Inductor and manufacturing method thereof

Abstract

The invention relates to an inductor and a manufacturing method thereof. The inductor comprises a closed magnetic loop magnetic core and a coil, wherein the closed magnetic loop magnetic core consists of non-E-type magnetic core bodies and takes the shape of a Chinese character 'ri'. The manufacturing method of the inductor comprises the following steps of firstly arranging an insulating layer on a magnetic core column which needs winding of the magnetic core at the central column, with the thickness less than 0.5 mm, and then according to the required number of circles, sequentially winding by using single-stranded enameled wires or multi-stranded intertwisted enameled wires; after winding the enameled wires, butt jointing the magnetic core at the central column and the magnetic core at the side column into the closed magnetic loop magnetic core body taking the shape of the Chinese character 'ri'; and tightly binding up the outer side of the magnetic core body by using insulating tapes, so as to lead the magnetic core at the central column and the magnetic core at the side column to be butt jointed tightly and firmly. The invention has the beneficial effects that: compared with the traditional inductor with the coil, the single-stranded enameled wire length of the winding coil is reduced, the number of windings is greatly reduced, and the copper material is saved by over 10 percent; simultaneously, the diffusion magnetic flux can be minimized so as to decrease the copper resistance and copper loss of the inductor, and the temperature rise of the inductor is decreased accordingly, thus saving both materials and electrical energy, and prolonging the service life of the product simultaneously.

Description

technical field [0001] The invention relates to electrical components, in particular to an inductance device and a manufacturing method thereof. The inductance device is a core component of power conversion for green lighting and power supply parts of various electronic equipment. Background technique [0002] Traditional coil inductance devices are generally composed of EE combined magnetic core or EI combined magnetic core with coil frame (skeleton) wound with enameled wire. The coil frame is an injection-molded integrated structure. The coil of the inductance device with the above-mentioned shape of the magnetic core must use a coil frame, and the inner hole of the middle winding post of the coil frame and the matching surface of the middle column of the magnetic core are an all-encompassing structure. There are thickness requirements for processing, and the thickness requirement is generally greater than 0.5mm, otherwise the quality of the produced skeleton (especially t...

AI Technical Summary

Problems solved by technology

The coil frame is an injection-molded integrated structure. The coil of the inductance device with the above-mentioned shape of the magnetic core must use a coil frame, and the inner hole of the middle winding post of the coil frame and the matching surface of the middle column of the magnetic core are an all-encompassing structure. There are thickness requirements for processing, and the thickness requirement is generally greater than 0.5mm, otherwise the quality of the produced skeleton (especially the wall thickness) is difficult to guarantee. There must be a certain gap of about 0.5mm, and one side is larger and the other is smaller, which will further increase the gap between the bobbin and the center column of the magnetic core. The sum of the two is about 1mm, so the circumference of the winding on the bobbin will increase. Large, increasing the length and material of the coil enameled wire, and the coils on the inductance device are generally hundreds or thousands of turns, which increases the copper resistance of the device itself, the copper loss also increases, and the temperature rise of the device will also increase. , which wastes both material and electric energy, and reduces the service life of the product

[0003] The traditional EE type magnetic core or EI type magnetic core will leave an air gap in the magnetic circuit, and the air gap is usually placed on the center column of the magnetic core, that is, the air gap is placed in the middle of the wire package. The magnetic permeability is low, and there will be magnetic flux leakage (leakage inductance) near the air gap. Therefore, the coils attached to the air gap cannot all participate in energy conversion, and most of them only play a filling role. As a result, the copper resistance and copper loss of the device itself increase, and the temperature rise of the device increases accordingly. This situation is the same as the above, which wastes both materials and electric energy, and at the same time reduces the service life of the product.

Images