Summary of the invention
The objective of the invention is: be optimized by two " mouth " font magnetic circuits to the traditional inductor part, thereby reduce coil and twine the number of turn, promptly shorten the enamelled wire length of winding coil, device self copper resistance and copper loss are reduced and the technical scheme of a kind of inductance component of proposing.This scheme is improved traditional coil class inductance component, is equipped with the bobbin and the air gap medium of special shape, reaches and promptly saves copper material saves energy again, improves the inductance precision, prolongs the useful life of product simultaneously.
Technical scheme of the present invention is achieved in that a kind of inductance component, comprises magnetic loop magnet, coil and coil rack, and described coil is fastened on coil rack; Described magnetic loop magnet comprises a center pillar magnetic core stack, be provided with at least three side column magnetic core stacks around the distribution of center pillar magnetic core stack, described side column magnetic core stack is " U " shape side column magnetic core stack of a side opening, coil rack is enclosed within on the center pillar magnetic core stack, described coil rack is provided with side column magnetic core stack detent, " U " shape side column magnetic core stack open side insertion detent is fixed on the coil rack and forms closed magnetic loop with the center pillar magnetic core stack, " U " shape side column magnetic core stack open side has two export-oriented end faces, evenly leave a air gap between described export-oriented end face and the center pillar magnetic core stack side, be filled with the air gap medium in the air gap less than 5mm.
In order to realize the fine setting of inductance component inductance value, improve the inductance value precision, described center pillar magnetic core stack side one end is provided with air gap and adjusts groove, described air gap is adjusted groove around an end that is arranged on center pillar magnetic core stack side, adjusting groove with air gap is that the boundary is divided into short side and long side surface with center pillar magnetic core stack side, and the trough rim that leans against long side surface from described air gap adjustment groove equals the length of side on " U " shape side column magnetic core stack extroversion end face a limit to the distance of the short side end face of center pillar magnetic core stack.
The present invention compared with prior art has the following advantages:
1. compare with " EE " type or " EI " molded lines circle class inductance component of the equal inductance value of tradition, inductance component of the present invention can be saved 20%~60% copper material, and volume also can reduce 10%~30%;
2. inductance component air gap of the present invention has reduced the influence of dispersing flux effectively away from the line bag, has reduced the power loss of device, not only saves energy but also prolong useful life of product;
3. behind the employing fine tuning structure, the inductance value precision from conventional coil class inductor current accuracy of measurement ± 4%~± 6% bring up to ± 1%.
Below in conjunction with drawings and Examples the present invention is described in detail.
Embodiment
Embodiment 1
A kind of inductance component embodiment, referring to Fig. 1, Fig. 2, Fig. 3, Fig. 4 and Fig. 5, described inductance component comprises magnetic loop magnet and coil 1, described magnetic loop magnet comprises a center pillar magnetic core stack 2,2-1 is the center with center pillar magnetic core stack central axis, be provided with at least three side column magnetic core stacks 3 around the distribution of center pillar magnetic core stack, described side column magnetic core stack is " U " shape side column magnetic core stack of a side opening 3-1, it is that a straight-arm 3-2 is arranged that described " U " shape side column magnetic core stack can be considered, be " U " shape side column magnetic core stack that the 90 folding arm 3-3 that spend angles form by two with straight-arm respectively at the straight-arm two ends, a coil rack 4 that includes side column magnetic core stack detent 4-1 is enclosed within on the center pillar magnetic core stack, " U " shape side column magnetic core stack open side insertion detent is fixed on the coil rack and forms closed magnetic loop with the center pillar magnetic core stack, two export-oriented end face 3-4 of " U " shape side column magnetic core stack open side, in closed magnetic loop, evenly leave a air gap between described " U " shape side column two export-oriented end faces of magnetic core stack open side and the center pillar magnetic core stack side less than 5mm, described coil is fastened on coil rack, be filled with air gap medium 5 in the described air gap, the air gap medium is as the PET plastic sheet, glass cloth epoxy sheet etc.
Described coil rack 4 is the integrated through injection molding structure, as shown in Figure 3, coil rack includes coil and twines axle 4-3, twine axle at coil and axially be provided with coil postive stop baffle 4-4 in two ends, lateral surface 4-4-1 center at postive stop baffle is provided with open-work 4-2, described open-work passes coil and twines axle, this open-work is used to install the center pillar magnetic core stack, lateral surface and edge end face 4-4-2 at postive stop baffle are provided with side column magnetic core stack detent 4-1, groove on the lateral surface of postive stop baffle and open-work connect, the groove of described detent for " U " side column magnetic core stack being snapped in; On the lateral surface of postive stop baffle, be provided with air gap medium insertion groove 4-5 around the open-work edge; Described medium insertion groove can be the groove that axial thorough coil twines axle; Described air gap medium insertion groove also can be the endless groove on the coil postive stop baffle only, the deep equality of its degree of depth and side column magnetic core stack detent.
If described open-work is a rectangular opening, then described air gap medium insertion groove can be provided with on three limits of open-work, perhaps be provided with simultaneously on four limits, the air gap medium insertion groove of this kind structure, use a rectangular sheet air gap dieelctric sheet that equates with center pillar magnetic core stack height to insert, can finish the air gap medium setting at two ends simultaneously, and not need the flip coils skeleton to carry out twice insertion from an end of coil rack, improved operating efficiency, rectangular sheet air gap dieelctric sheet as shown in Figure 4.
If air gap medium insertion groove is the annular recess on the coil postive stop baffle, the deep equality of its degree of depth and side column magnetic core stack detent, then described air gap dieelctric sheet can be an annular slice, ring segment inserts respectively from the postive stop baffle at coil rack two ends, the annular dieelctric sheet is with respect to the installation of single side face air gap dieelctric sheet, the annulus gap dieelctric sheet has improved operating efficiency equally, and annular slice air gap dieelctric sheet as shown in Figure 5.
Generally, the magnetic flux density that is less than or equal to the side column magnetic core stack for the magnetic flux density that guarantees the center pillar magnetic core stack, the cross-sectional area of described center pillar magnetic core stack will be equal to or slightly less than a plurality of side column magnetic core stack cross-sectional area sum totals, to avoid the close generation heating of the too high magnetic of magnetic core stack to increase loss, the close utilance that lowers magnetic core stack of perhaps low excessively magnetic.
The cross section of described center pillar magnetic core stack can be a polygon, and the cross section of center pillar magnetic core stack illustrated in figures 1 and 2 is a quadrangle; Described three side column magnetic core stacks are 90 degree angles mutually and are provided with around three sides of center pillar magnetic core stack, and its angle is with the angle 6 between three side column magnetic core stack central axis that are affixed to the center pillar magnetic core stack.
Certainly described three side column magnetic core stacks also can be 120 degree angles mutually around the setting of center pillar magnetic core stack, but this kind structure need change some traditional processing molds, increases the initial stage input cost.
Embodiment 2
A kind of inductance component embodiment of four " U " shape side column magnetic core stacks, referring to Fig. 6, Fig. 7, Fig. 8 and embodiment 1, present embodiment " U " shape side column magnetic core stack is four as different from Example 1, the export-oriented end face of four couples of described four " U " side column magnetic core stacks pastes mutually with center pillar magnetic core stack side, and four side column magnetic core stacks are 90 degree angles mutually around the setting of center pillar magnetic core stack.
Described side column magnetic core stack can also be that five or six evenly are provided with around the center pillar magnetic core stack.
The cross section of described center pillar magnetic core stack and " U " shape side column magnetic core stack is a rectangle, and the center pillar magnetic core stack is positioned in the middle of four side column magnetic core stacks, and the end face of two folding arms of four side column magnetic core stacks respectively relatively; Four " U " shape side column magnetic core stack inductance component coil racks as shown in Figure 6, described coil rack is the integrated through injection molding structure, coil rack two end-coil postive stop baffle outer surface centers are rectangle open-work 4-2, side column magnetic core stack location notch 4-1 for four cross grooves that the limit communicates of rectangle open-work, four limits of rectangle open-work are provided with air gap medium insertion groove 4-5, and the medium insertion groove forms etched skeleton type 4-6 on the open-work hole wall of coil rack; Described air gap medium is a book sheet side strip structure, the thickness of air gap medium requires to determine according to magnetic saturation, be generally 0.01~5mm, the method has changed the manufacture method of traditional inductance component, can adjust the thickness of medium according to process condition easily, thereby adjust the size of air gap, save time, laborsaving, province's fund; Coil twines and is arranged on the coil winding axle 2-2, the center pillar magnetic core stack inserts in the open-work of coil rack, four air gap media are inserted respectively in the air gap medium insertion groove, the folding arm of four side column magnetic core stacks inwardly inserts in the cross groove of coil rack coil postive stop baffle outer surface, make side column magnetic core stack straight-arm embed in the groove of postive stop baffle edge end face 4-4-2 and fit tightly the coil rack edge, the folding arm end face of side column magnetic core stack docks four " mouth " font closed magnetic loops of formation with center pillar magnetic core stack side and air gap medium-tight.
Concrete assembling is: the center pillar magnetic core stack of magnetic loop magnet is inserted in the central bore of coil rack, make the two ends of center pillar magnetic core stack all have a little part to be exposed to the coil rack postive stop baffle outside, two air gap media are inserted respectively vertically in the air gap medium insertion groove of two sides about coil rack center pillar magnetic core stack.The folding arm of two side column magnetic core stacks is inwardly inserted coil rack two postive stop baffle outer surfaces cross groove about in two side grooves, the straight-arm of side column magnetic core stack embeds in the groove at two postive stop baffle edges and fits tightly the coil rack edge, make the both ends of the surface of center pillar magnetic core stack and air gap medium concordant, and make end face and air gap medium and two " mouth " shape closed magnetic loop of center pillar magnetic core stack butt joint formation of side column magnetic core stack folding arm with the lateral surface 3-6 of side column magnetic core stack folding arm.In the outside of left and right sides side column magnetic core stack with insulating tape closely wrapping make dock between side column magnetic core stack and coil rack, air gap medium, the center pillar magnetic core stack tight, firm.Then, other two air gap media are inserted vertically in former and later two side medium insertion grooves of coil rack center pillar magnetic core stack respectively again, two other side column magnetic core stack folding arm is inwardly inserted in former and later two side grooves of cross groove of coil rack two postive stop baffle outer surfaces, the straight-arm of side column magnetic core stack embeds in the groove at two postive stop baffle edges and fits tightly the bobbin edge, make the both ends of the surface of center pillar magnetic core stack and air gap medium concordant, and make end face and air gap medium and center pillar magnetic core stack butt joint formation another pair " mouth " font closed magnetic loop of side column magnetic core stack folding arm with the lateral surface of side column magnetic core stack folding arm.Then, in the outside of both sides, front and back side column magnetic core stack with insulating tape closely wrapping make dock between side column magnetic core stack and coil rack, air gap medium, the center pillar magnetic core stack tight, firm.
Embodiment 3
A kind of center pillar magnetic core stack is cylindrical inductance component embodiment, and referring to Fig. 9 and embodiment 1, embodiment 2, different with the foregoing description is that described center pillar magnetic core stack is a cylinder; Because the center pillar magnetic core stack is a circular cylinder, therefore the export-oriented end face of described " U " shape side column magnetic core stack is the arc surface of indent, and the side of arc surface and cylinder magnetic core stack matches.
Embodiment 4
A kind of center pillar magnetic core stack side is provided with reeded inductance component embodiment, referring to Figure 10, Figure 11, embodiment 1, embodiment 2 and embodiment 3, different with the foregoing description is: in order to realize a kind of fine setting of inductance component, improve inductance component inductance value precision, described center pillar magnetic core stack side one end is provided with air gap and adjusts groove 2-3.
The end of present embodiment in described center pillar magnetic core stack side radially is provided with a circle air gap and adjusts groove, and promptly described air gap is adjusted groove is arranged on center pillar magnetic core stack side for annular a end; Adjusting groove with air gap is that center pillar magnetic core stack side, boundary has short side and long side surface, equals the length of side on the export-oriented end face a of " U " shape side column magnetic core stack limit from the distance of described air gap adjustment groove long side surface groove short side end 2-4 along 2-5 to the center pillar magnetic core stack; The height of described center pillar magnetic core stack is slightly less than the width between " U " shape side column magnetic core stack open outer side face (lateral surfaces of two folding arms) 3-5 simultaneously, and its difference equals the width that air gap is regulated groove.The width that air gap described in the embodiment is adjusted groove is less than 2mm, and the degree of depth of groove is less than 1mm.
Adopting this kind structure is to finely tune the center pillar magnetic core stack and the air gap of " U " shape side column magnetic core stack, realize the inductance fine setting after inductance component is made, this kind structure can with the inductance value precision of inductance component of the same type from traditional ± 4% and ± 6% bring up to ± 1%.
Present embodiment center pillar magnetic core stack axial height is arranged on less than the width between " U " shape side column magnetic core stack open outer side face, its objective is to prevent to exceed " U " shape side column magnetic core stack open outer side face height, cause the center pillar magnetic core stack to be easy to be subjected to the external force effect and change the device inductance value that has mixed up if adjust back center pillar magnetic core stack.
Embodiment 5
A kind of end has the inductance component embodiment of the center pillar magnetic core stack of groove, and referring to embodiment 4, the width that described air gap is adjusted groove is 1.5mm, and the degree of depth of groove is 0.5mm.
Embodiment 6
A kind of end has the inductance component embodiment of the center pillar magnetic core stack of groove, and referring to embodiment 4, the width that described air gap is adjusted groove is 1mm, and the degree of depth of groove is 0.2mm.
Embodiment 7
Present embodiment is the specific descriptions of inductance component making and inductance value fine tuning: referring to the foregoing description;
Twine winding around on the axle at a coil that includes the coil rack of side column magnetic core stack detent; At first, on the roll of coil rack,, twine successively with enamelled wire and insulating tape according to the required number of turns, winding order and insulation request; Coil lead is placed on the stitch or other positions that needs of coil rack, ward off tin again and make the line bag; Described skeleton twines axle at coil and axially is provided with the coil postive stop baffle in two ends, is provided with side column magnetic core stack detent, the groove of described detent for being meshed with side column magnetic core stack cross sectional shape at the lateral surface of postive stop baffle.
A center pillar magnetic core stack inserts in the open-work of coil rack, in the location notch on " U " shape side column magnetic core stack insertion shaped framework coil postive stop baffle of an end opening, two export-oriented end faces of its " U " shape side column magnetic core stack open side are affixed to center pillar magnetic core stack axial sides, make " U " shape side column magnetic core stack and center pillar magnetic core stack form closed magnetic loop; In closed magnetic loop, the air gap medium that inserts different-thickness is set between described " U " shape side column two export-oriented end faces of magnetic core stack open side and the center pillar magnetic core stack, forming distance is the even air gap of 0.1mm to 5mm, pressure acts on " U " shape side column magnetic core stack outside perpendicular to center pillar magnetic core stack axis, and described pressure is 0.1 to 0.5kg/cm
2, promptly closely wrap up with insulating tape in the outside of side column magnetic core stack, make coil rack, closed magnetic loop combination magnet, air gap medium dock each other closely, firmly; Guarantee that error is less than 0.01mm between each air gap.
Carry out coarse adjustment: the inductance value error is sifted out as waste product greater than 5% magnetic core stack by measuring.
One end of described center pillar magnetic core stack radially is provided with a circle width for adjusting groove less than 2mm, the degree of depth for the air gap less than 1mm, and described air gap is adjusted the inboard length distance that equals an end face of " U " shape side column magnetic core stack to the distance of center pillar magnetic core stack end face of groove; The height distance of described center pillar magnetic core stack is slightly less than the height distance between two export-oriented end face lateral surfaces of " U " shape side column magnetic core stack open side simultaneously, and described two height difference equal the width of adjustment of inductance groove promptly less than 2mm.
Concrete inductance value fine tuning is:
In the scope of described center pillar magnetic core stack axial height less than " U " shape side column magnetic core stack axial height 2mm, mobile center pillar magnetic core stack in the open-work of coil rack, air gap by described center pillar magnetic core stack one end adjusts that groove is upper and lower to be moved, and has promptly changed the air gap amount of closed magnetic loop and then has adjusted the inductance value of inductance component.