CN103489576A - Micro shielding magnetic part - Google Patents
Micro shielding magnetic part Download PDFInfo
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- CN103489576A CN103489576A CN201310199304.0A CN201310199304A CN103489576A CN 103489576 A CN103489576 A CN 103489576A CN 201310199304 A CN201310199304 A CN 201310199304A CN 103489576 A CN103489576 A CN 103489576A
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Abstract
The invention provides a micro shielding magnetic part. The invention also provides a low-outline shielding magnetic part. The magnetic part comprises a self-centering core and a coil assembly.
Description
The application is dividing an application of the application number submitted on June 15th, 2007 is 200710111096.9, denomination of invention is " minisize shielding magnetic component " application for a patent for invention.
Technical field
The present invention generally relates to the manufacture of electronic unit (component), and more specifically, relates to the manufacture such as the micro magnetic parts of inductor.
Summary of the invention
The invention provides a kind of low profile magnetic component, described low profile magnetic component comprises: but the first core of being made by permeability magnetic material and limit received block; But the second core of being made by permeability magnetic material, described the second core with described the first core independently mode make; And with described the first core and the second core coil that independently mode forms, described coil at least comprise the first lead-in wire, second the lead-in wire and described first the lead-in wire and second the lead-in wire between a plurality of circles; Wherein said the first core limit to be received the received block of described coil, and at least one in described the first core and the second core comprises the projection coordinated with described coil.
Wherein, described the second core limits described projection, and described projection extends in the central opening of described coil.
Wherein, when described core is assembled, the little distance of distance between described the first core of described protruding ratio of elongation and the second core forms gap thus between described the first core and the second core.
Wherein, described the first core limits described projection, and described projection extends through the central opening of described coil.
Wherein, described projection comprises the post extended from the pedestal of described the first core, and when described the first core and the second core, when assembled, described post is what to separate with described the second core.
Wherein, described the first core comprises the surperficial installation end for described coil lead.
Wherein, described low profile magnetic component also comprises the first conductive connection folder and the second conductive connection folder of receiving respectively described the first coil lead and the second coil lead.
Wherein, described coil also comprises the 3rd lead-in wire and the 4th lead-in wire.
Wherein, described coil comprises inner rim and neighboring, and each in wherein said the first lead-in wire and the second lead-in wire is connected to described coil in described neighboring.
Wherein, described parts are power inductors.
The present invention also provides a kind of low profile magnetic component, and described low profile magnetic component comprises: but the first core of being made by permeability magnetic material and limit received block; Be received within the preform coil in the described received block of described the first core, described coil at least comprises the first lead-in wire, the second lead-in wire and a plurality of circles between described the first lead-in wire and the second lead-in wire; But and the second core of being made by permeability magnetic material, described the second core with described the first core independently mode make, described the second core comprises post, described post extends through the central opening of described coil and sets up the gap with described the first core.
Wherein, described the first core comprises the surperficial installation end for described coil lead.
Wherein, described low profile magnetic component also comprises the first conductive connection folder and the second conductive connection folder of receiving respectively described the first coil lead and the second coil lead.
Wherein, described coil also comprises the 3rd lead-in wire and the 4th lead-in wire.
Wherein, described coil comprises inner rim and neighboring, and wherein said the first lead-in wire and the second lead-in wire are connected to described coil in described neighboring.
Wherein, described parts are power inductors.
Wherein, described the first core comprises pedestal and the upstanding sidewall extended from described pedestal, and extend between the top of described pedestal and described post in wherein said gap.
Wherein, described the first core also comprises the main body that covers described coil, and described main body has the neighboring larger than described post.
Wherein, described post is columniform basically.
The present invention also provides a kind of low profile magnetic component, and described low profile magnetic component comprises: but the first core of being made by permeability magnetic material and limit received block, and described core comprises the post in described received block protruding upward; Be received within the preform coil in the described received block of described the first core, wherein said post extends through the inner rim of described coil, and described coil at least comprises the first lead-in wire, the second lead-in wire and described a plurality of circles between the first lead-in wire and the second lead-in wire.
Wherein, but described low profile magnetic component also comprises the second core of being made by permeability magnetic material, described the second core with described the first core independently mode make, and cover described coil.
Wherein, described the second core comprises basically smooth body, and described body has the neighboring larger than described post.
Wherein, described the first core comprises the surperficial installation end for described coil lead.
Wherein, described low profile magnetic component also comprises the first conductive connection folder and the second conductive connection folder that is installed to described the first core and receives respectively described the first coil lead and the second coil lead.
Wherein, described coil also comprises the 3rd lead-in wire and the 4th lead-in wire.
Wherein, described coil comprises inner rim and neighboring, and each in wherein said the first lead-in wire and the second lead-in wire is connected to described coil in described neighboring.
Wherein, described parts are power inductors.
Wherein, described the first core comprises pedestal and the upstanding sidewall extended from described pedestal, and extend between the top of described the second core and described post in described gap.
The present invention also provides a kind of low profile magnetic component, and described low profile magnetic component comprises: the preform coil; Be used for the first device that the first magnetic core is provided and receives described preform coil; For the second device of the second magnetic core is provided, described second installs to be provided with described mode of separating for the device that the first magnetic core is provided, and described preform coil is enclosed in described first device; And, for being the device of described coil centering with respect to described core, described centring means is provided at one of described the first magnetic core for magnetic core is provided and second magnetic core in whole mode.
Wherein, described the first magnetic core, described the second magnetic core and described preform coil are worked in coordination.
Wherein, described coil comprises the first lead-in wire, the second lead-in wire, inner rim and neighboring, and each in going between of wherein said the first lead-in wire and second is connected to described coil in described neighboring.
Wherein, described parts are power inductors.
Wherein, described coil comprises more than a winding.
The present invention also provides a kind of method of manufacturing low profile magnetic component, and the method for described manufacture low profile magnetic component comprises: but the first core of being made by permeability magnetic material is provided, and described the first core limits received block; But the second core of being made by permeability magnetic material is provided, described the second core with described the first core independently mode make; And provide with described the first core and the second core coil that independently mode forms, described coil comprises the first lead-in wire, the second lead-in wire and a plurality of circles between described the first lead-in wire and the second lead-in wire, wherein said received block is received described coil, and at least one in described the first core and the second core comprises the projection coordinated with described coil.
Wherein, described coil comprises inner rim and neighboring, and each in wherein said the first lead-in wire and the second lead-in wire is connected to described coil in described neighboring.
Wherein, described coil is configured to make the distance minimization between described the first core and the second core.
The present invention also provides a kind of low profile magnetic component, and low profile magnetic component comprises: the first core, but described the first core by permeability magnetic material, made, and comprise received block; The second core, but described the second core is made by permeability magnetic material independently and with described the first core independently mode make; With with described the first core and the second core coil that independently mode forms, described coil comprises the first lead-in wire, the second lead-in wire and a plurality of circles between described the first lead-in wire and the second lead-in wire, described coil comprises inner rim and neighboring, and wherein said the first lead-in wire and the second lead-in wire are connected to described coil in described neighboring; And for receiving respectively the first conductive connection folder and the second conductive connection folder of described the first lead-in wire and the second lead-in wire; Wherein said the first core limits the received block be suitable for receiving described coil, and at least one in wherein said the first core and the second core comprise projection, and described projection is suitable for being inserted into described coil.
The accompanying drawing explanation
Fig. 1 is the perspective view of the known magnetic part for electronic equipment.
Fig. 2 is the decomposition view of conventional shielding magnetic component.
Fig. 3 is the base assemblies view of parts shown in Fig. 2.
Fig. 4 is the decomposition view of another conventional shielding magnetic component.
Fig. 5 is the base assemblies view of parts shown in Fig. 4.
Fig. 6 is the base assemblies view of another conventional shielding magnetic component.
Fig. 7 is the top for preform (preformed) coil (coil) of the routine of low profile (low profile) inductor components.
Fig. 8 is the top of the formed coil according to the present invention.
Fig. 9 is the decomposition view according to the formed parts of exemplary of the present invention.
Figure 10 is the parts shown in Fig. 9 in the situation that assemble the perspective view of (assembled).
Figure 11 is the bottom perspective view of parts shown in Figure 10.
Figure 12 is the side perspective view that the part of parts shown in Figure 10-12 is removed.
Figure 13 is the decomposition view according to the formed parts of another embodiment of the present invention.
Figure 14 is that the parts shown in Figure 13 are in the situation that the perspective view of having assembled.
Figure 15 is the bottom perspective view of parts shown in Figure 14.
Figure 16 is the side schematic views of parts shown in Figure 13-15.
Figure 17 is the decomposed view according to formed another parts of exemplary of the present invention.
Figure 18 is the side perspective view that the part of parts shown in Figure 17 is removed.
Figure 19 illustrates parts shown in Figure 17 in the situation that part is assembled.
Figure 20 illustrates the bottom perspective view of parts shown in Figure 19.
Figure 21 is the top perspective of parts shown in Figure 17 in assembling situation fully.
Figure 22 is the formed perspective view of a magnetic part again of another exemplary according to the present invention.
Figure 23 illustrates parts shown in Figure 22 in another fabrication stage.
Figure 24 is the top perspective of parts shown in Figure 23 in assembling situation fully.
Figure 25 is the bottom perspective view of parts shown in Figure 23.
Figure 26 is the formed perspective view of a magnetic part again of another exemplary according to the present invention.
Figure 27 illustrates parts shown in Figure 26 in another fabrication stage.
Figure 28 is the top perspective of parts shown in Figure 26 in assembling situation fully.
Figure 29 is the bottom perspective view of parts shown in Figure 28.
Figure 30 is the basic circuit diagram that transducer falls in step.
Figure 31 is the basic circuit diagram that step rises transducer.
Figure 32 is the circuit diagram for high-voltage drive.
Figure 33 illustrates the figure of inductance to current capability for exemplary means.
Figure 34 illustrates the roll-off figure of (rolloff) of inductance for exemplary means.
Embodiment
Disclose the exemplary of such magnetic part here, described magnetic part has overcome in this area for the various challenges for the low profile parts of electronic equipment with the reasonable cost manufacture.More specifically, exemplary minisize shielding formula power component (for example inductor and transformer) and manufacture method thereof are disclosed.Described parts adopt unique cored structure, preform coil, and the melting welding (welding) and the plating technology that are used to form termination (termination) structure of this preform coil.Gap length can control core closely under large production lot in, provide the inductance value of more strict control.By means of the easier assembleability of comparing with the known magnetic part for board application and the productive rate of Geng Gao, described parts can provide originally with lower one-tenth.Therefore described parts also provide the power density with respect to the increase of known elements, and described parts are specially adapted to the power circuit of electronic equipment.
In order the most fully to be familiar with the present invention, following disclosure will be divided into different piece, and wherein part i is set forth conventional shielding magnetic component and relative challenge; And part ii is set forth the exemplary of the magnetic part formed according to exemplary of the present invention.
i. invention is introduced
In the electronic equipment of many types, having started to be desirably in less physical package size provides ever-increasing feature and functional array.For example, comprise now the electronic unit of accelerating such as the hand-held electronic equipment of cell phone, personal digital assistant (PDA) equipment and personal music and amusement equipment, at these equipment, to comprise the functional of desired increase.For these equipment, in the physical package size reduced, receive the parts of accelerating to cause a large amount of uses " low profile " parts, described " low profile " parts have the relatively little height outstanding from circuit board surface.The low profile of parts has reduced required clear height (clearance) on the plate in electronic equipment, and allows a plurality of circuit boards to be stacked in the amount of space reduced in equipment.
Yet there is multiple practical challenge in the manufacture of such low profile parts, make the manufacture difficulty of the desired less low profile of the more and more less equipment of production and expensive.It is difficult for example, producing unified performance in very little magnetic part (inductor and transformer), particularly, when described parts comprise the cored structure of unmanageable band gap during manufacture, causes performance and Cost Problems.In the situation that a large amount of electronic units, the changeability between parts on any performance do not expect, even and relatively little cost savings may be also significant.
The various magnetic parts for board application (including but not limited to inductor and transformer for electronic equipment) comprise that at least one is arranged at magnetic core conductive winding (winding) on every side.In some magnetic parts, core assembly is to be made by band gap and ferrite (ferrite) core that is bonded together.In use, require the gap between core to store the energy in core, and this gap affects magnetic characteristic, described magnetic characteristic includes but not limited to open inductance and DC biasing characteristic.Particularly, in micro-component, the gap that produces homogeneous between core is important for stable manufacture reliable, high-quality magnetic part.
Therefore, expect for board application provides a kind of magnetic part with efficiency and improved manufacturability of raising, and without increasing the big or small of parts and excessively taking the amount of space on printed circuit board (PCB).
Fig. 1 is the perspective view for the known magnetic parts 100 of electronic equipment.Illustrated in Fig. 1, parts 100 are the power inductors that comprise pedestal 102, but described pedestal 102 for example, is made by for example non-conductive path plate material (phenolic resins).Ferrite cydariform core (drum core) 104 (sometimes being called as the winding axle) is attached to pedestal 102 with the adhesive 106 such as epoxy resin-matrix glue.Winding or coil 108 be provided as the reeling wire form of the described cydariform core 104 specific number of turns, and winding 108 ends at (terminate at) each opposite end with the form of the coil lead 110,112 that extends from cydariform core 104.At the relative side of pedestal 102, along metal terminal binding clip (clip) 114,116 is provided, and described binding clip 114,116 can for example be made by sheet metal individually, and is assembled into pedestal 102.The part of each binding clip 114,116 can be by soldering (solder) the led trace to the circuit board (not shown) of electronic equipment, and the part of binding clip 114,116 is with machinery be electrically connected to coil lead 110,112.Ferrite shields ring core 118 basically around (surround) cydariform core 104, and is spaced apart with respect to cydariform core 104 in gapped mode.
Winding 108 directly is wrapped on cydariform core 104, and shielding ring core 118 is assembled into cydariform core 104.Require cydariform core 104 to feel relieved meticulously (centering) to control inductance value with respect to shielding core 118 assemblies, and guarantee the DC offset capability of conductor.Usually with the soldering processes of relatively-high temperature, line lead-in wire 110,112 is soldered to terminal connections folder 114,116.
For microminiaturized low profile parts, the centering operation of cydariform core 104 in shielding core 118 causes the difficulty in multiple practice.In some cases, with epoxy resin, engage ferrite core 104 and 118, to produce the core assembly for the joint of magnetic part.For the gap that core is consistent, often non magnetic pearl (bead) (being generally glass marble) is mixed with the insulating material of viscosity, and be dispersed between core 104 and 118, to form described gap.When by hot curing, epoxy resin engages core 104 and 118, and described pearl keeps apart to form described gap by core 104 and 118.Yet, the ratio that the joint between core 104 and 118 mainly depends on the viscosity of epoxy resin and is dispersed in epoxy resin and pearl in the cementitious mixtures between core.Have been noted that in some applications, sufficiently engage the application desired for them of the core 104 and 118 of joint, and the ratio of epoxy resin and glass marble of controlling in cementitious mixtures is also very difficult.
The method that another kind of known cydariform core 104 is felt relieved in shielding core 118 relates to non magnetic isolated material (spacer material) (not shown) be placed between core 104 and 118.Isolated material is often by paper or steps and to draw the polyester film insulating material to form.Typically, core 104 and 118 and isolated material fastened to each other with the band outside twisting in described two and half cores (core halves), wherein with adhesive, described two and half cores are fixed together, or fix described two and half cores and remain in the gap between described two and half cores with holder.Seldom use many (more than two) isolated materials, very complicated, difficult and expensive because the problem that structure is fixed together becomes.
For coil lead 110,112 being electrically connected to the brazing operation process of terminal connections folder 114 and 116, having been found that in one or two in cydariform core 104 and shielding core 118 and crack may occur, particularly when using very little core.In addition, in winding 108, electrical short may appear in the brazing operation process.Any situation all causes electrical inductor assembly the Performance And Reliability problem in use to occur.
Fig. 2 and 3 illustrates respectively decomposition view and the perspective view of the shielding magnetic component 150 of another kind of known type, and this shielding magnetic component 150 will be easy to manufacture and assemble than the parts 100 shown in Fig. 1 in some aspects.In addition, parts 150 can also provide with the profile lower than parts 100.
Parts 150 comprise the shielding core 156 of cydariform core 152 and this cydariform core of receiving, and coil or winding 154 extend multi-turn on described cydariform core 152.Shielding core 156 comprises and is formed on its lip-deep plating end 160.Linear lead-in wire 162,164 extends from winding 154, and in end 158 and 160 side along being electrically connected to end 158 and 160.Electroplate end 160 and avoided the terminal connections folder (example is binding clip 114 and 116 as shown in Figure 1) of independent making and the pedestal 102 (also shown in Figure 1) that binding clip 114 and 116 is assembled into.Eliminate and in other cases the binding clip of needs 114,116 and pedestal 102 have been saved to material and assembly cost, and the profile height lower than parts 100 (Fig. 1) is provided.
Yet, for being manufactured with low profile more, parts 150 remain a kind of challenge.Cydariform core 152 is still difficult and expensive with respect to the centering operation of shielding core 156.During the manufacture of parts 150, parts 150 also easily are subject to the thermal shock of the high temperature brazing operation for coil lead 162 and 164 being terminated to the end 158 of shielding on core 156 and 160 and potential infringement, or easily are subject to the impact of the thermal shock experienced when parts 150 are surface mounted to circuit board.The thermal shock meeting reduces one of core 104,118 or both structural strengths.Along with the trend that more the low profile parts develop, the size of cydariform core 152 and shielding core 156 just is reduced, and causes them more to be subject to the impact of thermal shock problem.In being used to form the electroplating process of described end, observed the crack of shielding core 156, described crack causes the Performance And Reliability problem, and the qualified parts low-yield of not expecting.
The Figure 4 and 5 diagram is similar to another embodiment of the parts 180 of parts 150 in some aspects.In Fig. 4 and Fig. 5, for similar reference symbol in common trait use and Fig. 2 and 3.Different from parts 150, parts 180 comprise the termination groove 182,184 (Fig. 4) be embedded in shielding core 156.Embedded end access slot 182 and 184 is received winding leads 166,168 (Fig. 5) on shielding core 156 surfaces, and described shielding core 156 can be surface mounted to the circuit board of electronic equipment.With parts 150, compare, embedded end access slot 182 and 184 allows to reduce component height, perhaps reduce the profile of parts, but still face the potential damage of the plating of aforesaid difficulty when feeling relieved for core, end 158 and 160 to core, and the thermal shock problem caused due to the high temperature brazing operation when parts 180 are surface mounted to circuit board.
Fig. 6 illustrates another known parts 200, described parts 200 can, according in parts 150 or 180, any is constructed, still comprise the coil terminals binding clip 202,204 provided in independent mode, maintain more firmly coil lead 166,168 (Fig. 2-5).Binding clip 202,204 is provided to be electroplated on end 158,160 (Fig. 2-5), and clamping (capture) coil lead 166,168.Except termination coil lead 166,168 more reliably, parts 200 are subject to the difficulty of similarly feeling relieved for cydariform core 154 in shielding core 156, when electroplating end to the infringement of core relevant Similar Problems, and the reliability of negative effect parts 200 and the similar thermal shock problem of performance in use.
For fear of the difficulty when coil winding is arrived to more and more less cydariform core 152, and under the target of the low profile height that further reduces such parts, proposed to use preformed loop construction, be replaced in and be wound onto on cored structure, preformed loop construction can be made separately, and can be assembled in cored structure.Fig. 7 is a kind of top of conventional preform coil 220 like this, and described preform coil 220 can be used to construct the low profile inductors parts.Coil 220 comprises the first and second lead-in wires 222 and 224, and is wound around a few one section line between the first and second lead-in wires 222 and 224.Because coil 220 is wound used usual manner, lead-in wire 222 inner rims from coil 220 extend, and extend another root lead-in wire 224 neighborings from coil 220.
iI. exemplary of the present invention
Fig. 8 is for formed miniature or the preform winding of low profile magnetic component or the top of coil 240 according to the present invention.Similar with coil 220 (Fig. 7), coil 240 has the first and second lead-in wires 242 and 244, and be wound around a few to reach one section line of desired effects between the first and second lead-in wires 222 and 224, the inductance value that described desired effects example is applied for selected final use as desired.
In the illustrative embodiment, coil 240 can be formed according to known technology by wire.If desired, the wire that is used to form coil 240 can be coated with paint (enamel) coating etc., to improve the 26S Proteasome Structure and Function aspect of coil 240.As skilled in the art will be aware of, the inductance value of coil 240 depends in part on the number of turns of the type of line, coil neutralization, and the diameter of line.Therefore, the inductance rated value of coil 240 can be for different application and significantly different.
Different from coil 220, go between 242 and 244 both all from the neighboring of coil 240, extend.In other words, go between and 242 and 244 all do not extend from the inner rim of coil 240 or center open circuit.Because go between, 242 and 244 all do not extend from the inner rim of coil 240, so the winding space in cored structure (not shown in Fig. 8, but be described below) can be with than being used by the more effective mode of coil 220.More effectively use the winding space of coil 240 that performance advantage is provided, and further reduce the low profile height of magnetic part.
In addition, more effectively use winding space that extra benefit is provided, be included in when taking the physical area identical with the conventional coil of being made by less ga(u)ge number (wire gauge), by larger ga(u)ge number, make coil.Replacedly, for given ga(u)ge number, by eliminating obsolete space, can provide with identical physical space more wire circle, and conventional coil will take this physical space under the less number of turns.Moreover, more effectively use winding space can reduce parts 260 D.C. resistance (DCR) in use, and reduce the power loss in electronic equipment.
The various views of the magnetic part 260 that Fig. 9-12 diagram forms according to exemplary of the present invention.Parts 260 comprise the first core 262, can insert the preform coil 240 (also shown in Figure 8) of shielding core 262, and cover coil 240 and be received within the second core 264 in the first core 262 in self-centering mode.The shielding core of describing before the first core 262 is somewhat similar, and the second core 264 refers to sometimes by coil 240 encirclement (enclose) guard shields in the first core 262.
As seen best from Fig. 9, but the first core 262 can be formed in solid (solid) flat base 266 by permeability magnetic material (magnetic permeable material), wherein upstanding wall 268,270 extends from pedestal 266 at normal or common vertical direction.Wall 268 and 270 can limit and be generally columniform winding space or winding received block (receptacle) 272 to receive coil 240 between them or on pedestal 266.Otch (cutout) or opening 273 extend between the end of sidewall 268 and 270, and for dividing other coil lead 242 and 244 that space is provided.
The known multiple magnetic material that is suitable for manufacturing core 262.For example, known and can use ferrocart core, comprise iron nickel molybdenum powder (molypermalloy powder, the MPP) core of powdery nickel, iron and molybdenum; Ferrite Material; And high magnetic flux magnet ring material, depend on that parts are for energy supply or power conversion circuits or apply (for example filter inductor) for another kind.Exemplary Ferrite Material comprises commercial the use and extensive obtainable manganese-zinc ferrite and specific power ferrite, nickel-zinc ferrite, lithium-zinc-ferrite, magnesium Mn ferrite etc.Also expect that low-loss iron powder, the ceramic material based on iron or other known materials can be used to make core, realize at least some advantages of the present invention simultaneously.
As shown in Figure 10-12, the first core 262 can also comprise the surperficial mounting end 276,278 on the outer surface that is formed on the first core 262.End 276,278 can be formed on core 262 with for example physical vapour deposition (PVD) (PVD) technique rather than as the normally used plating in this area by leading material.The electroplating technology used with routine is compared, and physical vapour deposition (PVD) allows technology controlling and process greatly, and in the quality of the raising of very little cored structure upper end 268,270.Physical vapour deposition (PVD) can also avoid electroplating core infringement and the relevant problem presented.Although can believe for forming end 268,270 physical gas-phase depositions more useful, but can recognize, can provide other end on structures equally, comprise plating end, terminal connections folder, pass through with the formed surperficial end of the part of the dipping cores 262 such as conductive ink, and other terminating method known in the art or end on structures.
As also illustrated in Figure 10-12, end 276 and 278 can form separately has embedded end access slot 280, and described termination groove 280 is received the terminal of coil lead 242 and 244.In embodiment in the accompanying drawings, as seen best in Fig. 9, when coil 240 is assembled into the first core 262, the lead-in wire of coil 240 can be close to pedestal 266 orientations (orient), and lead-in wire can be bent to and 280 engagements of termination groove.Lead-in wire 242 and 244 can for example be fusion welded to end 276 and 278 subsequently, with guarantee coil lead 242 and 244 to end 276 and 278 enough machinery and being electrically connected.Specifically, can utilize spark melting welding and laser fusion welding to come termination coil lead 242 and 244.
Contrary with brazing operation, coil lead 242 and 244 is fusion welded to end 276 and 278 and has avoided the impact do not expected of soldering on parts 260 total heights, and avoided the thermal shock problem of not expecting and the high-temperature effect to coil 240, and the potential core that brazing operation must cause damages.Yet, although melting welding is helpful, should be appreciated that and can use brazing operation in some embodiments of the present invention and still obtain a lot of benefit of the present invention.
The second core 264 can be to make with the first core 262 independences and the mode of separating, and be assembled into the first core 262 in the mode of explained later subsequently.The second core 262 can be made as smooth dish shape main body (main body) 290 usually by permeability magnetic material but (but for example above-described those permeability magnetic materials), described main body 290 has the first diameter, and comprise with main body 290, in whole mode, form, from the outward extending centering of one end projection 292.Centering projection 292 is positioned at main body 290 center, and can for example be formed cylinder plugs (plug) or the post (post) with diameter less than main body 290.In addition, but post 292 can be resized as the tight coupling of the inner rim with coil 240 be received within the inner rim of coil 240.Therefore, when parts 260 are assembled, post 292 can serve as alignment or centering feature.Post 292 can extend in the coil aperture at peripheral 248 places in coil, and the neighboring of main body 290 can be set to relative with the upper surface of the sidewall 268,270 of the first core 262.When using that for example epoxy resin-based adhesive is bonded together core 262 and 264, coil 240 is sandwiched between core 262 and 264, and is held in place by the post 292 of the second core 264.
When particularly the inside dimension of the received block 272 in the neighboring of coil 240 (reference number 246 expressions in Fig. 8) and the first core 262 is closely mated, core 262 and 264 and the assembling of working in coordination of coil 240 compact and mechanically stable especially parts 260 are provided, in parts 260 without outside centring element.With its coil, directly to be wrapped in the assembling of conventional components on little cored structure contrary, independence and make individually core 262 and 264 and preform coil 240 convenience of assembling of parts 260 and the manufacture of simplification are provided.
As seen best in Figure 12 (in end view, wherein not shown coil 240), the post 292 of the second core 264 has only extended from the part of the distance of the pedestal 266 of main body 290 to first cores 262 through coil inner rim 248 (Fig. 9).That is, an end of post 292 does not extend to the pedestal 266 of the first core 262 and separates with it, so that the core gap 296 of physics to be provided.Physical clearance 296 allows the energy storage in cores, and affects the magnetic characteristic (for example open inductance and DC biasing characteristic) of parts 260.By the gap 296 between post 292 and pedestal 266 is provided, with the conventional low profile magnetic component with for electronic equipment compared directly when and the mode of relatively low cost stable and consistent gap 296 processing for a large amount of parts 260 are provided.Therefore, with existing parts structure, compare, can be with the relatively low cost inductance value of control assembly 260 closely.The higher parts accepted productive rate results from better technology controlling and process.
Figure 13-16 diagram is according to the various views of formed another parts 300 of another embodiment of the present invention.The parts 260 that parts 300 are described about Fig. 9-12 above being similar to aspect a lot, and therefore in Figure 14-16, by similar reference symbol, indicate common feature.Except following noticed, parts 300 are equal to parts 260 basically textural, and substantially similar benefit is provided.
Different from parts 260, the first core 262 of parts 300 is formed has basically solid and continuous sidewall 302, and described sidewall 302 is defined for the received block 272 of preform coil 240.That is, parts 300 do not comprise the otch 273 in the first core 262 shown in Fig. 9.Similarly, as illustrated best in Figure 14, lead-in wire 242,244 orientations that coil 240 extends with the upper surface from coil 240, rather than be the structure shown in Fig. 9, in the structure shown in Fig. 9, lead-in wire is arranged on the lower surface of coil 240 contiguous pedestals 266.Due to the orientation of coil 240 and cube wall 302 of non-incision, contrary with the embodiment in Fig. 9 (wherein termination groove 280 only extends the height of pedestal 266), the termination groove 280 in end 276 and 278 extends on the whole height of the first core 162. End 276 and 278 and groove 280 elongate whole height to sidewall 302 on end 276 and 278 for coil lead 242 and 244 provides the bonding area increased, and can be convenient for soldering or the melting welding operation of the end 276,278 that coil lead 242 and 244 is fixed to the first core 262.
Another parts 320 that Figure 17-21 form with various figure shows another embodiment according to the present invention.The parts 260 that parts 320 are described about Fig. 9-12 above being similar to aspect a lot, and therefore in Figure 17-21, by similar reference symbol, indicate common feature.Except following noticed, parts 320 are equal to parts 260 basically textural, and substantially similar benefit is provided.
As shown in Figure 17-22, parts 320 comprise that preform can lead terminal connections folder 322 and 324, described lead terminal connections folder 322 and 324 with core 262 independently mode be formed into the stand-alone configuration that is assembled into core 262.Binding clip 322 and 324 can for example be made by leading sheet metal, and be stamped, crooked or otherwise form the shape of expectation. Terminal connections folder 322 and 324 provides the termination of coil lead 242 and 244 and for the surface of circuit board, terminal pads is installed.Binding clip 322 can substitute or be additional to above-described end 276,278 and use.
The formed various views of a magnetic part 350 again of Figure 22-25 diagram another exemplary according to the present invention.The parts 260 that parts 350 are described about Fig. 9-12 above being similar to aspect a lot, and therefore in Figure 22-25, by similar reference symbol, indicate common feature.Except following noticed, parts 350 are equal to parts 260 basically textural, and substantially similar benefit is provided.
Different from parts 260, parts 300 comprise and are formed on the first core 262 but not are formed on as described above centering projection or the post 352 in the second core 264.Post 352 can be positioned at received block 272 centers of the first core 262, and can extend upward from the pedestal 266 of the first core 262.Like this, post 352 can extend up in the inner rim 248 of coil 240, so that coil 240 is maintained at fixing, predetermined center with respect to core 262.Yet core 264 only comprises main body 290.That is,, in exemplary, core 264 does not comprise the post 292 shown in Fig. 9 and 12.
In further and/or interchangeable embodiment, each in core 262 and core 264 can be formed has centering projection or post, and the gap provided between styletable is provided the size of its center pillar.In such embodiments, can provide isolated component to limit in whole or in part gap.
The various views of another magnetic part 370 that Figure 26-29 diagram another exemplary according to the present invention forms.The parts 350 that parts 370 are described about Figure 22-25 above being similar to aspect a lot, and therefore in Figure 26-29, by similar reference symbol, indicate common feature.Except following noticed, parts 370 are equal to parts 350 basically textural, and substantially similar benefit is provided.
When expectation during coupling inductor, or, for the manufacture of the transformer such as door driving transformer etc., a plurality of windings in coil 240 may be useful especially.
Inductor mentioned herein can be for various device, and for example step is fallen or walked and rises transducer.For example, Figure 30 illustrates step and falls or the typical circuit figure of step-down controller (buck converter), and Figure 31 illustrates, step rises or the typical circuit figure of boost converter.Inductor prepared in accordance with the present invention can also be for various electronic equipments, for example mobile phone, PDA and GPS equipment.In an exemplary, as shown in the circuit diagram provided in Figure 32, the inductor prepared according to method described herein can be included in and be designed in the high-voltage drive that drives electroluminescent lamp, and described electroluminescent lamp is used in the electronic equipment such as mobile phone.
In exemplary, inductor is provided with the size of 2.5mm * 2.5mm * 0.7mm.Peak value inductance for this exemplary means is 4.7 μ H ± 20%, has the peak current of 0.7A and the average current of 0.46A.The resistance of line is measured as 0.83Ohm.As shown in table 1, the characteristic of the characteristic of this exemplary means and two competitors' device compares.Comparison example 1 is the Murata inductor, model is _ _ _ _.As shown in Table, example inductor (embodiment 1) is encapsulated in inductance and the peak current aspect provides identical performance with much smaller.The performance of embodiment 1 is shown in Figure 33, and wherein inductance is illustrated as the function of electric current.Roll-off (percentage that increases the loss inductance with electric current) of the inductor of embodiment is shown in Figure 34, and is about 20% when peak current is 0.7A.
Table 1
iII. conclusion
Believe that present benefit of the present invention and advantage have obtained detailed demonstration in the above-described embodiment.Unique cored structure, preform coil, and be used to the preform coil to form the melting welding of terminal structure and the thermal shock problem that the plating technology has avoided the conventional components structure to face, outer gap element and the medium (agent) of the cored structure of band gap have been avoided being used to form, and the gap length in allowing to control core closely under large production lot scale, think that described parts provide the inductance value of more strict control.The easier assembleability of comparing due to the magnetic part for board application with known and the productive rate of Geng Gao, can provide with lower cost described parts.
Although disclose various embodiments, expected that other variants of exemplary disclosed herein and reorganization fall in those skilled in the art's limit of power, and can not depart from scope and spirit of the present invention.For example, the distributed air gap core material that for example comprises the iron powder that mixes mutually in microsize grade and resin-bonded agent (produce thus channel effect and without form discrete gap in structure) is also utilized, and can be used in the situation that produce self-centering core and core construct to a great extent without discontinuous physical clearance, with further simplified manufacturing technique, and improve potentially DC biasing characteristic and the AC winding loss that reduces parts.
Such low profile magnetic component has been described, but described magnetic part comprises the first core of being made and comprised received block wherein by permeability magnetic material, but and the second core of being made by permeability magnetic material, wherein the second core is that the mode that is independent of the first core is made into.Described parts also comprise with described the first and second cores coil that independently mode is made, wherein said coil at least comprise the first lead-in wire, second the lead-in wire and a plurality of circles between described lead-in wire.The first core comprises the received block that is suitable for receiving described coil, and at least one in the first and second cores comprises the projection coordinated with described coil.
In one embodiment, described projection extends to the central opening of described coil from described the second core.In another embodiment, when described core is assembled, described projection extends in described received block and reaches the distance less than distance between described the first and second cores, forms gap thus between described the first and second cores.In another embodiment, described the first core comprises the projection of the central opening that extends through described coil.In a further embodiment, described projection is extended from the pedestal of described the first core, thereby when described the first and second cores when assembled, post is what to separate with described the second core.
In another embodiment, described the first core comprises the surperficial installation end for described coil lead.In another embodiment, described parts also comprise the first and second conductive connection folders that are suitable for receiving respectively described the first and second coil leads.In another embodiment, described coil also comprises the third and fourth lead-in wire.In another embodiment, described coil comprises inner rim and neighboring, and each in wherein said the first and second lead-in wires is connected to described coil in described outer circumference.Thereby low profile magnetic component can be used as power inductor.
On the other hand, described a kind of low profile magnetic component, but described low profile magnetic component comprises first core of being made and being had the received block formed therein by permeability magnetic material.Described parts comprise the preform coil in the described received block that is received within described the first core, and wherein said coil at least comprises a plurality of circles between the first lead-in wire, the second lead-in wire and described the first and second lead-in wires.But described parts also comprise the second core of being made by permeability magnetic material, described the second core with described the first core independently mode make, and comprise post, described post extends through the central opening of described coil and sets up the gap with described the first core.
In one embodiment, described the first core comprises the surperficial installation end for described coil lead.In another embodiment, described parts also comprise the first and second conductive connection folders of receiving respectively described the first and second coil leads.In another embodiment, described coil also comprises the third and fourth lead-in wire.In a further embodiment, described coil comprises inner rim and neighboring, and described the first and second lead-in wires are connected to described coil in described outer circumference.In a further embodiment, described the first core comprises pedestal and the upstanding sidewall extended from described pedestal, and extend between the top of described pedestal and described post in a gap.In another embodiment, described post is columniform basically.In another embodiment, described the first core also comprises the main body that covers described coil, and described main body has the neighboring larger than described post.
On the other hand, described a kind of low profile magnetic component, but described low profile magnetic component comprises the first core of being made by permeability magnetic material, wherein said the first core comprises received block and the post in described received block protruding upward.Described parts also comprise in the described received block that is received within described the first core and the preform coil on described post, and wherein said post extends through the inner rim of described coil.Described coil at least comprises a plurality of circles between the first lead-in wire, the second lead-in wire and described the first and second lead-in wires.
In one embodiment, but described parts comprise the second core of being made by permeability magnetic material, wherein said the second core with described the first core independently mode make, and cover described coil.In another embodiment, described the second core comprises basically smooth body (body), and described body has the neighboring larger than described post.In another embodiment, described the first core comprises the surperficial installation end for described coil lead.In another embodiment, described parts comprise the first and second conductive connection folders that are installed to described the first core and receive respectively described the first and second coil leads.In another embodiment, described coil also comprises the third and fourth lead-in wire.In another embodiment, described coil comprises inner rim and neighboring, and each in wherein said the first and second lead-in wires is connected to described coil in described outer circumference.In another embodiment, described parts are power inductors.In another embodiment, described the first core comprises pedestal and the upstanding sidewall extended from described pedestal, and extend between the top of described pedestal and described post in a gap.
On the other hand, a kind of low profile magnetic component, described low profile magnetic component comprises the preform coil, for the first magnetic core being provided and receiving the first device of described preform coil, and for the second device of the second magnetic core is provided.Described second installs to be provided with described mode of separating for the device that the first magnetic core is provided, and described preform coil is enclosed in described first device.Described parts also comprise the device for respect to described core being described coil centering, and described centring means is provided at one of described first and second magnetic cores for magnetic core is provided in whole mode.
On the other hand, described a kind of method of manufacturing low profile magnetic component, said method comprising the steps of: but (a) provide the first core of being made by permeability magnetic material, and wherein said the first core comprises received block; (b) but the second core of being made by permeability magnetic material is provided, wherein said the second core with described the first core independently mode make; And (c) provide with described the first and second cores coil that independently mode forms, wherein said coil at least comprises a plurality of circles between the first lead-in wire, the second lead-in wire and described the first and second lead-in wires, and the described received block wherein be formed in described the first core is received described coil, and at least one in described the first and second cores comprises the projection coordinated with described coil.
On the other hand, described a kind of low profile magnetic component, described low profile magnetic component comprises the first core, but wherein said the first core is made by permeability magnetic material.Described the first core comprises the received block be formed at wherein.Described magnetic part also comprises the second core, but wherein said the second core is made by permeability magnetic material and with described the first core independently mode make.Described parts comprise with described the first and second cores coil that independently mode forms, wherein said coil comprise the first lead-in wire, second the lead-in wire and described first and second the lead-in wire between a plurality of circles.Described coil comprises inner rim and neighboring, and wherein said the first and second lead-in wires are connected to described coil in described outer circumference.Described parts also comprise for receiving respectively the first and second conductive connection folders of described the first and second lead-in wires.The described received block be formed in described the first core is suitable for receiving described coil, and at least one in wherein said the first and second cores comprise fitting projection, and described projection is suitable for being inserted into described coil.
Although about various specific embodiments, described the present invention, those skilled in the art will recognize that, can in the spirit and scope of claims, by modification, put into practice the present invention.
Claims (27)
1. a low profile magnetic component comprises:
But that by permeability magnetic material, made and limit the first core of received block;
But the second core of being made by permeability magnetic material, described the second core with from described the first core independently mode make and there is the shape different with described the first core; And
With with described the first core and the second core preform coil that independently mode forms, described coil at least comprise the first lead-in wire, second the lead-in wire and described first the lead-in wire and second the lead-in wire between a plurality of circles;
Wherein said the first core limit to be received the received block of all described a plurality of circles basically of described coil, and at least one in described the first core and the second core comprises the projection coordinated with described coil; And
Wherein between another of at least one in described projection and described the first core and the second core, set up non-magnetic gap, thereby store energy in described gap when electric current flows through described a plurality of circle.
2. low profile magnetic component as claimed in claim 1, wherein when described core is assembled, the little distance of distance between described the first core of described protruding ratio of elongation and the second core.
3. low profile magnetic component as claimed in claim 1, wherein said the first core limits described projection, and described projection extends through the central opening of described coil.
4. low profile magnetic component as claimed in claim 3, wherein said projection comprises the post extended from the pedestal of described the first core, when described the first core and the second core, when assembled, described post is what to separate with described the second core.
5. low profile magnetic component as claimed in claim 1, wherein said the first core comprises the surperficial installation end for described coil lead.
6. low profile magnetic component as claimed in claim 1, also comprise the first conductive connection folder and the second conductive connection folder of receiving respectively described the first coil lead and the second coil lead.
7. low profile magnetic component as claimed in claim 1, wherein said coil also comprises the 3rd lead-in wire and the 4th lead-in wire.
8. low profile magnetic component as claimed in claim 1, wherein said coil comprises inner rim and neighboring, each during wherein said the first lead-in wire and second goes between is connected to described coil in described neighboring.
9. low profile magnetic component as claimed in claim 1, wherein said parts are power inductors.
10. a low profile magnetic component comprises:
But that by permeability magnetic material, made and limit the first core of received block, and described core comprises the post in described received block protruding upward; And
Be received within the preform coil in the described received block of described the first core, wherein said post extends through the inner rim of described coil, and described coil at least comprises the first lead-in wire, the second lead-in wire and described a plurality of circles between the first lead-in wire and the second lead-in wire.
11. low profile magnetic component as claimed in claim 10, but also comprise the second core of being made by permeability magnetic material, described the second core with described the first core independently mode make, and cover described coil.
12. low profile magnetic component as claimed in claim 11, wherein said the second core comprises basically smooth body, and described body has the neighboring larger than described post.
13. low profile magnetic component as claimed in claim 10, wherein said the first core comprises the surperficial installation end for described coil lead.
14. low profile magnetic component as claimed in claim 10, also comprise the first conductive connection folder and the second conductive connection folder that are installed to described the first core and receive respectively described the first coil lead and the second coil lead.
15. low profile magnetic component as claimed in claim 10, wherein said coil also comprises the 3rd lead-in wire and the 4th lead-in wire.
16. low profile magnetic component as claimed in claim 10, wherein said coil comprises inner rim and neighboring, and each in wherein said the first lead-in wire and the second lead-in wire is connected to described coil in described neighboring.
17. low profile magnetic component as claimed in claim 10, wherein said parts are power inductors.
18. low profile magnetic component as claimed in claim 11, wherein said the first core comprises pedestal and the upstanding sidewall extended from described pedestal, and extend between the top of described the second core and described post in gap.
19. a low profile magnetic component comprises:
The preform coil;
Be used for the first device that the first magnetic core is provided and receives described preform coil; And
For the second device of the second magnetic core is provided, described second installs to be provided with described mode of separating for the device that the first magnetic core is provided, and described preform coil is enclosed in described first device; And
For being the device of described coil centering with respect to described core, described centring means is provided at one of described the first magnetic core for magnetic core is provided and second magnetic core in whole mode; And
For setting up the device of the non-magnetic gap be associated with the device that is used to described coil centering.
20. low profile magnetic component as claimed in claim 19, wherein said the first magnetic core, described the second magnetic core and described preform coil are worked in coordination.
21. low profile magnetic component as claimed in claim 19, wherein said coil comprises the first lead-in wire, the second lead-in wire, inner rim and neighboring, and each in going between of wherein said the first lead-in wire and second is connected to described coil in described neighboring.
22. low profile magnetic component as claimed in claim 19, wherein said parts are power inductors.
23. low profile magnetic component as claimed in claim 19, wherein said coil comprises more than a winding.
24. a method of manufacturing low profile magnetic component, described magnetic part comprises:
The first core, but received block made and limited by described the first core by permeability magnetic material;
The second core, but described the second core is made by permeability magnetic material and with described the first core independently mode make, at least one in described the first and second cores also has the projection be formed at therebetween; And
Coil, described coil with described the first core and the second core independently mode form, described coil comprises the first lead-in wire, the second lead-in wire and a plurality of circles between described the first lead-in wire and the second lead-in wire, described method comprises:
Assemble described the first core, described the second core and described coil, thereby all circle basically of described coil all is arranged in described received block, described projection is inserted into described coil, and non-magnetic gap is established at an end of described projection;
Described core is engaged with each other with the position relationship of fixing; And
Described the first lead-in wire and the second lead end are received to surperficial installation end.
25. method as claimed in claim 24, wherein said coil comprises inner rim and neighboring, and each in wherein said the first lead-in wire and the second lead-in wire is connected to described coil in described neighboring.
26. method as claimed in claim 24, wherein said coil is configured to make the distance minimization between described the first core and the second core.
27. a low profile magnetic component comprises:
The first core, but described the first core by permeability magnetic material, made, and comprise received block;
The second core, but described the second core is made by permeability magnetic material independently and with described the first core independently mode make;
With with described the first core and the second core coil that independently mode forms, described coil comprises the first lead-in wire, the second lead-in wire and a plurality of circles between described the first lead-in wire and the second lead-in wire, described coil comprises inner rim and neighboring, and wherein said the first lead-in wire and the second lead-in wire are connected to described coil in described neighboring; And
Be configured to respectively described the first lead-in wire and second be gone between and is connected to first surface installation end and the second surface installation end of circuit board;
Wherein said the first core limits the received block that is suitable for receiving described coil, and at least one in wherein said the first core and the second core comprises projection, described projection is suitable for being inserted into described coil, and utilizes another in described the first core and the second core to set up non-magnetic gap.
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|---|---|---|---|
| CN201310199304.0A CN103489576A (en) | 2007-06-15 | 2007-06-15 | Micro shielding magnetic part |
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| CN201310199304.0A CN103489576A (en) | 2007-06-15 | 2007-06-15 | Micro shielding magnetic part |
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| CN2007101110969A Division CN101325122B (en) | 2007-06-15 | 2007-06-15 | Miniature Shielded Magnetics |
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