view showing the assembled inductor of the first embodiment of the present invention;

Figure 3 (a) is a cross-sectional view showing the assembled inductor of the second embodiment of the present invention;

3(b) is a schematic view showing an adhesive inside a cap core in the assembled inductor of the second embodiment of the present invention;

4(a) is a schematic view showing the finished product of the assembled inductor according to the third embodiment of the present invention;

Figure 4 (b) is a cross-sectional view showing the assembled inductor of the third embodiment of the present invention;

Fig. 4 (c) is a left side view of the assembled inductor of the third embodiment of the present invention.

Symbol Description:

10 T core;

11 hat core;

12 conductive windings;

13 hardware assembly parts;

16 gaps;

14, 15, 17, 18 binder.

detailed description

The invention will be further described in detail below by means of embodiments with reference to the accompanying drawings. It is to be understood that the following description is only illustrative, and is not intended to limit the scope of the invention. Those skilled in the art will appreciate that the disclosed concepts and embodiments can be readily utilized as a basis for modifying or designing other structures to accomplish the same objectives of the invention. Those skilled in the art should also appreciate that such equivalent constructions do not depart from the spirit and scope of the invention. The novel features, the structure and operation of the invention, together with the It is to be understood, however, that the description of the invention is not intended to limit the invention.

Referring to FIGS. 1 through 4(c), in some embodiments, an assembled inductor includes a hat core 11, a T-shaped core 10, a conductive winding 12, and a pair of hardware assemblies 13, the hat core The inside of the 11 is formed with a groove, the conductive winding 12 is wound around the center pillar of the T-shaped core 10, the center pillar of the T-shaped core 10, and the conductive winding is inserted into the hat core 11 In the inner groove, a gap 16 of a predetermined distance between the center pillar of the T-shaped core 10 and the bottom of the groove of the hat core 11 forms an air gap, and the hardware assembly The member 13 is fixed on the hat core 11 and electrically connected to the conductive winding 12, and the hat core 11 and the T-shaped core 10 are filled at least inside the hat core 11 The

adhesive

15, 17, 18 of the bottom region of the recess is fixed, and the adhesive filling the bottom region of the recess inside the cap core 11 fills the air gap.

In some preferred embodiments, the hardware assembly 13 is secured to the hat core 11 by an adhesive 14.

In some preferred embodiments, the air gap formed by the combination of the T-shaped magnetic core 10 and the hat core 11 has an interval ranging from 0.1 mm to 0.6 mm.

In some more preferred embodiments, the T-shaped magnetic core 10 and the hat core 11 are made of NiZn ferrite, the relative magnetic permeability is 350-500, and the air gap is spaced between 0.25 mm and 0.45. Mm.

In other more preferred embodiments, the T-shaped magnetic core 10 is made of alloy powder, the relative magnetic permeability is 45-60, and the material of the hat core 11 is NiZn ferrite, and the relative magnetic permeability is 350 to 500, the interval of the air gap is in the range of 0.15 mm to 0.25 mm.

In other more preferred embodiments, the T-shaped magnetic core 10 is made of MnZn ferrite, the relative magnetic permeability is 2000 to 3500, the material of the hat core 11 is NiZn ferrite, and the relative magnetic permeability. 350 to 500, the interval of the air gap is in the range of 0.30 mm to 0.50 mm.

In other more preferred embodiments, the T-shaped magnetic core 10 and the hat core 11 are made of alloy powder having a relative magnetic permeability of 45 to 60 and a width of the air gap of not more than 0.20 mm.

In some preferred embodiments, the binder filled in the bottom region of the recess inside the cap core 11 is an epoxy system adhesive having a relative magnetic permeability of one.

In some preferred embodiments, the binder filled in the bottom region of the groove inside the cap core 11 is mixed with spherical or nearly spherical soft magnetic powder particles.

In some more preferred embodiments, the binder having a bottom region of the recess filled inside the cap core 11 has a relative magnetic permeability of 1.5 to 6.0.

Referring to FIGS. 1 through 4(c), in some embodiments, a method of fabricating the assembled inductor includes the following steps:

Winding the conductive winding 12 onto the center pillar of the T-shaped core 10;

In the inner groove of the hat core 11, at least the bottom region of the groove is filled with the adhesive 15, 17, 18;

Assembling the T-shaped core 10 and the hat core 11 , placing the center pillar of the T-shaped core 10 and the conductive winding 12 into the groove of the hat core 11 so that An inner portion of the T-shaped magnetic core 10 forms an air gap filled by the adhesive between the T-shaped magnetic core 10 and the hat core 11;

Fixing a pair of hardware assemblies 13 to the hat core 11 and electrically connecting the hardware assembly 13 with the conductive windings 12; preferably, the inner sides of the pair of hardware assemblies 13 are The outer side of the hat core 11 is bonded and fixed together by an adhesive 14;

The obtained semi-finished product is baked, and the

binders

15, 17, 18 (and, if appropriate, the binder 14) are solidified to obtain a final product, that is, an assembled inductor.

In some preferred embodiments, the winding of the conductive winding 12 onto the center post of the T-shaped core 10 is an alpha winding.

In still other preferred embodiments, the binder filled in the bottom region of the groove inside the cap core 11 is mixed with spherical or nearly spherical soft magnetic powder particles.

Embodiment 1

Referring to FIG. 2(a) to FIG. 2(b), an assembled inductor includes a hat core 11, a T-shaped core 10, a conductive winding 12 and a pair of hardware assemblies 13, the inside of the hat core 11. Formed with a groove, the conductive winding 12 is wound around the center pillar of the T-shaped core 10, the center pillar of the T-shaped core 10, and the conductive winding around the inside of the hat core 11 In the groove, there is a gap 16 between the center pillar of the T-shaped core 10 and the bottom of the groove of the hat core 11 at a predetermined distance to form an air gap, and the hardware assembly 13 passes The adhesive 14 is fixed on the hat core 11 and electrically connected to the conductive winding 12, and the hat core 11 and the T-shaped core 10 are filled in the hat core 11 The adhesive 15, 15, 18 of the bottom region of the inner groove is fixed, and the adhesive 15, 17, 18 filling the bottom region of the groove inside the cap core 11 will The air gap is filled.

The assembled inductor manufacturing method of this embodiment may include the following steps:

(1) winding the conductive winding 12 onto the T-shaped magnetic core 10, preferably in a winding manner;

(2) the inside of the hat core 11 is filled with the adhesive 15;

(3) assembling the T-shaped core 10 and the hat core 11, the inside of the hat core 11 forms an air gap 16 filled with the adhesive;

(4) The inner side of the hardware assembly 13 is coated with the adhesive 14 and assembled with the cap core 11 to form an electrical connection between the hardware assembly 13 and the conductive winding 12;

(5) The assembled semi-finished product is solidified in an oven, and the

binders

14, 15 are solidified to obtain a final product.

Embodiment 2

Referring to FIG. 3( a ) to FIG. 3( b ), the assembled inductor of the second embodiment is different from the assembled inductor of the first embodiment only in the second embodiment, and is filled in the inside of the hat core 11 . The binder 17 in the bottom region of the groove is mixed with spherical or approximately spherical soft magnetic powder particles, and in the first embodiment, the groove is filled in the inside of the hat core 11. The binder 15 in the bottom region does not contain the soft magnetic powder particles.

(2) The inside of the hat core 11 is filled with the binder 17, and the binder 17 is mixed with a spherical soft magnetic powder having the same particle diameter;

(3) The T-shaped magnetic core 10 and the hat core 11 are assembled, and an air gap 16 filled by the adhesive 17 is formed inside;

(5) The assembled semi-finished product is solidified in an oven, and the

binders

14, 17 are solidified to obtain a final product.

Embodiment 3

Referring to FIG. 4( a ) to FIG. 4( c ), the assembled inductor of the third embodiment is different from the assembled inductor of the first embodiment only in that the hardware assembly of the first embodiment is formed with the conductive winding. The electrical connection is located on a diagonal of the approximately square top blade of the T-shaped core at an angle between the two sides of the tip blade; and the hardware assembly of the third embodiment is The location where the electrically conductive windings form an electrical connection is on the edge of the approximately square top blade of the T-shaped core, rather than at the corner of the edge and edge of the tip blade. Compared with the first embodiment, the hardware assembly of the third embodiment is electrically connected to the conductive winding, and only needs to form a relatively small gap on the top blade of the T-shaped core and the hardware assembly. The hardware assembly is electrically connected to the conductive winding in the T-shaped magnetic core. Therefore, compared with the first embodiment, the contact area of the T-shaped magnetic core and the hat magnetic core of the third embodiment is compared. Large, thus having better structural stability and magnetic shielding properties.

The steps employed in the method of fabricating the assembled inductor of this embodiment may be the same as those employed in the method of fabricating the assembled inductor of the first embodiment or the second embodiment.

The above is a further detailed description of the present invention in combination with specific/preferred embodiments, and it is not intended that the specific embodiments of the invention are limited to the description. It will be apparent to those skilled in the art that <RTIgt; </ RTI> <RTIgt; </ RTI> <RTIgt; </ RTI> <RTIgt; It belongs to the scope of protection of the present invention. In the description of the present specification, the description with reference to the terms "one embodiment", "some embodiments", "preferred embodiment", "example", "specific example", or "some examples", etc. Particular features, structures, materials or features described in the examples or examples are included in at least one embodiment or example of the invention. In the present specification, the schematic representation of the above terms is not necessarily directed to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in a suitable manner in any one or more embodiments or examples. In addition, various embodiments or examples described in the specification, as well as features of various embodiments or examples, may be combined and combined. Having described the embodiments of the present invention and the advantages thereof, it is understood that various changes, substitutions and changes can be made herein without departing from the spirit and scope of the embodiments. Further, the scope of the invention is not intended to be limited to the specific embodiments of the process, machine, manufacture, composition, means, methods, and steps. Those of ordinary skill in the art will readily appreciate that the above-disclosed processes, processes, machines, presently present or later developed may be utilized to perform substantially the same functions as the corresponding embodiments described herein or obtain substantially the same results as the embodiments described herein. Manufacturing, material composition, means, method or procedure. Therefore, the appended claims are intended to cover such <RTIgt; </ RTI> <RTIgt; </ RTI> processes, machines, manufactures, compositions, means, methods or steps.

Claims

An assembled inductor, comprising: a hat core, a T-shaped core, a conductive winding and a pair of hardware assemblies, the inside of the hat core is formed with a groove, and the conductive winding is wound around the T a center pillar of the magnetic core, a center pillar of the T-shaped core, and the conductive coiled into the recess inside the hat core, a center pillar of the T-shaped core and the cap a gap of a predetermined separation distance between the bottoms of the grooves of the magnetic core forms an air gap, and the hardware assembly is fixed on the hat core and electrically connected with the conductive winding, the hat magnetic The core and the T-shaped core are fixed by an adhesive filled at least in a bottom region of the groove inside the cap core, and filled in the bottom of the groove inside the cap core The adhesive of the region fills the air gap; preferably, the hardware assembly is secured to the hat core by an adhesive.
The assembled inductor according to claim 1, wherein the T-shaped core and the hat core are made of NiZn ferrite, and the relative magnetic permeability is 350-500, and the interval of the air gap is in the range of 0.25mm ~ 0.45mm.
The assembled inductor according to claim 1, wherein the material of the T-shaped magnetic core is alloy powder, the relative magnetic permeability is 45 to 60, and the material of the hat core is NiZn ferrite, and the relative The magnetic permeability is 350 to 500, and the interval of the air gap is in the range of 0.15 mm to 0.25 mm.
The assembled inductor according to claim 1, wherein the T-shaped magnetic core is made of MnZn ferrite, and the relative magnetic permeability is 2000 to 3500, and the material of the hat core is NiZn ferrite. The magnetic permeability is 350 to 500, and the interval of the air gap is in the range of 0.30 mm to 0.50 mm.
The assembled inductor according to claim 1, wherein the T-shaped magnetic core and the cap magnetic core are made of alloy powder, the relative magnetic permeability is 45 to 60, and the width of the air gap is not more than 0.20mm.
The assembled inductor according to any one of claims 1 to 5, wherein the adhesive filled in a bottom region of the recess inside the cap core is an epoxy system adhesive. The relative magnetic permeability is 1.
The assembled inductor according to any one of claims 1 to 5, characterized in that the binder filled in the bottom region of the groove inside the cap core is mixed with a spherical or approximately spherical shape. Soft magnetic powder particles.
The assembled inductor of claim 7 wherein said binder of said bottom region of said recess filled in said cap core has a relative magnetic permeability of from 1.5 to 6.0.
A method of fabricating an assembled inductor according to any one of claims 1 to 8, characterized by comprising the steps of:

Winding the conductive winding onto the center pillar of the T-shaped core, preferably in a winding manner;

In the inner groove of the hat core, at least the bottom region of the groove is filled with an adhesive;

Assembling the T-shaped core and the cap core, placing the center pillar of the T-shaped core and the conductive winding into the recess of the cap core, thereby forming the T-shaped magnetic An inner portion of the core, an air gap filled by the adhesive is formed between the T-shaped core and the cap core;

Fixing a pair of hardware assemblies to the hat core and electrically connecting the hardware assembly to the conductive winding; preferably, the inner side of the pair of hardware assemblies and the hat core The outer side is bonded and fixed together by an adhesive;

The obtained semi-finished product is baked to solidify the binder to obtain a final product, that is, an assembled inductor.
The method according to claim 9, wherein said binder filled in a bottom portion of said groove inside said cap core is mixed with spherical or approximately spherical soft magnetic powder particles.