TW201535435A - Method of manufacturing combined inductors - Google Patents

Abstract

A combined inductor and its production method is disclosed. The combined inductor includes a bobbin having a hollow part and an outer surface; a long magnet and a short magnet disposed in the hollow part of the bobbin and leaning against each other; a coil wrapped around the outer surface of the tube; and an outer magnet for wrapping the long magnet, the short magnet, the tube and the coil. Accordingly, this invention uses the long magnet and the short magnet leaning against each other to avoid problems in which a conventional inductor merely has a single magnet to cause inductance offset resulted by poor grinding the single magnet or worse alignment between the single magnet and the bobbin as well as high cost due to simultaneous disposal of the single magnet and the outer magnet.

Description

Combined inductor and its manufacturing method

The invention provides a combined inductor and a manufacturing method thereof, in particular to an inductor with a combined magnet and a manufacturing method thereof.

Referring to FIGS. 1A and 1B, there is shown an assembled cross-sectional view of a conventional inductor using an E-shaped magnet. As shown in FIG. 1A, the coil 12 is wound around the outer surface 103 of the bobbin 10, and the bobbin 10 is The hollow portion 101 sleeves the central protrusions 131 of the two E-shaped magnets 13. In this step, the two E-shaped magnets 13 can be in contact with each other or can have a slight gap, and then electrical test is performed. The length of the E-shaped magnet 13 is removed depending on the result of the electrical test. However, as shown in FIG. 1B, if the length of the E-shaped magnet 13 is removed too much, the gap P between the E-shaped magnets 13 of the combined inductor will be too large, resulting in poor electrical quality. This results in a high cost of scrapping all of the E-shaped magnets 13. In addition, a portion of the E-shaped magnet 13 other than the central projection 131 may also obstruct the removal of a portion of the single magnet.

Referring to FIGS. 1A' and 1B', there is shown an assembled cross-sectional view of a conventional inductor using a cap-shaped outer magnet 14 and a single magnet 11. As shown in FIG. 1A', the coil 12 is wound around the bobbin 10. Outer surface 103, single magnet 11 It is fixed in the hollow portion 101 of the bobbin 10, and then electrical test is performed and the partial length of the single magnet 11 is removed depending on the result of the electrical test. After the partial length of the single magnet 11 is removed, as shown in Fig. 1B', the cover-shaped outer magnet 14 is further mounted to cover the single magnet 11, the bobbin 10, and the coil 12. However, if the length of the single magnet 11 is removed too much and the gap P' between the cap-shaped outer magnet 14 and the single magnet 11 is too large, the bobbin 10, the single magnet 11 and the coil 12 will be scrapped. cost. In addition, if the single magnet 11 is fixed in the bobbin 10 and the bobbin 10 is misaligned, the additional cost of the bobbin 10, the single magnet 11 and the coil 12 is also scrapped.

Referring to FIGS. 1A and 1B, there is shown an assembled cross-sectional view of an inductor using a U-shaped outer magnet 14' and a single magnet 11. As shown in FIG. 1A, the single magnet 11 is first fixed. In the hollow portion 101 of the bobbin 10, electrical testing is performed and the partial length of the single magnet 11 and the U-shaped outer magnet 14' is removed according to the electrical test result. Thereafter, as shown in FIG. 1B", the joint is A U-shaped outer magnet 14' covers the single magnet 11, the bobbin 10, and the coil 12. However, if the length of the single magnet 11 or the U-shaped outer magnet 14' is removed too much, the gap P between the U-shaped outer magnet 14' and the single magnet 11 or the gap between the U-shaped outer magnets 14' is P. "Excessively large, or the length of the single magnet 11 and the U-shaped outer magnet 14' removed is in accordance with the designed inductance value, but the single magnet 11 is poorly aligned within the bobbin 10, which will result in the bobbin 10, the single magnet 11 and the coil. 12 additional costs of scrapping.

Therefore, how to overcome the shortcomings of the prior art inductors described above is a major issue for those skilled in the art.

In view of the above-mentioned shortcomings of the prior art, the present invention provides a combined inductor comprising: a bobbin having a hollow portion and an outer surface; a long magnet fixed to the hollow portion of the bobbin; a short magnet, Provided in the hollow portion of the bobbin and abutting against the long magnet; a coil wound around the outer surface of the bobbin; and an outer magnet covering the long magnet, the short magnet, and A bobbin in which the coil is wound.

The long magnet, the short magnet, and the outer magnetic system are made of a magnetic material.

The outer magnetic system consists of two U-shaped outer magnets joined to each other or a cap-shaped outer magnet.

In addition, the present invention also provides a method for manufacturing a combined inductor, comprising: (1) winding a coil on a bobbin; (2) fixing a long magnet in the bobbin around which the coil is wound; (3) Inserting a short magnet in the bobbin around which the coil is wound, the short magnet abuts the long magnet; (4) joining the short magnet and the long magnet; and (5) mounting an outer magnet to cover The long magnet, the short magnet, and the bobbin around which the coil is wound.

Before the step (4), the electrical test is further included, and part of the length of the short magnet is removed according to the test result, so that steps (4) to (5) are performed after the test is successful.

The outer magnetic system is composed of two U-shaped outer magnets joined to each other, and further includes performing an electrical test before the step (4), and removing a part of the length of the short magnet according to the test result and removing the U-shaped outer portions. Part of the length of at least one of the magnets to perform steps (4) through (5) after successful testing.

The present invention can be finely adjusted in length by both long magnets and short magnets accompanied by electrical testing, and can be removed and removed by partial length thereof. The short magnet makes the combined inductor of the present invention have better assembly yield, lower scrap cost and better manufacturing convenience than the prior art inductor, thereby greatly reducing the production cost.

10, 20‧‧ ‧ bobbin

101, 201‧‧‧ hollow

103, 203‧‧‧ outer surface

11‧‧‧ single magnet

12, 22‧‧‧ coil

221‧‧‧Wiring

13‧‧‧E-shaped magnet

131‧‧‧Central bulge

14, 24‧‧‧ Covered outer magnets

14', 24'‧‧‧U-shaped outer magnet

240‧‧‧ inner surface

21‧‧‧Long magnet

25‧‧‧ Short magnet

P, P’, P” ‧ ‧ gap

1A and 1B are assembled cross-sectional views of a conventional inductor using an E-shaped magnet; FIGS. 1A' and 1B' are assembled cross-sectional views of a conventional inductor using a cap-shaped outer magnet and a single magnet; The "1B" diagram is an assembled cross-sectional view of a conventional U-shaped outer magnet and a single magnet inductor; and FIGS. 2A to 2D are assembled sectional views of the manufacturing method of the combined inductor of the present invention, wherein the 2D 1 is a cross-sectional view of a combined inductor of the present invention; and 2D' is an assembled cross-sectional view of another aspect of the combined inductor of the present invention.

The other embodiments of the present invention will be readily understood by those skilled in the art from this disclosure. The present invention may be embodied or applied in various other specific embodiments, and various modifications and changes can be made without departing from the spirit and scope of the invention.

Please refer to FIG. 2A to FIG. 2D, which are schematic diagrams of the manufacturing method of the combined inductor of the present invention, wherein the method of manufacturing the combined inductor Each step will be described in detail below with reference to the drawings.

Referring to FIG. 2A, first, a bobbin 20 having an outer surface 203 and a hollow portion 201 is provided, and a coil 22 is wound around the outer surface 203 of the bobbin 20. In detail, the coil 22 may be wound by a wire having an insulating material on the outer surface (a loop of the wire once wound) and a winding (a certain distance between each wire of the coil when wound) The form is wound around the outer surface 203 of the bobbin 20, or is wound around the outer surface 203 of the bobbin 20 in the form of layered flat winding, chaotic winding, honeycomb winding, etc., but the invention is not limited thereto. Furthermore, the coil 22 may have two terminals 221 that are not wound around the outer surface 203 of the bobbin 20, and the combined inductor may have a bobbin (not shown) connected to the bobbin 20, and the bobbin There is a second outlet portion (not shown) for the connection portion 221 to be exposed from the outlet portion.

Referring to FIG. 2B, the long magnet 21 is fixed to the bobbin 20 around which the coil 22 is wound. In detail, the long magnet 21 is fixed in the hollow portion 201 of the bobbin 20. The long magnet 21 may be in the shape of any hollow portion 201 of the adapter bobbin 20, such as a cylinder or a polygonal cylinder, but the invention is not limited thereto. Further, the long magnet 21 is made of a magnetic material (for example, a silicon steel sheet, a permalloy, or the like, but the invention is not limited thereto).

Referring to FIG. 2C, a short magnet 25 is provided in the hollow portion 201 of the bobbin 20 to abut against the long magnet 21, and the long magnet 21 and the short magnet 25 are joined. It should be noted that electrical testing is required before the short magnet 25 and the long magnet 21 are joined, and part of the length of the short magnet 25 is removed according to the test result, so that the long magnet 21 and the short magnet 25 are joined after the test is successful. In detail, the short magnet 25 is made of the same material as the long magnet 21 to adjust the present invention as needed. The inductance of the combined inductor. In the present invention, the short magnet 25 is first disposed in the hollow portion 201 of the bobbin 20 and abuts against the long magnet 21, but the long magnet 21 is not joined to the short magnet 25, and thereafter, the long magnet 21, the short magnet 25, The semi-finished product of the combined inductor of the present invention, which is composed of the coil 22 and the bobbin 20, is electrically tested. If the inductance value of the semi-finished product does not meet the design range of the inductance value, the short magnet 25 is taken out and the short magnet 25 is removed. Part of the length, and the removal method is generally performed by grinding, but the invention is not limited thereto, and thereafter, the short magnet 25 is newly disposed in the hollow portion 201 of the bobbin 20 and abuts against the long magnet 21, and the semi-finished product is Conduct electrical test. If the design range of the inductance value is still not met, remove and test as described above until the inductance value of the semi-finished product meets the design range of the inductance value. After the inductance value of the semi-finished product meets the design range of the inductance value, the short magnet 25 is bonded to the long magnet 21 so that the long magnet 21 and the short magnet 25 are tightly fixed together, thereby preventing the magnetic flux from leaking out.

Therefore, the present invention can be finely adjusted in length by using both the long magnet 21 and the short magnet 25 with electrical test, thereby avoiding the use of an E-shaped magnet or a single magnet in the prior art when the inductance value is failed to be adjusted. The resulting extra cost of the E-shaped magnet, single magnet, bobbin and coil are simultaneously scrapped.

Referring to FIG. 2D, finally, an outer magnet is mounted to cover the long magnet 21, the short magnet 25, the bobbin 20, and the coil 22, thereby forming a combined inductor as shown in FIG. 2D. In detail, the material used for the outer magnet may be the same as that of the long magnet 21 and the short magnet 25, however, the outer magnet may also be made of other kinds of magnetic materials (for example, nickel zinc ferrite (NX series) or manganese zinc ferrite. (MX system The material, but not limited to this, can be made, and the outer magnet can be either a cap-shaped outer magnet 24 or two U-shaped outer magnets 24' joined to each other, as shown in Fig. 2D'. The cover-shaped outer magnet 24 covers the long magnet 21, the short magnet 25, the bobbin 20, and the coil 22 to form a closed magnetic line circuit, and the cover-shaped outer magnet 24 and the U-shaped outer magnet 24' are not as in the prior art, the E-shaped magnet This prevents the removal of a single magnet.

A schematic diagram of the combined inductor of the present invention is shown in FIG. 2D, wherein the combined inductor includes a long magnet 21, a short magnet 25, a bobbin 20, a coil 22, and an outer magnet, and the present invention is clearly understood. See, the combined inductor and its components will be described in detail below.

The long magnet 21 is made of a magnetic material (for example, a silicon steel sheet, a permalloy, etc., but the invention is not limited thereto), and the long magnet 21 may be a cylinder of any shape, such as a cylinder or a polygonal cylinder. However, the invention is not limited thereto. The short magnet 25 is made of the same material as the long magnet 21, or other kinds of magnetic materials (for example, nickel zinc ferrite (NX series) or manganese zinc ferrite (MX series), but this The invention is not limited to being made to adjust the inductance value of the combined inductor of the present invention as needed, and the shape of the short magnet 25 is the same cylindrical shape of the shorter magnet 21 and can be precisely adjusted in length. In order to meet the target inductance value of the design, and the long magnet 21 and the short magnet 25 are closely fixed together, thereby avoiding leakage of magnetic lines.

The bobbin 20 has an outer surface 203 and a hollow portion 201, and the hollow portion 201 is for accommodating the long magnet 21 and the short magnet 25. In detail, the long magnet 21 and the short magnet 25 are fixed in the hollow portion 201.

The coil 22 is wound around the outer surface 203 of the bobbin 20.

The outer magnetic system covers the long magnet 21, the short magnet 25, the bobbin 20, and the coil 22. In detail, the outer magnet may use the same material as the long magnet 21, or other types of magnetic materials (for example, nickel zinc ferrite (NX series) or manganese zinc ferrite (MX series) may be used. However, the invention is not limited to this. The cover outer magnet 24 is sleeved outside the bobbin 20 to cover the long magnet 21, the short magnet 25, the bobbin 20 and the coil 22, and forms a closed magnetic line circuit. In addition, the combined inductor of the present invention may include a bobbin (not shown) having two outlet portions, the bobbin is connected to the bobbin 20, and the wiring portion 221 is exposed from the outlet portion (not shown). .

Please refer to FIG. 2D', which is an assembly diagram of another aspect of the combined inductor of the present invention, wherein the difference between the manufacturing method of the combined inductor and the manufacturing method of the combined inductor in FIG. 2D is In this embodiment, a U-shaped outer magnet 24' is used, and part of the length of the U-shaped outer magnet 24' is removed based on the electrical test results of the short magnet 25, the long magnet 21, the bobbin 20, and the coil 22. In addition, the bobbin 20 can be precisely fixed to the selected position of the inner surface 240 of the U-shaped outer magnet 24' and then fixed to the selected position, and then the other U-shaped outer magnet 24' and the bobbin 20 and U. The combination of the extra-shaped magnets 24' is joined such that the two U-shaped outer magnets 24' are tightly joined to cover the long magnets 21, the short magnets 25, the bobbins 20, and the coils 22 to form a closed magnetic line circuit.

In summary, compared to the prior art, since the present invention performs electrical testing before bonding long magnets and short magnets, and finely adjusting the length of the short magnets, the present invention is more advanced than the prior art inductors. The word can have the following advantages: 1. Avoid a single magnet caused by improper grinding of a single magnet and Simultaneous scrapping of the external magnet; 2. Avoiding the offset of the inductance caused by poor alignment of the single magnet and the bobbin; 3. Avoiding the removal of the single magnet by the external magnet.

The above embodiments are intended to illustrate the principles of the invention and its effects, and are not intended to limit the invention. Any of the above-described embodiments may be modified by those skilled in the art without departing from the spirit and scope of the invention. Therefore, the scope of protection of the present invention should be as set forth in the appended claims.

20‧‧‧ bobbin

203‧‧‧ outer surface

21‧‧‧Long magnet

22‧‧‧ coil

24‧‧‧ Covered outer magnet

25‧‧‧ Short magnet

Claims (8)

A combined inductor includes: a bobbin having a hollow portion and an outer surface; a long magnet fixed to the hollow portion of the bobbin; and a short magnet disposed in the hollow portion of the bobbin, and Abutting against the long magnet; a coil wound around the outer surface of the bobbin; and an outer magnet covering the long magnet, the short magnet, and a bobbin around which the coil is disposed. The combined inductor of claim 1, wherein the long magnet, the short magnet, and the outer magnetic system are made of a magnetic material. The combined inductor of claim 1, wherein the outer magnetic system is composed of two U-shaped outer magnets joined to each other or is a cover-shaped outer magnet. A method for manufacturing a combined inductor includes the steps of: (1) winding a coil on a bobbin; (2) fixing a long magnet in the bobbin around which the coil is wound; and (3) winding the coil a short magnet is inserted into the bobbin having the coil, and the short magnet is abutted against the long magnet; (4) the short magnet and the long magnet are joined; and (5) an outer magnet is mounted to cover the long magnet, The short magnet and the bobbin around which the coil is wound. The method for manufacturing a combined inductor according to claim 4, wherein the electrical test is performed before the step (4), and the test result is obtained. The length of the short magnet is removed to perform steps (4) through (5) after the test is successful. The method of manufacturing a combined inductor according to claim 4, wherein the long magnet, the short magnet, and the outer magnetic system are made of a magnetic material. The method of manufacturing a combined inductor according to claim 4, wherein the outer magnetic system is composed of two U-shaped outer magnets joined to each other or is a cover-shaped outer magnet. The method of manufacturing a combined inductor according to claim 4, wherein the external magnetic system is composed of two U-shaped outer magnets joined to each other, and is electrically tested before the step (4), and is based on the test result. Removing a portion of the length of the short magnet and removing a portion of the length of at least one of the U-shaped outer magnets to perform steps (4) through (5) after the test is successful.