CN1302492C - 电感线圈构造及其制造方法 - Google Patents

电感线圈构造及其制造方法 Download PDF

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CN1302492C
CN1302492C CNB008002401A CN00800240A CN1302492C CN 1302492 C CN1302492 C CN 1302492C CN B008002401 A CNB008002401 A CN B008002401A CN 00800240 A CN00800240 A CN 00800240A CN 1302492 C CN1302492 C CN 1302492C
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T·M·谢弗
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    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
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Abstract

一种高电流小型电感包括用于形成电感主体而被磁性材料包围的电感线圈。电感线圈是由平板形成，所述平板被切割成正弦形结构并且折叠成褶皱状而用来形成螺线形线圈。

Description

电感线圈构造及其制造方法
发明背景
本发明涉及一种电感线圈构造及其制造方法。本发明的线圈构造适用于通常称为IHLP的高电流小型电感。然而，这种特殊的电感构造也可以用于其它类型的电感。
电感线圈首先是由形成各了种螺线形状的各种形状的材料构成。然而，需要一种改进的线圈构造，它制造简单且效率高而且由它可以制造出可靠的电感线圈。
因此，本发明的主要目的是提供一种改进的电感线圈构造及其制造方法。
本发明的另一目的是提供一种电感线圈构造，它可以用于电感中无空间的高电流小型电感并且它包括完全包围线圈的磁性材料。
本发明的另一目的是提供一种电感线圈构造，它包括一个具有自屏蔽能力的闭合磁系统。
本发明的另一目的是提供一种电感线圈构造，它能够使给定电感性能所需空间的利用率为最大，因而，电感可以为最小尺寸。
本发明的另一目的是提供一种改进的电感线圈构造，它体积小、制造价格低并且与以往的电感线圈构造相比，可以承受较大电流而不会饱和。
本发明的另一目的是提供一种电感线圈构造，它可以降低电感的串联电阻。
发明概述
上述目的可以通过一种高电流小型电感来实现，它包括带有第1及第2线圈端面的电感线圈。一种磁性材料绕着此电感线圈而构成电感主体。此电感线圈包括按沿纵向轴前进的大致螺线形轨迹围绕所述纵向轴而延伸的多个线圈匝。所述线圈匝由具有第1及第2相对的平表面的平板构成，每个所述线圈匝的平表面的至少一部分相对于线圈轴而向着轴的方向。
制造这种电感包括采用带有第1端面、第2端面、相对侧端面、相对平表面及纵向板轴的细长平板电感。在平板电感的每个相对侧端切割多个槽而使得平板电极形成多个沿着平板轴线横向延伸的交叉电极以及多个沿着平板轴线几乎轴向延伸的连接单元，连接单元将交叉单元连接在一起而形成一个正弦形轨迹延伸的连续的电感。这里所述的“正弦形”一般类似于正弦曲线，但是不限于一个连续的曲线，可以包括顶峰，以及可以是制成方形的角状或者其它形状。
在平板电感的相对侧端面上切割成槽之后，按沿平板轴线横向延伸的一条或多条弯曲轴线来弯曲连接单元，使平板电感形成多个褶皱，每个褶皱包括一个交叉单元以及连接单元的一部分。在最后的构造是交叉单元及连接单元形成了一个连续的近似螺线形的电感，并且具有第1及第2相对端。
附图简述
图1是依照本发明并装置在电路板上的电感的立体图。
图2是在压铸步骤之前电感线圈的视图。
图3是在完成压铸步骤后而引线形成之前本发明电感的视图。
图4是图2中沿线4-4的端视图。
图5是图4中沿线5-5的端视图。
图6是形成电感线圈的细长导体毛坯的立体图。
图7是表示图6的毛坯在形成从对面端向里延伸的槽后的形态。
图8是类似于图7，表示形成本发明电感线圈的第一次折叠步骤。
图9是图8中相同步骤的侧视图。
图10类似于图8，表示形成本发明电感线圈的第二次折叠步骤。
图11是电感压模后而形成引线之前的反向视图。
图12类似于11，表示了形成部分引线后的电感。
图13类似于11及12，表示引线的最后成型。
实施形态详述
参照附图，图中数字10一般指装置于电路板12上的本发明的电感。电感10包括具有第1引线16以及第2引线18的电感主体14，第1引线16及第2引线18从电感主体14延伸出去并被折向电感主体14相对的端面。引线16及18以焊接或其它形式在电板12上电连接着。
如图2所示，本发明的电感线圈一般指图中的20。引线16以及18形成线圈20的端面。在引线16及18之间是多个各自具备一个水平支脚28与一个垂直支脚30的L形电感单元26。垂直支脚30端接在连接单元32上，连接单元32折叠成近似180°而为了形成如电感线圈20结构那样的褶皱状。L形线圈单元连接在一起来形成具有沿着纵向线圈轴线36的线圈中心空孔34的螺线形线圈。
图6-10表示制造线圈20的步骤。首先图6所示的由铜或其它导电性材料构成的毛坯导体平板50包括：第1及第2端52、54；一对相对的平表面56；一对相对的侧端面58、60。
图7表示形成线圈20的第1步骤。此步骤中，分别在毛坯平板50的相对端58、60上切下多个槽62、64。可以使用各种切割方法，例如利用激光进行冲压或实际切割，或者其它已有的切割工具。
在完成切割工序之后，毛坯50变为了一个细长的正弦形主体，此主体是由多个横向地沿着平板50纵向轴线的交叉单元66以及多个轴向地沿着平板50纵向轴线的连接单元67而形成。如图7所示，单元66、67形成一个连续的正弦形结构。
图8表示制造线圈20的下一个步骤。将端面52折叠约180°，而为了在第1连接单元67上形成180°角度的弯曲部63。图10表示在下一个连接单元67上的第2弯曲部65。弯曲部63、65是朝着相反的方向，并且重复这样的结构直到构成如图5所示那样的褶皱形构造。
图5中，线圈20具备由毛坯50的相对端面52、54所形成的端面16、18。毛坯50的交叉单元66形成线圈的第1水平支脚28，毛坯50的连接单元67形成线圈20的第2垂直支脚30与连接单元32。
作为用于线圈20首选材料的例子是一种由纯度为99.95％的OFHC铜102制成的铜平板。
主体14的磁性成型材料包含铁粉、树脂及润滑剂。磁性成型材料最好是由BASF Corporation，100 Cherryhill Road，Parsippany，New Jersey制造的等级SQ的羰基铁。此SQ材料由质量分数为0.875％的75％H3PO4来进行绝缘。
在此混合物中经常加入环氧树脂，为此最好选用由Morton Internation，Post Office Box 15240，Reading，Pennsylvania制造的第10-7986名为CorvelBlack的环氧树脂。
另外，在此混合物中还加入了一种润滑剂。这种润滑剂由WitcoCorporation，Box 45296，Huston Texas制造的名为Lubrazinc W的硬脂酸锌。
上述成分的各种化合物可以混合在一起，然而，最好是下述的混合物：
1,000克铁粉
3.3％质量的树脂
0.3％质量的润滑剂
将上述材料(除了润滑剂)混合在一起并且在其中加入丙酮来使材料潮湿而变得如泥一样稠。然后，可以将材料进行干燥以及来屏蔽50网孔的微粒。此时，再将润滑剂加入而来完成制造材料。材料就可以准备进行冲压成型。
下一个步骤是压缩完全绕着线圈20的磁性材料，因此，具有通过施加每平方英寸15至25吨的压力而形成的密度。这使得粉状材料在线圈周围被完全地压紧并成型，而形成如图1及图11-13所示的电感主体14。
此时的产品压铸装配件是图11所示的形状。在烘烤后，如图12及13所示，形成或弯曲了引线16、18。压铸装配件是在325下烘烤1小时45分钟而定型树脂。
与其它电感元件相比，本发明的IHLP电感具一些有独特的性质。电感线圈、引线框架、磁芯材料以及保护外壳都被压铸成一个整体化小型的组合体，并具备适于表面安置的端线。这种构造可以获得已有空间最大的利用率并且这种构造为磁性自屏蔽。
此单一的构造不需要2个一半的磁芯，如以往技术的E磁芯或者其它磁芯形状，并且不需要相应的安装工作。
本发明独特的电感可以使用在高电流的操作中并且能够随着电感而优化磁性参数。
本发明的制造步骤提供了一种低成本、低价格的高特性组合体、高耐压磁性材料以及特别的绕组技术。
此磁芯材料具有高的电阻系数(大于3兆欧)，使得不需要表面安装引线间的导电通路而制造出电感。这种磁芯材料还使得有效工作提高到1MHz。此电感组性能产生一个较低的(DC)每毫亨2毫欧的电阻对电感比。比值为5或小于5较好。
线圈20的特殊构造降低了制造的成本。线圈20可以用于各种电感构造或者IHLP电感中。
在附图以及说明中提出了4各最佳实施形态，虽然进行了详尽表述，只是一般地描述并不是为了进行限定。当实际情况要求或再现效果，可能会存在形式及各部分比例的改变以及等价替代物，但并没有离开本发明的主体以及本发明限定的范围。

Claims (4)

1.一种高电流小型电感，其特征在于，包括：
沿纵向线圈轴延伸的螺旋电感线圈；所述螺旋电感线圈包括一个细长平板，它具有纵轴、第一和第二相对端、一对相对侧端面和一对相对平表面；所述平板具有多个彼此交替并相对于所述平板纵轴横向延伸的第一和第二交叉单元；所述平板还具有多个第一和第二连接单元，每个连接单元分别从第一和第二交叉单元之一延伸；所述第一和第二连接单元的每一个分别沿第一和第二弯曲部被弯曲，横向延伸到所述平板纵轴，所述第一和第二弯曲彼此方向相反；所述第一和第二交叉单元和第一和第二线圈单元在从线圈轴向外的径向方向上在空间上被隔开，由此留下沿线圈轴延伸的线圈中心空孔；由围绕所述电感线圈被完全压缩的绝缘的铁粉、树脂和润滑剂组成的并压铸成单一整体化主体的电感主体。
2.如权利要求1所述的高电流小型电感，其特征在于，位于第一和第二线圈单元上以及位于第二和第二连接单元一部分上的平板的相对平表面朝向相对于纵向线圈轴的轴向方向。
3.一种制造高电流小型电感的方法，其特征在于，包括：
从导电材料形成螺旋电感线圈，所述电感线圈具有第一和第二端子端，其中所述形成螺旋线圈的步骤包括：
从具有纵轴、第一和第二相对端、一对相对侧端面和一对相对平表面的细长平板来形成螺旋线圈；
在所述平板导体的每个所述相对侧端面制备多个槽，而使得所述平板导体形成多个沿着所述纵轴横向延伸的第一和第二交叉单元以及多个沿着所述纵轴轴向延伸的第一和第二连接单元，所述连接单元将所述交叉单元连接在一起而形成一个以正弦形轨迹延伸的连续导体；
沿第一和第二弯曲部分别弯曲所述第一和第二连接单元，而使所述平板导体形成多个褶皱，每个褶皱包括一个所述交叉单元以及一个所述连接单元的一部分，由此所述第一和第二交叉单元以及所述第一和第二连接单元形成了一个连续螺旋导体线圈；
所述第一和第二交叉单元和第一和第二线圈单元在从线圈轴向外的径向上在空间上被隔开，由此留下沿线圈轴延伸的线圈中心空孔；
制备包含电绝缘的铁粉材料、树脂和润滑剂的干燥粉末混合物；
围绕所述电感线圈完全紧紧压缩由绝缘的铁粉材料、树脂和润滑剂组成的粉末混合物，以形成单一整体化电感主体。
4.如权利要求3所述的方法，其特征在于，所述压缩步骤是通过对所述干燥粉末混合物施加每平方英寸至少15吨的压力。
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