KR20120052031A - Inductor core, inductor using the same and method thereof - Google Patents

Abstract

PURPOSE: An inductor core and an inductor using the same and a manufacturing method thereof are provided to rapidly form an amorphous inductor core without a separate impregnation process by laminating and coupling a plurality of single thin films of amorphous metal. CONSTITUTION: An amorphous laminate(11) is formed by laminating a plurality of single thin films of amorphous metal in which one or more punched holes are formed. A top cover(12) and a bottom cover(13) cover the top and bottom of the amorphous laminate. A connecting part arranges the top cover and the bottom cover through the punched hole of the amorphous laminate. The connecting part is composed of a support stand(14a) and a connecting member(14b). The support stand is fixed to the top cover or the bottom cover. The connecting member unitizes the top cover, the amorphous laminate, and the bottom cover.

Description

INDUCTOR CORE, INDUCTOR USING THE SAME AND MANUFACTURING METHOD THEREOF {INDUCTOR CORE, INDUCTOR USING THE SAME AND METHOD THEREOF}

The present invention relates to an inductor core, an inductor using the same, and a method for manufacturing the same. More specifically, by stacking a plurality of single thin plates of amorphous metal having at least one perforation formed therein, through the perforations, and aligning and fastening them integrally, The present invention relates to an inductor core, an inductor using the same, and a method of manufacturing the same, for forming an amorphous inductor core without using an impregnation process and forming an inductor using the same.

Induction devices are used in a variety of electronic components such as transformers, choke coils, inductors, noise countermeasures, and the like. Most induction devices consist of a core comprising a soft ferromagnetic material and one or more coils surrounding the core. These inducers are optimized for their type to operate at the desired frequency from DC to kHz.

In particular, the soft magnetic material is selected depending on the combination of the required properties, the usefulness of the material in any form that enables effective manufacture, and the size / cost required for use in a given market.

In general, preferred soft magnetic materials exhibit high saturation induction, high permeability and low core loss to minimize core size and low saturation coercivity. (silicon steel sheets), ferrites, amorphous metals and the like are known.

Specifically, the silicon steel sheet is inexpensive and has a high density, but has a limit of high magnetic core loss in high frequency applications. In addition, ferrite has a low saturation magnetic flux density and poor temperature characteristics, and therefore, ferrite is easily saturated magnetically and is not suitable for high power applications such as coil components of large capacity inverters and power supplies and transformers for power distribution. In addition, the amorphous metal has a disordered structure similar to the liquid state, and exhibits various characteristics different from the existing crystalline materials by quenching the molten liquid metal, and particularly, exhibits excellent soft magnetic properties.

These amorphous metals are classified into iron (Fe) and cobalt (Co) based on their main components.In the case of iron, the saturation magnetic flux density is high and the core loss is smaller than that of silicon steel. In the case of the cobalt system, the magnetic permeability is high and the core loss and coercive force are small.

In particular, the amorphous metal has no crystal structure and thus does not exhibit crystalline magnetic anisotropy, in which magnetism is different depending on the crystal direction. Accordingly, since amorphous metals have a relatively large influence of induced magnetic anisotropy, different magnetic properties can be obtained by applying a magnetic field during heat treatment. For example, when an amorphous metal applies a magnetic field in the circumferential direction of a toroidal magnetic core at a high temperature below Curie-temperature (Tc), the ratio of saturation magnetic flux density (Bs) and residual magnetic flux density (Br) High squarness (Br / Bs) defined can obtain high characteristics. On the other hand, in the amorphous metal, when the magnetic field is applied in the height direction of the magnetic core, a low angular ratio can be obtained.

For reference, products using the high-angle ratio feature include a magnetic amplifier for a switched-mode power supply (SMPS), a spark killer bead core, a magnetic modulator, and a magnetic switch.

Moreover, amorphous metals are in the spotlight as soft magnetic materials for magnetic cores in place of silicon steel sheets or ferrites because of their characteristics of lower core loss and eddy current loss than other soft magnetic materials. Such amorphous metals have excellent response to high frequency characteristics due to eddy current losses such as high efficiency, large electrical resistivity, noise suppression characteristics due to high permeability and high saturation flux density, DC bias characteristics, and miniaturization requirements.

For reference, products using low core loss characteristics include choke cores, high frequency transformers for inverters, transformers for transformers, and various reactors. Products using high permeability characteristics include pulse transformers, boost transformers, audio transformers, current transformers, and noise. Filter and the like. In this case, the magnetic core is divided into a relatively small gap type toroidal core and a large rectangular cut core.

Hereinafter, a manufacturing method for a conventional amorphous magnetic core will be briefly described.

First, as described above, the amorphous metal is sprayed onto a cooling roller made of a high thermal conductor (copper, etc.) rotating at a high speed in a molten liquid state and cooled at a high speed of 10 ⁶ ° C / sec or more, thereby providing a uniform thickness. It is provided as a thin, continuous ribbon with:

Thereafter, the slitting process is performed. That is, the amorphous metal ribbon wound on one side is wound after being wound in a toroidal or rectangular shape while being wound on a support bar (or support rod) on the other side while the tension is adjusted.

Next, a heat treatment process is performed. In other words, the wound toroidal or rectangular amorphous metal is heat-treated to relieve magnetic properties and stress during winding.

Thereafter, an impregnation and drying process is performed. That is, the heat-treated toroidal or rectangular amorphous metal is dipped in the shape maintaining impregnation liquid and then dried.

Then, the cutting process is performed. That is, a gap is formed to impart unique magnetic properties to the gap type amorphous toroidal core or amorphous cut core to provide an amorphous magnetic core. At this time, the amorphous magnetic core is assembled to the case to complete the final product.

Amorphous metals, however, exhibit superior magnetic properties compared to other ferromagnetic materials, but there are difficulties in material processing due to their physical properties. That is, in the related art, excessive wear may be generated in a manufacturing tool or the like in performing a cutting process for forming a gap for imparting unique magnetic properties to an amorphous toroidal core or an amorphous cut core.

Meanwhile, Korean Patent Laid-Open Publication No. 2005-67222 discloses cutting an amorphous metal strip material to form each of a plurality of planar thin plates, and then laminating and aligning the thin plates to form a thin laminate having a three-dimensional shape, and the magnetic of the part. After annealing the thin plates to improve the properties, a method of adhering the thin laminate as an adhesive has been proposed. That is, Korean Patent Laid-Open Publication No. 2005-67222 discloses a structure for assembling in parallel to form a parallel laminate adjacent to each other by adhering a thin laminate with an adhesive without a bracket (bracket). When the single thin laminates of type I are combined to form an 'EI' or 'square' amorphous magnetic core, it is difficult to mechanically assemble by adjusting the spacing and parallelism for each single thin laminate. Occasional cases may require recalibration to reveal the core shape.

In addition, Japanese Patent Laid-Open No. 1985-21511 proposes a structure in which a laminate is assembled and fixed in a non-penetrating manner by using two pairs of iron core fastening members and bolts / nuts. A structure for assembling a laminate using bolts / nuts has been proposed. These Japanese Patent Laid-Open Publication Nos. 1985-21511 and 1999-186082 have an external structure for fastening the laminate in a non-penetrating manner to increase the volume of the assembly, and to laminate the laminate through bolts / nuts by the external structure. Because of the assembly, there is a limit that is difficult to align the laminate.

In particular, in the case of such an amorphous magnetic core, when a single thin plate is fixed to form a constant thin laminate, the adhesive is deposited and adhered. Having a size of 10 cm × 2 to 5 cm]. That is, a large-capacity induction device used to improve efficiency such as wind power or solar power generation needs to perform a heat treatment process following vacuum impregnation when forming a thin laminate using an adhesive, and equipment for performing such a process is essential. As it is required, the facility cost for accommodating a large-capacity induction apparatus is expensive, and the impregnation and heat treatment process takes a lot of time.

Therefore, in the present invention, by stacking a plurality of single thin plates of amorphous metal having at least one perforation formed therein through the perforations to be integrally aligned and fastened, forming an inductor core without a separate impregnation process and forming an inductor using the same. An object of the present invention is to provide an inductor core, an inductor using the same, and a method of manufacturing the same.

The objects of the present invention are not limited to the above-mentioned objects, and other objects and advantages of the present invention which are not mentioned can be understood by the following description, and will be more clearly understood by the embodiments of the present invention. It will also be readily apparent that the objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.

In order to achieve the above object, the inductor core of the present invention comprises: an amorphous laminate in which a plurality of single thin plates of amorphous metal having at least one aperture formed therein; Upper and lower covers for covering upper and lower portions of the amorphous laminate; And a fastening part for integrally aligning and assembling the upper and lower covers through the perforation of the amorphous laminate.

The fastening part may include: a support having one end fixed to the upper cover or the lower cover and extending through a perforation of the amorphous laminate; And a fastening member coupled to the other end of the support to integrate the upper cover, the amorphous stack, and the lower cover.

The fastening part is characterized in that the support rod for welding or riveting the upper cover and the lower cover through the aperture of the amorphous laminate.

The amorphous laminate is formed of any one of I type, C type, E type, T type, and trapezoid.

The inductor core of the present invention further includes an anti-oxidation coating film formed on the outer circumferential surface of the core by spraying or dipping.

The upper cover and the lower cover, characterized in that formed in any one of the type I, C, E, T, trapezoid.

On the other hand, the inductor of the present invention, at least two inductor cores are integrally fastened by stacking a plurality of single thin plate of amorphous metal having a perforation formed, and combined to form a magnetic circuit; A bobbin mounted to and insulated a leg of the inductor core; And at least one coil wound around the bobbin.

Each of the inductor cores may include: an amorphous laminate including a plurality of single thin plates of an amorphous metal having at least one aperture formed therein; Upper and lower covers for covering upper and lower portions of the amorphous laminate; And a fastening part for integrally aligning and assembling the upper and lower covers through the perforation of the amorphous laminate.

The inductor core further includes at least one spacer inserted into a coupling surface of the amorphous laminate.

The inductor core further includes a fixing band in the form of a strip for integrating a plurality of amorphous laminates.

The inductor core may be implemented in any one of a multi-gap type structure, a normal gap type structure, a one-way type structure, and an L type structure.

In addition, the inductor of the present invention comprises: an inductor core for stacking a plurality of single thin plates of amorphous metal having perforations formed therein and forming a magnetic circuit in at least two combinations; A case including the inductor core therein and having a flange for distinguishing a portion corresponding to a leg of the inductor core at an outer circumference thereof; And a coil wound along the flange of the case.

The inductor core may include an amorphous laminate including a plurality of single thin plates of an amorphous metal having at least one aperture formed therein; Upper and lower covers for covering upper and lower portions of the amorphous laminate; And a fastening part for integrally aligning and assembling the upper and lower covers through the perforation of the amorphous laminate.

The inductor core may be implemented in a normal gap type structure.

On the other hand, the manufacturing method of the inductor of the present invention, the first step of producing a single thin plate formed with a perforation from the ribbon of amorphous metal; A second step of forming an inductor core by integrating the amorphous laminate, the upper and lower covers by disposing an upper and lower cover on the amorphous laminate on which the single thin plate is laminated, and then engaging fastening portions for perforations; Performing a heat treatment on the inductor core; And a fourth step of manufacturing the inductor on which the magnetic circuit is formed by combining the heat-treated inductor core into at least two.

The third step may be performed before or after the anti-oxidation coating process on the outer wall of the inductor core.

The third step is characterized in that carried out for 2 to 10 hours at a temperature condition of 380 ℃ ~ 450 ℃.

In the fourth step, a bobbin is coupled to a leg of the inductor core, and a coil is wound.

In the second step, the inductor core may be combined to form a magnetic circuit having any one of a multi-gap type structure, a normal gap type structure, a one-way gap type structure, and an L type structure.

In the fourth step, the coil is wound after the inductor core is enclosed in a case having a flange.

As described above, the present invention has the effect of rapidly forming an amorphous inductor core without a separate impregnation process by stacking a plurality of single thin plates of amorphous metal having at least one perforation formed therethrough through the perforations to be aligned and fastened. have.

In addition, since the present invention does not perform a separate impregnation process, it is easy to form a large inductor at low cost of equipment investment.

In addition, the present invention has the effect of reducing the core loss (core loss) compared to the inductor core manufactured by cutting after winding the core.

1A is an exploded perspective view of a first embodiment of an inductor core according to the present invention;
1B is a perspective view of the inductor core of FIG. 1A,
2A is an exploded perspective view of a second embodiment of an inductor core according to the present invention;
FIG. 2B is a perspective view of the inductor core of FIG. 2A;
3A is an exploded perspective view of a third embodiment of an inductor core according to the present invention;
3B is a perspective view of the inductor core of FIG. 3A,
4 is a configuration diagram of a first embodiment of an inductor configuration according to the present invention;
5 is a configuration diagram of a second embodiment of an inductor configuration according to the present invention;
6 is a configuration diagram of a third embodiment of an inductor configuration according to the present invention;
7 is a configuration diagram of a fourth embodiment of an inductor configuration according to the present invention;
8A and 8B are schematic views of a fifth embodiment of an inductor configuration according to the present invention;
9 is a flowchart illustrating a method of manufacturing an inductor according to the present invention;
FIG. 10 is a graph illustrating a comparison of the inductor core of FIG. 3A and FIG. 3B with a conventional inductor core. FIG.

BRIEF DESCRIPTION OF THE DRAWINGS The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings, It can be easily carried out.

In the following description, well-known functions or constructions are not described in detail since they would obscure the invention in unnecessary detail. Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings.

Prior to describing the present invention, the term 'amorphous laminate' refers to a three-dimensional matrix for forming a core by laminating and aligning a plurality of single thin plates having a predetermined shape. At this time, the amorphous laminate does not perform a separate impregnation process for bonding or assembling each single thin plate, and the upper and lower covers, the amorphous laminate and the upper and lower portions for fixing and assembling a plurality of stacked single thin plates. The coupling state and the support for fastening to the cover, etc. (hereinafter referred to as "assembly bracket for assembly") is maintained in the engaged state. However, the amorphous laminate may be subjected to an anti-oxidation coating process around the outer wall in a short time by spraying or dipping rather than an impregnation process in which a plurality of single thin plates are stacked in an impregnation solution for a long time. This is not only for the purpose of preventing oxidation, but also for preventing the debris of the debris of the amorphous metal material due to punching molding. At this time, the antioxidant coating agent may be a coating agent made of a material such as epoxy (epoxy), silicon (silicone), urethane (urethane).

In addition, the single thin plate is a planar thin plate of amorphous metal material, and is formed through a cutting process by various conventional methods. In this case, the single thin plate is cut into a shape similar to a letter identified as "I" or "C", and the amorphous laminate in which the I-type single thin plates are stacked and aligned is referred to as "I-type laminate", and C-type single An amorphous laminate in which thin plates are stacked and aligned is referred to as a "C laminate" below. Here, in the case of the I-type single thin plate, the cutting is performed after slitting is performed, and in the case of the C-type single thin plate, the slitting is formed and then punched out.

In particular, the I-type and C-type laminates are provided with joining holes (i.e., through-holes) with the mounting bracket on each single sheet surface for fixing and joining by the mounting bracket. To this end, the I-type single sheet is punched while cutting, and the C-type single sheet is punched while punching. In addition, type I single thin plates and type C single thin plates can also be produced by an etching process.

Meanwhile, in the present invention, an inductor core may be implemented by using an I-type laminate and a C-type laminate, and an inductor core manufactured using one I-type laminate (see FIGS. 1A and 1B to be described below) I-type inductor core "), an inductor core manufactured by combining three I-type laminates to form a C-type laminate (see FIGS. 2A and 2B to be described below) (hereinafter referred to as" C-type inductor core "), An inductor core (see FIGS. 3A and 3B to be described later) manufactured using a C-type laminate (hereinafter, referred to as "C-type single inductor core") will be described in detail.

As described above, since the inductor core for manufacturing the inductor does not perform a separate impregnation process and heat treatment process, a large inductor can be manufactured quickly and easily, and as a result, a low cost can be manufactured.

1A is an exploded perspective view of a first embodiment of an inductor core according to the present invention, and FIG. 1B is a perspective view of the inductor core of FIG. 1A.

The inductor core 100 shown in FIGS. 1A and 1B is an I-type inductor core, which is a mounting bracket (ie, an upper cover 12, a lower cover 13, a fastening member 14a, and a support 14b). Fixing and assembling each single thin plate constituting the I-type stacked body 11 using the above. Here, the assembly bracket may be made of sus (SUS), synthetic resin, silicon steel and the like.

As described above, the I-type inductor core 100 is a type I by arranging the upper cover 12 on the upper portion of the I-shaped stack 11 in which a plurality of single thin films are stacked and the lower cover 13 on the lower portion of the I-type inductor core 100 The upper part and the lower part of the laminated body 11 are covered. At this time, the I-type inductor core 100 is integrally assembled by fastening the upper cover 12-the I-type stack 11-the lower cover 13 by the fastening portion 14a and the support 14b.

Here, the I-type laminate 11 is formed by aligning and stacking the I-type single thin plate by passing at least one perforation formed in the I-type single thin plate through the support 14b formed integrally with the lower cover 13. In addition, perforations are formed in the upper cover 12 in the same position, size and number according to the perforations formed in the single I-shaped thin plate. As such, the I-shaped stack 11 and the top cover 12 each form at least one perforation as an integral through path along the vertical direction in the drawing (for example, two in the case of FIG. 1A). This is to assemble using the fastening member 14a and the support 14b in the stacked structure in the order of the upper cover 12-I type stack 11-lower cover 13.

Meanwhile, the fastening member 14a and the support 14b may be implemented in various ways. Here, the bolt member is formed on the outside of the fastening member 14a, and the fastening member 14a is fastened to the inside of the support 14b. The case where the nut structure corresponding to the thread of the member 14a is implemented is shown. At this time, the fastening member 14a is preferably embedded in the perforation of the upper cover 12 through engagement with the support 14b and does not protrude. The support 14b supports and aligns the I-shaped stack 11, and preferably, a thread for engaging with the fastening member 14a is partially formed at the tip. On the other hand, the fastening member 14a implements a socket-type nut structure with threads formed on the inside, and the support 14b may implement a bolt structure on the outside. Here, the support 14b is preferably fixed in advance to the lower cover 13 in order to increase the assembly.

In addition, the fastening member 14a may adopt a general polygonal head nut structure, and the support 14b may employ a bolt structure corresponding to the fastening member 14a. At this time, the fastening member 14a may protrude on the surface of the upper cover 12.

In addition, the method of assembling using the bolt-nut structure by the fastening member 14a and the support 14b is formed in the lower cover 13, and then the rivet fastening for the puncture is performed with a blind rivet. Method of performing, after forming the perforations in the lower cover 13, and then inserting the support rods penetrating the perforations to perform welding (welding) on both ends of the support rods in contact with the upper cover 12 and the lower cover 13 Can be replaced by a scheme.

Here, the fastening member 14a and the support 14b, blind rivets and support rods, etc. used to align and assemble the upper cover 12 and the lower cover 13 are collectively referred to as "fastening portions".

At the time of fastening to the above-described upper cover 12-I stacked body 11-lower cover 13, the pressing jig is installed at both ends of the upper cover 12 and the lower cover 13, and then assembled while being compressed. It is preferable.

As such, the I-type inductor core 100 is mechanically assembled by the upper cover 12, the I-type stack 11, and the lower cover 13 using the fastening portion, thereby automatically or without performing an impregnation process. It can be mass produced in a semi-automatic simple mechanical assembly.

On the other hand, the I-type single thin plate may be cut differently in length as needed. This is to distinguish and form the inductor cores for the left and right legs of the coil in which the upper and lower yokes and bobbins are wound when the rectangular inductor is formed (see FIGS. 2A and 2B to be described later). ).

Figure 2a is an exploded perspective view of a second embodiment of the inductor core according to the present invention, Figure 2b is a perspective view of the inductor core of Figure 2a.

The inductor core 200 shown in FIGS. 2A and 2B is a C-type combination inductor core, which is a mounting bracket (ie, an upper cover 24, a lower cover 25, a fastening member 26a, and a support 26b). The C-type structure is implemented by fixing and assembling the first to third I-type laminates 21 to 23 by using.

The upper cover 24 and the lower cover 25 are made of a C type capable of integrally fixing and assembling each of the first to third I-type stacks 21 to 23. That is, the first I-type laminate 21 and the third I-type laminate 23 are arranged in parallel to the left and right of the C-type structure, and the first I-type laminate 21 and the third I-type laminate ( 23) each of which is disposed at both ends of the second I-type laminate 22. At this time, the first I-type laminate 21 and the third I-type laminate 23 form a leg in which coils are wound by combining bobbins when the inductor is formed, and the second I-type laminate 22 has an upper portion. Or to form a lower yoke. Therefore, the I-type single thin plates constituting the first I-type laminate 21 and the third I-type laminated body 23 are relatively longer than the I-type single thin plates constituting the second I-type laminate 22. It is preferred to be cut.

Each of the first to third I-type stacks 21 to 23 is formed with at least one perforation for assembly to the upper cover 24 and the lower cover 25. At this time, the fastening member 26a and the support 26b are integrally aligned and fastened through the perforations of each of the first to third I-type laminates 21 to 23.

Figure 3a is an exploded perspective view of a third embodiment of the inductor core according to the present invention, Figure 3b is a perspective view of the inductor core of Figure 3a.

The inductor core 300 shown in FIGS. 3A and 3B is a C type single inductor core, which is a mounting bracket (ie, an upper cover 32, a lower cover 33, a fastening member 34a, and a support 34b). By using the C-type laminate (31) consisting of a plurality of thin plates to secure and assemble the C-type structure. That is, the upper cover 32 and the lower cover 33 is made of a C-type structure that can be fixed and assembled integrally the C-type laminate 31. At this time, the C-type laminated body 31 is integrally formed, but in the case of the parts facing each other, the bobbin is coupled when the inductor is formed to form a leg in which the coil is wound, and the parts are coupled to both ends of the parts facing each other. Forms the upper or lower yoke.

The C-shaped stack 31 is formed with at least one perforation for assembly to the top cover 32 and the bottom cover 33. At this time, the fastening member 34a and the support stand 34b are integrally aligned and fastened through the perforations of the C-type laminate 31.

Hereinafter, an inductor configuration using the inductor core described above will be described. For convenience of description, the bobbin and the coil are not shown in the inductor.

On the other hand, the inductor arranges a spacer in the gap between the inductor cores (that is, the magnetic gap), where the gap between the inductor cores is reduced to reduce the eddy current loss in consideration of the characteristic that the inductance is lowered as the magnetic gap becomes farther apart. Configure by adjusting.

In addition, when assembling at least two inductor cores, the inductor is preferably fastened and fastened with a strip-type separation prevention fixing band made of sus material. At this time, the inductor is finally insulated by performing varnish molding with any one of epoxy, acrylic, and urethane.

4 is a configuration diagram of a first embodiment of the inductor configuration according to the present invention.

The inductor 400 illustrated in FIG. 4 forms a square by arranging two pairs of I-type inductor cores 40a to 40d so as to face each other, and forms each of the two pairs of spacers 41a to 41d. A multi-gap type structure in which the 40a to 40d are disposed in the gaps in contact with each other is implemented.

5 is a configuration diagram of a second embodiment of the inductor configuration according to the present invention.

The inductor 500 shown in FIG. 5 forms a square by arranging a pair of C-type combined inductor cores 50a and 50b to face each other, and forms each of the pair of spacers 51a and 51b into a C-type combined inductor core. A normal gap type structure in which (50a, 50b) is disposed in the gaps in contact with each other is implemented.

6 is a configuration diagram of a third embodiment of the inductor configuration according to the present invention.

The inductor 600 shown in FIG. 6 forms a quadrangle by arranging either a C-type combined inductor core or a C-type single inductor core at a lower side with respect to one I-type inductor core 60a positioned at an upper side thereof. A one-way gap type structure in which each of the pair of spacers 61a and 61b is disposed in a gap between the upper inductor core 60a and the lower inductor core 60b is in contact with each other. Here, the C type combined inductor core 61b is disposed below.

7 is a configuration diagram of a fourth embodiment of the inductor configuration according to the present invention.

The inductor 700 shown in FIG. 7 is a pair of coupling each of the I-type inductor cores 70a-70b and 70c-70d that are perpendicular to each other in the two pairs of I-type inductor cores 70a to 70d at right angles to each other. A rectangular shape is formed using the L-shaped fixing frames 72a and 72b, and an L type structure in which a pair of spacers 71a and 71b are disposed in one space is implemented.

8A and 8B are schematic diagrams of a fifth embodiment of the inductor configuration according to the present invention.

The inductor 800 illustrated in FIGS. 8A and 8B shows a structure that does not need to be combined with a separate bobbin for constructing the inductor as shown in FIGS. 5 to 7. That is, the inductor 800 has respective cases 82a and 82c, 83a and 83c for accommodating a pair of C-type single inductor cores 80a and 80b, where each case 82a and 82c and 83a is provided. And 83c are provided with flanges 82b and 82d, 83b and 83d, flanges, respectively, for winding the coil (not shown). Here, the cases 82a and 82c, 83a and 83c of the fifth embodiment are provided with housing grooves corresponding to the shapes of the inductor cores 80a and 80b, and the case main bodies 82c and 83c and the case main body (opened at the upper side). It consists of covers 82a and 83a which cover the openings of 82c and 83c. In addition, since the inductor 800 of the fifth embodiment has a structure in which the inductor cores 80a and 80b are embedded in the case and the bobbin is removed, the inductor 800 may be packaged to minimize the overall size. In this case, the inductor cores 80a and 80b may be embedded in the case after combining the upper and lower covers, or may be embedded in the case without combining the upper and lower covers.

The pair of C-type single inductor cores 80a and 80b are accommodated in the cases 82a and 82c, 83a and 83c and disposed to face each other, and each of the pair of spacers 81a and 81b is disposed in a gap in contact with each other. .

9 is a flowchart illustrating a method of manufacturing an inductor according to the present invention.

First, after the slitting process is performed, a single thin plate is generated (S901). In other words, type I single sheet is produced by cutting an amorphous metal ribbon provided as a thin, continuous wide ribbon having a uniform thickness after slitting to a desired width, and forming a type C single sheet using a wide amorphous metal ribbon to a desired width. After slitting, it is punched into Form C or produced by etching. At this time, perforations are simultaneously formed in a single thin plate.

Next, an inductor core is formed using an amorphous laminate in which a plurality of single thin plates are stacked (S902). In other words, the inductor core is assembled and fastened through the through coupling of the fastening portion for the perforations, the upper and lower covers are disposed on the amorphous laminate. At this time, the inductor core is preferably subjected to an anti-oxidation coating process around the outer wall in a short time by spraying or dipping.

Subsequently, magnetic field heat treatment is performed on the inductor core in order to relieve the magnetic properties of the amorphous laminate and the stress in the laminate assembly (S903). At this time, the heat treatment step is carried out for 2 to 10 hours at a temperature condition of 380 ℃ ~ 450 ℃. This heat treatment process may be carried out before or after the oxidation coating process.

Then, after the magnetic circuit is formed by the combination of the at least two inductor core, the bobbin is coupled to the legs of the inductor core and the coil is wound to manufacture the inductor (S904). In this case it is also possible to couple the coiled bobbin to the legs of the inductor core. At this time, the inductor has a magnetic circuit formed of any one of a multi-gap type structure, a normal gap type structure, a one-way gap type structure, and an L type structure. Here, when at least two inductor cores are combined, it is preferable to be fixed to the outer circumference of the combined inductor core by a fixing band made of sus or silicon steel strip.

Meanwhile, an inductor may be manufactured by winding a coil after the inductor core is embedded in a flanged case. In this case, the inductor is preferably formed of a magnetic circuit having a normal gap type structure.

Here, only the case where the inductor core is manufactured by using the I-type and C-type single thin plates is described, but the inductor core may be manufactured by stacking a plurality of E-type, T-type, and trapezoidal single thin plates as necessary. In this case, the E-type and T-type inductor cores may be formed of a single-type structure punched out of the E-type and T-type, or may be formed of a combination structure of I-type single thin plates. The trapezoidal inductor core is formed by stacking the left and right oblique directions of the I-type single thin plate. The trapezoidal inductor core is arranged on four sides of the square to form a square inductor. Detailed description thereof will be omitted since it can be easily understood by those skilled in the art through the foregoing.

FIG. 10 is a graph illustrating a comparison of the inductor core of FIG. 3A and FIG. 3B with a conventional inductor core. FIG. Here, the conventional inductor core is manufactured by cutting the core to a C-type inductor core after winding the core.

In this case, the inductor core 300 of FIGS. 3A and 3B was heated for 1 hour at 410 ° C. in the air, and then maintained for 7 hours to perform heat treatment. Similarly, the conventional inductor core 301 was also heated for 1 hour after heating up to 410 ° C. in the air for 7 hours.

In addition, each inductor core 300 and 301 used a core loss device to measure core loss. At this time, the measurement frequency was 20 Hz, and the coil winding necessary for the measurement was wound 18 times on the primary side and 5 times on the secondary side.

As shown in FIG. 10, the inductor core 300 of FIGS. 3A and 3B has a core loss value of about 5.0 W / kg, and the conventional inductor core 301 has a core loss value of 10.1 W / kg. This results in a reduction of about 2 times core loss in the inductor core 300 of FIGS. 3A and 3B compared to the conventional inductor core 301.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is clearly understood that the same is by way of illustration and example only and is not to be construed as limited to the embodiments set forth herein. Various changes and modifications may be made by those skilled in the art.

11: Type I laminate 12: Top cover
13: lower cover 14a: fastening member
14b: support 100: inductor core

Claims (21)

An amorphous laminate in which a plurality of single thin plates of amorphous metal having at least one perforation formed thereon are laminated;
Upper and lower covers for covering upper and lower portions of the amorphous laminate; And
A fastening portion for integrally aligning and assembling the upper and lower covers through the perforation of the amorphous laminate;
Inductor core comprising a. The method of claim 1,
The fastening portion
A support having one end fixed to the upper cover or the lower cover and extending through the perforation of the amorphous laminate; And
And a fastening member coupled to the other end of the support to integrate the upper cover, the amorphous stack, and the lower cover. The inductor core of claim 1, wherein the fastening part is a support rod for penetrating and welding or riveting the upper cover and the lower cover through the perforation of the amorphous laminate. The inductor core according to claim 1, wherein the amorphous laminate is formed of any one of I type, C type, E type, T type, and trapezoid. The inductor core of claim 1, wherein the upper cover and the lower cover are formed of any one of an I type, a C type, an E type, a T type, and a trapezoid. The inductor core according to any one of claims 1 to 5, further comprising an anti-oxidation coating film formed on the outer circumferential surface of the core by spraying or dipping. At least two inductor cores that are integrally fastened by stacking a plurality of single thin plates of amorphous metal having perforations formed thereon and combined to form a magnetic circuit;
A bobbin mounted to and insulated a leg of the inductor core; And
At least one coil wound on the bobbin;
Inductor comprising a. The method of claim 7, wherein
Each of the inductor cores,
An amorphous laminate in which a plurality of single thin plates of amorphous metal having at least one perforation formed thereon are laminated;
Upper and lower covers for covering upper and lower portions of the amorphous laminate; And
A fastening portion for integrally aligning and assembling the upper and lower covers through the perforation of the amorphous laminate;
Inductor comprising a. The inductor of claim 7, wherein the inductor core further comprises at least one spacer inserted into a coupling surface of the amorphous laminate. 8. The inductor of claim 7, wherein the inductor core further comprises a fixed band in the form of a strip to integrate the plurality of amorphous stacks. The inductor according to any one of claims 7 to 10, wherein the inductor core is implemented by any one of a multi-gap type structure, a normal gap type structure, a one-way type structure, and an L type structure. . An inductor core for stacking a plurality of single thin plates of amorphous metal having perforations formed therein and forming a magnetic circuit in at least two combinations;
A case including the inductor core therein and having a flange for distinguishing a portion corresponding to a leg of the inductor core at an outer circumference thereof; And
A coil wound along the flange of the case;
Inductor comprising a. The method of claim 12,
The inductor core,
An amorphous laminate in which a plurality of single thin plates of amorphous metal having at least one perforation formed thereon are laminated;
Upper and lower covers for covering upper and lower portions of the amorphous laminate; And
A fastening portion for integrally aligning and assembling the upper and lower covers through the perforation of the amorphous laminate;
Inductor comprising a. The inductor of claim 12, wherein the inductor core is implemented in a normal gap type structure. As a method of manufacturing an inductor,
A first step of creating a single sheet having a perforation formed from a ribbon of amorphous metal;
A second step of forming an inductor core by integrating the amorphous laminate, the upper and lower covers by disposing an upper and lower cover on the amorphous laminate on which the single thin plate is laminated, and then engaging fastening portions for perforations;
Performing a heat treatment on the inductor core; And
A fourth step of manufacturing an inductor having a magnetic circuit by combining the heat-treated inductor cores into at least two;
Method of manufacturing an inductor comprising a. The method of claim 15, wherein the third step is performed before or after an oxidation coating process on an outer wall of the inductor core. The method of claim 15, wherein the third step is performed at a temperature of 380 ° C. to 450 ° C. for 2 to 10 hours. 18. The method of any one of claims 15 to 17, wherein in the fourth step, a bobbin is coupled to a leg of the inductor core and a coil is wound. 19. The inductor of claim 18, wherein in the second step, the inductor core is combined to form a magnetic circuit using any one of a multi-gap type structure, a normal gap type structure, a one-way gap type structure, and an L type structure. Manufacturing method. 18. The method of any one of claims 15 to 17, wherein the fourth step includes winding the coil after the inductor core is enclosed in a flanged case. 21. The method of claim 20, wherein in the second step, the inductor core is combined to form a magnetic circuit having a normal gap type structure.

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