CN112259351A - 一种减少线损的高频电感器制造方法 - Google Patents
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
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- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/34—Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/34—Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
- H01F27/346—Preventing or reducing leakage fields
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- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/10—Connecting leads to windings
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/12—Insulating of windings
- H01F41/125—Other insulating structures; Insulating between coil and core, between different winding sections, around the coil
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/34—Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
- H01F2027/348—Preventing eddy currents
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Abstract
本发明提供一种减少线损的高频电感器制造方法,涉及电开关电源使用的高频变压器领域,本发明中,通过该方法将磁芯进行绕制时,避开填充磁芯气隙处,并将绝缘材料填充磁芯气隙处,尺寸为磁芯气隙高度的2倍,工序简化,且控制方便,避免电感器受磁芯气隙处漏磁线作用,绕组的涡流损耗剧增,造成该处绕组温度剧升的缺点,降低电感器温升、可靠性提高,使用寿命提升,使电感器的整体使用效率提高、降低能耗。
Description
技术领域
本发明涉及开关电源使用的高频变压器领域,尤其涉及一种减少线损的高频电感器制造方法。
背景技术
电感器是能够把电能转化为磁能而存储起来的元件。电感器的结构类似于变压器,但只有一个绕组。电感器具有一定的电感,它只阻碍电流的变化。如果电感器在没有电流通过的状态下,电路接通时它将试图阻碍电流流过它;如果电感器在有电流通过的状态下,电路断开时它将试图维持电流不变。电感器又称扼流器、电抗器、动态电抗器。
但是由于电感器生产制造过程中,线圈绕组在磁芯的气隙处,由磁芯气隙处漏磁线作用,绕组的涡流损耗剧增,造成该处绕组温度剧升,较长时间后该处绕组绝缘层破坏,该处绕组短路绕毁。
发明内容
本发明的目的在于提供一种减少线损的高频电感器制造方法,以解决上述技术问题。
本发明为解决上述技术问题,采用以下技术方案来实现:一种减少线损的高频电感器制造方法,包括以下步骤:
S1、将导线缠绕组成的绕组套接在磁芯体上组成电感线圈;
S2、在磁芯气隙处不绕组,用绝缘材料填充,尺寸为磁芯气隙高度的2倍即可
S3、电感线圈安装到骨架上,并在侧面安装绝缘板,将电感线圈裸露部分盖住;
S4、将绕组引出与骨架上的连接引脚连接;
S5、将以上步骤得到的电感器浸漆烘干。
优选的,所述磁芯采用镍锌铁氧体或锰锌铁氧体材料制成。
优选的,所述绕杆左右侧设置有两个限位盘,且限位盘螺纹固定设置有卡槽。
优选的,所述绝缘板通过胶水固定或熔接固定的方式与骨架连接。
优选的,所述绕组线圈材质为漆包铜线,由导体铜和绝缘漆包膜两部分构成。
优选的,所述采用点焊工艺将所述绕组线圈的首尾引出端与连接引脚相连接。
本发明的有益效果是:
本发明中,通过该方法将磁芯进行绕制时,避开填充磁芯气隙处,并将绝缘材料填充磁芯气隙处,尺寸为磁芯气隙高度的2倍,工序简化,且控制方便,避免电感器受磁芯气隙处漏磁线作用,绕组的涡流损耗剧增,造成该处绕组温度剧升的缺点,降低电感器温升、可靠性提高,使用寿命提升,使电感器的整体使用效率提高、降低能耗。
附图说明
图1为本发明一种减少线损的高频电感器的磁芯结构示意图;
具体实施方式
为了使本发明实现的技术手段、创作特征、达成目的与功效易于明白了解,下面结合具体实施例和附图,进一步阐述本发明,但下述实施例仅仅为本发明的优选实施例,并非全部。基于实施方式中的实施例,本领域技术人员在没有做出创造性劳动的前提下所获得其它实施例,都属于本发明的保护范围。
下面结合附图描述本发明的具体实施例。
如图1所示,一种减少线损的高频电感器制造方法,包括以下步骤:S1、将导线缠绕组成的绕组套接在磁芯体上组成电感线圈,其中将漆包铜线均匀缠绕在磁芯上形成绕组线圈;S2、在磁芯气隙处不绕组,用绝缘材料填充,尺寸为磁芯气隙高度的2倍即可;S3、电感线圈安装到骨架上,并在侧面安装绝缘板,将电感线圈裸露部分盖住,其中绝缘板通过胶水固定或熔接固定的方式与骨架连接;S4、将绕组引出与骨架上的连接引脚连接,其中采用点焊工艺将所述绕组线圈的首尾引出端与连接引脚相连接;S5、将以上步骤得到的电感器浸漆烘干。
将磁芯进行绕制时,避开填充磁芯气隙处,并将绝缘材料填充磁芯气隙处,尺寸为磁芯气隙高度的2倍,避免电感器受磁芯气隙处漏磁线作用,绕组的涡流损耗剧增,造成该处绕组温度剧升,进行测试时,不采用本次技术的电感器产品,电感器负载为80%时,电感器工作4小时后,环境温度为29度电感器温升到53度,8小时后电感器温升比4小时后高出7度左右,并且还在上升,还没有稳定。采用本方案制作的电感器,电感器负载为80%时,电感器工作4小时后,环境温度为29度的变压器温升已经到最高56度,8小时后电感器温升比4小时后低了7度左右,并且基本稳定。
在本发明中,除非另有明确的规定和限定,第一特征在第二特征之“上”或之“下”可以包括第一和第二特征直接接触,也可以包括第一和第二特征不是直接接触而是通过它们之间的另外的特征接触。而且,第一特征在第二特征“之上”、“上方”和“上面”包括第一特征在第二特征正上方和斜上方,或仅仅表示第一特征水平高度高于第二特征。第一特征在第二特征“之下”、“下方”和“下面”包括第一特征在第二特征正下方和斜下方,或仅仅表示第一特征水平高度小于第二特征。
以上显示和描述了本发明的基本原理、主要特征和本发明的优点。本行业的技术人员应该了解,本发明不受上述实施例的限制,上述实施例和说明书中描述的仅为本发明的优选例,并不用来限制本发明,在不脱离本发明精神和范围的前提下,本发明还会有各种变化和改进,这些变化和改进都落入要求保护的本发明范围内。本发明要求保护范围由所附的权利要求书及其等效物界定。
Claims (5)
1.一种减少线损的高频电感器制造方法,其特征在于,包括以下步骤:
S1、将导线缠绕组成的绕组套接在磁芯体上组成电感线圈;
S2、在磁芯气隙处不绕组,用绝缘材料填充,尺寸为磁芯气隙高度的2倍即可
S3、电感线圈安装到骨架上,并在侧面安装绝缘板,将电感线圈裸露部分盖住;
S4、将绕组引出与骨架上的连接引脚连接;
S5、将以上步骤得到的电感器浸漆烘干。
2.根据权利要求1所述的一种减少线损的高频电感器制造方法,其特征在于:所述磁芯采用镍锌铁氧体或锰锌铁氧体材料制成。
3.根据权利要求1所述的一种减少线损的高频电感器制造方法,其特征在于:所述绝缘板通过胶水固定或熔接固定的方式与骨架连接。
4.根据权利要求1所述的一种减少线损的高频电感器制造方法,其特征在于:所述绕组线圈材质为漆包铜线,由导体铜和绝缘漆包膜两部分构成。
5.根据权利要求1所述的一种减少线损的高频电感器制造方法,其特征在于:所述采用点焊工艺将所述绕组线圈的首尾引出端与连接引脚相连接。
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CN113451009A (zh) * | 2021-05-25 | 2021-09-28 | 无锡燊旺和电子科技有限公司 | 电磁装置、电磁装置的制备方法及绕组组件 |
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CN2429899Y (zh) * | 2000-06-14 | 2001-05-09 | 伊博电源(杭州)有限公司 | 一种线圈骨架 |
JP2007201207A (ja) * | 2006-01-27 | 2007-08-09 | Tdk Corp | コイル用ボビン及びインダクタンス素子 |
JP2008210998A (ja) * | 2007-02-27 | 2008-09-11 | Pony Denki Kk | エアギャップ付きリアクトル素子 |
CN102693825A (zh) * | 2012-06-05 | 2012-09-26 | 遂宁龙凯光电科技有限公司 | 一种电感器的制作方法 |
US20140300440A1 (en) * | 2013-04-05 | 2014-10-09 | Hamilton Sundstrand Corporation | Inductor gap spacer |
JP2017135292A (ja) * | 2016-01-28 | 2017-08-03 | パナソニックIpマネジメント株式会社 | リアクトル |
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Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
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CN2429899Y (zh) * | 2000-06-14 | 2001-05-09 | 伊博电源(杭州)有限公司 | 一种线圈骨架 |
JP2007201207A (ja) * | 2006-01-27 | 2007-08-09 | Tdk Corp | コイル用ボビン及びインダクタンス素子 |
JP2008210998A (ja) * | 2007-02-27 | 2008-09-11 | Pony Denki Kk | エアギャップ付きリアクトル素子 |
CN102693825A (zh) * | 2012-06-05 | 2012-09-26 | 遂宁龙凯光电科技有限公司 | 一种电感器的制作方法 |
US20140300440A1 (en) * | 2013-04-05 | 2014-10-09 | Hamilton Sundstrand Corporation | Inductor gap spacer |
JP2017135292A (ja) * | 2016-01-28 | 2017-08-03 | パナソニックIpマネジメント株式会社 | リアクトル |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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CN113451009A (zh) * | 2021-05-25 | 2021-09-28 | 无锡燊旺和电子科技有限公司 | 电磁装置、电磁装置的制备方法及绕组组件 |
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