KR20150010315A - Inductor with magnetic flux concentration structure, method for manufacturing this and hybrid-inductor included this - Google Patents

Abstract

The present invention relates to an inductor having a magnetic flux concentration structure, a method for manufacturing the same and a hybrid inductor having the same, which include: a core assembly which has a core having a core body with a predetermined length and a coil wound to the periphery of the core body; and a concentration cover which is formed by having a magnetic material to surround a part of the coil from the outside of the core assembly by having the core assembly inserted, and to concentrate magnetic flux generated according to current flow of the coil by restricting diffusion of the magnetic flux toward outside. According to the present invention, the efficiency of choke transformer or transformer can be further improved, an air gap can be formed through a gap flange and the manufacturing costs can be reduced due to the simple structure by concentrating a magnetic flux using the concentration cover.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an inductor having a self-focusing structure, a manufacturing method thereof, and a hybrid inductor including the same.

The present invention relates to an inductor having a self-focusing structure, a method of manufacturing the inductor, and a hybrid inductor including the inductor. More particularly, the present invention relates to an inductor applied to various power supply devices such as a discharge lamp, Inductance is easily controlled through a gap flange functioning as an air gap or functioning as a winding guide and a method of manufacturing the inductor. Disclosed is a hybrid inductor including an inductor such as a transformer and an inductor for controlling a trigger of the switching element.

Generally, a choke transformer is applied to the power supply for the purpose of controlling the output voltage to be constant. For example, a discharge lamp such as a fluorescent lamp is required to have a higher voltage than a commercial power source in its driving (starting and sustaining), and the discharge is stable when the voltage to be supplied is constant. Is used.

1 is a cross-sectional view showing an example of an inductor that can function as a general choke transformer.

1, the inductor for a choke transformer includes cores 11a, 11b, 12a, and 12b made of ferrite, a bobbin 40 having the core inserted therein, and a bobbin 40 And a coil 50 wound around the coil 50. As shown in FIG. FIG. 1 (a) shows an embodiment in which E-type cores 11a and 12b are applied, and FIG. 1 (b) shows an embodiment in which E-type cores 11b and 12b are applied.

When the voltage is controlled by the choke transformer (current flows in the coil), a magnetic force is generated in the choke transformer as shown in FIG. 2. The magnetic force lines generated in the choke transformer are concentrated so as not to spread widely to the outside of the coil 50 The function as an inductor is improved.

However, a general inductor for a choke transformer is structurally limited to limit the spread of magnetic force lines to the outside of the coil 50. [ Particularly, in the case of the T-shaped core or the choke transformer inductor having the I-shaped core shown in FIG. 2, since the structure is simple as compared with the inductor for the choke transformer having the EE type core or the EI type core, However, since there is no structure for concentrating magnetic force lines around the coil, the efficiency is lower than that of an inductor for a choke transformer having an EE-type core or an EI-type core, and is used only to a small extent.

Furthermore, the inductor accumulates energy in the form of a magnetic field in the core, and when it exceeds the amount of energy that the inductor can accumulate, the inductor does not accumulate energy and reaches a saturation state, and the winding becomes short-circuited.

Therefore, an air gap is used to impart a larger magnetic field strength to the inductor. Referring to the concept of the air gap of the inductor shown in FIG. 3, in contrast to the case where no air gap is applied The larger the size of the air gap, the greater the inductor's ability to store more energy on the air gap, thus increasing the magnetic field strength of the inductor.

To this end, the portions of the EE cores 11a and 12a shown in FIG. 1 (a) and the portions of the EI cores 11b and 12b shown in FIG. 1 (b) An air gap is formed so that a larger current can flow in the same core without reaching saturation.

When air is used to form such an air gap in the inductor, the inductors are not easily assembled due to the formation of voids, and voids are not formed with an accurate thickness. In addition, In addition, it is difficult to precisely control the thickness of the pores and the manufacturing process of the inductor is complicated.

Further, unlike the EE type core and the EI type core, when a T-shaped core or an I-shaped core is used, it is difficult to apply an air gap due to the morphological limitation of the core.

It is an object of the present invention to solve the problems of the prior art as described above and to provide a structure of an inductor that can effectively focus a magnetic field generated at the time of voltage control and can be used as a simple choke transformer, And a manufacturing method which can be simply manufactured.

Furthermore, when air is used to form an air gap in the inductor, it is difficult to assemble the inductor due to the formation of the air gap and the air gap is not formed with an accurate thickness. In the case of forming the air gap by inserting a microfilm or the like In particular, unlike the EE type core and the EI type core, when the T-shaped core or the I-shaped core is applied, the morphological limitation of the core It is not easy to apply an air gap and a problem that a coil wound around the coil is easily released in the case of a straight core or a T-shaped core is solved.

It is still another object of the present invention to provide a hybrid inductor including an inductor for a choke transformer and a switching trigger.

Also, the present invention proposes a manufacturing method that can easily and easily manufacture an inductor such as a transformer or a choke transformer by eliminating a dangerous pressing process in a manufacturing process of a conventional transformer or a choke transformer.

The problems to be solved by the present invention are not limited to the above-mentioned problems, and other matters not mentioned can be clearly understood from the following description if they are common knowledge (those skilled in the art to which the present invention belongs).

According to an aspect of the present invention, there is provided an inductor including: a core assembly including a core having a core body having a predetermined length and a coil wound around the core body; And a porcelain material, wherein the core assembly is inserted to surround at least a portion of the coil at an outer angle of the core assembly to limit external diffusion of magnetic force lines generated in accordance with the current flow of the coil, And a focusing cover for focusing.

Preferably, the core assembly may include a core having a flange formed of a ceramic material at one or both ends in the lengthwise direction of the core body, and having a vertical cross-section of I-type or T-type.

More preferably, the flange may be formed so that the thickness becomes thinner toward the side from the center portion so that the vertical cross-sectional area of the inner circumference on the flange and the horizontal cross-sectional area of the core body are equal to each other.

Alternatively, the core assembly may include a core having a gap flange formed of a nonmagnetic material at one or both ends of the longitudinal direction of the core body, and having a vertical cross-section of I-type or T-type.

Further, the core assembly may include a core having a flange formed of a porcelain material on one of both ends in the longitudinal direction of the core body and a gap flange formed of a non-magnetic material on the other of the flanges, .

The core assembly may further include: a bobbin having the core body inserted into the center thereof; And a coil wound around the bobbin.

Preferably, the core assembly further comprises: an insulating layer formed on a part or the whole of the core; And a coil wound around a portion of the core on which the insulating layer is formed.

More preferably, the focusing cover may have a circular or polygonal pipe structure having both ends thereof penetrated to form an opening, and the core assembly may be inserted to surround the outer periphery of the coil.

Here, the focusing cover may include a plurality of focusing cover pieces divided vertically in the longitudinal direction.

Furthermore, the focusing cover may be formed with a plurality of through holes spaced apart at regular intervals along the side surface.

Alternatively, the focusing cover may be formed with a plurality of grooves spaced at regular intervals in the longitudinal direction from the upper or lower side of the side surface, or alternatively the upper and lower sides of the focusing cover may alternately be spaced apart at regular intervals in the longitudinal direction to form a plurality of grooves It is possible.

Furthermore, the focusing cover may have a cup structure having an opening at one end and a shield at the other end, and the core assembly may be inserted into the opening to surround the outer periphery of the coil.

The focusing cover includes an upper focusing cover formed in a cup structure into which the upper end of the core assembly is inserted; And a lower focusing cover formed in a cup structure in which a lower end of the core assembly is inserted.

Preferably, the focusing cover may be formed with a plurality of openings whose sides are opened from the one end to the other end.

Also, the focusing cover may be formed in a plurality of fan shapes or cross shapes extending from the center to the outer periphery of the shield portion, and the opening portion may be formed corresponding to the shape of the shield portion.

Further, an engagement groove corresponding to the shape of the upper end of the core assembly may be formed on the inner surface of the shield cover of the focusing cover, and the upper end of the core assembly may be inserted into the coupling groove and fastened.

The other type of the focusing cover is formed in a closed cylindrical structure having a shielding portion formed at both ends of a circular or polygonal pipe to accommodate the core assembly. The plurality of focusing cover pieces, which are vertically divided in the longitudinal direction, .

Here, the focal cover may be formed with a plurality of openings whose sides are open from the upper surface to the lower surface.

Another type of the focusing cover is formed in a rectangular frame structure having a certain thickness, and the core assembly is inserted into the focusing cover and can be fitted into the rectangular frame of the focusing cover in the longitudinal direction.

Further, another type of the focusing cover may include a plurality of supporting members having faces corresponding to the longitudinal outer surface of the core assembly and spaced apart from each other along the outer periphery of the core assembly; And a connecting member connecting between the supporting members between the supporting members.

Preferably, the support member has a horizontal cross section with three faces, one face corresponding to the outer surface of the core assembly, two faces perpendicular to each other, and four support members contacting the outer periphery of the core assembly The outer surface of the focusing cover may have a quadrangular shape.

The end of the flange or the gap flange and the end of the flange or the cover cover may be fixed to each other so as to maintain a distance between the core assembly and the focusing cover while maintaining the core assembly at a predetermined position on the inside of the focusing cover. And a coupling portion to be fastened to each other may be formed at one end.

Another type of core assembly includes a first core body having a first coil wound thereon; A second core body on which a second coil is wound; And a gap flange positioned between the first coil and the second coil.

Further, the hybrid inductor according to the present invention includes: a core assembly including a core having a core body of a predetermined length and a coil wound around the core body; And a porcelain material, wherein the core assembly is inserted to surround at least a portion of the coil at an outer angle of the core assembly to limit external diffusion of magnetic force lines generated in accordance with the current flow of the coil, A first inductor including a focusing cover for focusing; And a second inductor including a toroidal coil wound in the longitudinal direction on the focusing cover.

Preferably, the first inductor is formed with a plurality of grooves spaced at regular intervals in the longitudinal direction from the upper or lower side of the side surface, alternately alternating the upper and lower sides of the side surface at regular intervals in the longitudinal direction, And a toroidal coil of the second inductor may be wound around the groove of the focusing cover.

And an insulating layer coated on the surface of the focusing cover, wherein the toroidal coil may be wound on the insulating layer.

Or the first inductor includes a plurality of support members having faces corresponding to the longitudinal outer surface of the core assembly and spaced apart from each other along the outer periphery of the core assembly; And a collecting cover including a connecting member connecting the supporting members between the supporting members, and the toroidal coil of the second inductor may be wound on the connecting member.

A core assembly including a core having a core body of a predetermined length and a coil wound around the core body; And a porcelain material, wherein the core assembly is inserted to surround at least a portion of the coil at an outer angle of the core assembly to limit external diffusion of magnetic force lines generated in accordance with the current flow of the coil, A first inductor including a focusing cover for focusing; And a second inductor spaced apart from the upper portion of the focusing cover and connected to the focusing cover with a plurality of supporting legs and a second inductor including a coil wound in a toroidal shape in the inductor ring.

Furthermore, a method of manufacturing an inductor according to the present invention includes: a core body manufacturing step of manufacturing a core body having a round or polygonal cross section with a predetermined number of turns of a steel plate having porcelain; A core assembly manufacturing step of winding the core around the core body at an intermediate portion of the core body to manufacture a core assembly; A focusing cover manufacturing step of manufacturing a focusing cover containing a porcelain material and having an opening corresponding to an end surface of the core assembly; And a focusing cover forming step of inserting the core assembly into a focusing cover so as to surround at least a part of the coil at an outer angle of the core assembly.

Preferably, the collecting cover manufacturing step may include winding a corrugated steel sheet a certain number of times so that the core assembly is inserted and has a through-space surrounding the core assembly.

The flange manufacturing method may further include a flange manufacturing step of fabricating a flange having a predetermined number of turns of a ceramic plate having a porosity so as to have a through space corresponding to a cross sectional diameter of the core body, Coupling the flange to the core body by inserting the flange into at least one of the first and second ends; And forming a coil wound around the core body at an intermediate portion of the core body.

Further, the core body manufacturing step may include the steps of: preparing a core body having a round or polygonal cross section with a predetermined number of turns of a ceramic plate having a porosity; And inserting the core body into an insulating member having the outer surface of the core body coded with an insulating material or having a through hole corresponding to the diameter of the core body.

According to the inductor having the self-focusing structure according to the present invention, the efficiency of the inductor applied to the choke transformer, the transformer, or the like can be improved by focusing the magnetic flux lines by the focusing cover, and the coil usage amount of the core assembly is relatively reduced The manufacturing cost can be reduced, and the inductor used for the choke transformer, the transformer, and the like can be made more compact, so that the occupied area at the time of installation can be reduced.

Also, in the present invention, the inductance of the inductor can be easily controlled by the reluctance according to the thickness of the gap flange by applying the gap flange. Especially, it is easy to apply the air gap according to the structure of the I-shaped or T- And further, the gap flange can be applied to the straight type or the T-shaped core to facilitate the winding of the coil and prevent the winding coil from escaping.

Further, in the present invention, the bobbin is removed and replaced with an insulating layer, thereby simplifying the manufacturing process and reducing the manufacturing cost, and at the same time, the overall volume and the installation area of the inductor are reduced and the amount of coil used is reduced And the additional effect of efficient use of resources can be obtained.

In order to ensure a proper thickness, the condensing cover of the present invention may be formed by removing a certain non-cylindrical portion or by applying an opening portion to heat the generated heat from the inner coil to the atmosphere, thereby lowering the temperature of the coil , It becomes possible to provide an inductor that effectively concentrates the magnetic field lines while saving the material for manufacturing the focusing cover.

The present invention provides a core in which a magnetic force line forming a closed loop can pass through the same cross sectional area similarly to an EE type core by applying a core having a flange thickness adjusted, The overall length of the core can be reduced while increasing the number of windings or having the same number of turns, thereby reducing the overall size while improving the performance of the inductor.

The hybrid inductor according to the present invention can be manufactured by packaging a first inductor used as a choke transformer or the like and a second inductor used as an oscillator for triggering a switching element into one package to further increase the degree of integration of components, . ≪ / RTI >

The method of manufacturing an inductor having a self-focusing structure according to the present invention includes manufacturing a core by winding a steel sheet in a roll form, thereby eliminating the existing dangerous and complicated press-forming process, making it possible to manufacture an inductor through a simple and safe process The manufacturing cost can be reduced. In particular, since the thickness of the steel sheet forming the core and the number of turns of the roll can be selectively controlled, the core itself can be adjusted independently of the winding of the coil to control the characteristics of the inductor.

1 is a cross-sectional view showing an example of an inductor capable of functioning as a general choke transformer,
2 shows an example of the magnetic force generated in the inductor,
Fig. 3 shows a conceptual diagram of an air gap of the illustrated inductor,
4 shows a perspective view of a first embodiment of the inductor according to the present invention,
Fig. 5 shows an exploded perspective view of a modified focusing cover of the first embodiment of Fig. 4,
Fig. 6 shows a cross-sectional view of the first embodiment of Fig. 4,
FIG. 7 shows an example of a magnetic field line generated in the inductor according to the present invention shown in FIG. 6,
Figure 8 shows a cross-sectional view of an alternate embodiment of the first embodiment of Figure 4,
Fig. 9 shows a conceptual view of a core having the same cross-sectional area in the direction of the magnetic-force-generating line shown in the present invention,
Fig. 10 shows a cross-sectional view of the core according to the invention of Fig. 9,
11 shows various examples of the focusing cover of the inductor according to the present invention,
12 shows an embodiment of the fastening structure of the core assembly and the focusing cover in the inductor according to the present invention,
13 shows a perspective view of a second embodiment of the inductor according to the present invention,
Fig. 14 shows a sectional view of the second embodiment of Fig. 13,
Fig. 15 shows a cross-sectional view of an alternative embodiment to the second embodiment of Fig. 13,
Fig. 16 shows a perspective view of another modified embodiment of the second embodiment of Fig. 13,
17 shows a perspective view of a third embodiment of the inductor according to the present invention,
Fig. 18 shows a perspective view of a modified embodiment of the third embodiment of Fig. 16,
19 shows a perspective view of a fourth embodiment of the inductor according to the present invention,
20 shows a perspective view of an alternative embodiment to the fourth embodiment of FIG. 18,
21 shows a perspective view of a fifth embodiment of the inductor according to the present invention,
Figure 22 shows a perspective view of an alternative embodiment to the fifth embodiment of Figure 20,
23 shows a perspective view of a sixth embodiment of the inductor according to the present invention,
Fig. 24 shows a cross-sectional view of the sixth embodiment of Fig. 22,
25 shows a perspective view of a seventh embodiment of the inductor according to the present invention,
26 shows a perspective view of an eighth embodiment of the inductor according to the present invention,
27 shows a perspective view of a ninth embodiment of the inductor according to the present invention,
28 shows a perspective view of a tenth embodiment of the inductor according to the present invention,
29 shows a perspective view of an eleventh embodiment of the inductor according to the present invention,
Figure 30 shows a process embodiment of a method of manufacturing an inductor according to the present invention,
31 shows various modified embodiments of a process for manufacturing a core assembly in a manufacturing method of an inductor according to the present invention,
32 shows a first embodiment of a hybrid inductor according to the present invention,
33 shows magnetic force lines in the hybrid inductor according to the present invention,
34 shows a second embodiment of a hybrid inductor according to the present invention,
35 shows a third embodiment of a hybrid inductor according to the present invention,
Fig. 36 shows a fourth embodiment of the hybrid inductor according to the present invention.

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.

First, the terminology used in the present application is used only to describe a specific embodiment, and is not intended to limit the present invention, and the singular expressions may include plural expressions unless the context clearly indicates otherwise. Also, in this application, the terms "comprise", "having", and the like are intended to specify that there are stated features, integers, steps, operations, elements, parts or combinations thereof, But do not preclude the presence or addition of features, numbers, steps, operations, components, parts, or combinations thereof.

In the following description of the present invention, a detailed description of known functions and configurations incorporated herein will be omitted when it may make the subject matter of the present invention rather unclear.

In the present invention, the inductor having a self-focusing structure through the first focusing cover, the core having the flange thickness adjusted so that the second magnetic force lines pass through the same, the magnetic focusing A fifth coil and a fifth coil, and a sixth hybrid inductor; and the sixth and seventh hybrid inductors will be described below in order. In the following, Hereinafter, the present invention will be described in detail.

First, an inductor having a self-focusing structure through a focusing cover will be described as a first main feature of the present invention.

4 shows a perspective view of a first embodiment of the inductor according to the present invention.

The inductor 100 in the first embodiment of the inductor having the self focusing structure according to the present invention is composed of the core assembly 110 and the focusing cover 160 into which the core assembly 110 is inserted. The focusing cover 160 limits the magnetic force lines generated in accordance with the current flow of the coils of the core assembly to limit the outward diffusion of the magnetic force lines. For this purpose, So as to be able to flow.

In the first embodiment shown in FIG. 4, the collecting cover 160 is a cylindrical pipe structure having openings 161 and 162 through which the both ends thereof are passed, and the collecting cover 160 covers the coil of the assembly 110 And the core assembly 110 is inserted into the openings 161 and 162 of the focusing cover 160. Here, the collective cover 160 may be formed of a polygonal pipe such as a square in addition to the cylindrical shape.

5 shows an exploded perspective view of the modified focusing cover of the first embodiment shown in FIG. 4. As shown in FIG. 5, the focusing cover 160 of a pipe structure is divided into a plurality (A, b) may be combined with each other. It is easy to accommodate the core assembly 160 in the focusing cover 160 irrespective of the shape of the core assembly 110 by constructing the focusing cover 160 by combining the plurality of divided focusing cover pieces ab, It becomes.

6, the core 120 of the core assembly 110 is divided into two parts, that is, the upper part and the lower part of the core body 121, The core body 121 is inserted into the bobbin 140 in which the coil 150 is wound as the I-shaped core having the flanges 123 and 124 formed thereon. Here, the core body 121 and the flanges 123 and 124 may be made of various materials having magnetic force including ferrite, silicon steel, general steel, etc. In addition to the I-shaped core, Various types of cores such as straight cores and T-shaped cores can be applied.

The focusing cover 160 is a pipe structure provided so as to surround the bobbin 120 with a predetermined gap therebetween. The coil 150 of the core assembly 110 is positioned inside the focusing cover 200. Such a focusing cover 200 may contain ferromagnetic materials such as ferrite, silicon steel, general steel, etc., and magnetic force. For example, in the case where the focusing cover 160 is made of ferrite, it can be manufactured by pressing and molding and then sintering. In the case where the focusing cover 160 is made of silicon steel, it can be cut after drawing, A method of joining both ends bent, or the like, and further, the sheet material may be manufactured by winding a plurality of rolls in the form of a round roll.

The core assembly 110 and the focusing cover 160 can be coupled using an adhesive, an adhesive tape, a shrink tube, or the like, or a mechanical coupling method such as indentation, Various schemes that can be tightly coupled may also be used.

4 to 6, the flange 123 and the flange 123 of the core assembly 110 are inserted into the focusing cover 160. However, depending on the application and the manufacturing process, Either or both of the flanges 123 and 124 of the assembly 110 may be configured to span the focusing cover 160 without being inserted into the focusing cover 160. [

In the first embodiment, a magnetic force line is generated in the core assembly 110 when a current flows in the coil 150. In the present invention, the focusing cover 160 is used to focus the magnetic force lines generated in the core assembly 110. [ 7 shows an example of a magnetic force line generated in the inductor according to the present invention shown in FIG. 6. As shown in FIG. 7, the coil cover of the core assembly 110 is surrounded by a condensing cover 160 The magnetic force lines directed to the outside flow along the focusing cover 160, so that the diffusion of the magnetic field lines to the outside of the focusing cover 160 is restricted while being concentrated.

Accordingly, in the inductor having the magnetic focusing structure according to the first embodiment of the present invention, the efficiency of the inductor can be improved by focusing the magnetic force lines. Thus, in the first embodiment, the amount of use of the coil 150 of the core assembly 110 is relatively The manufacturing cost can be reduced, and the inductor used for the choke transformer, the transformer, and the like can be made more compact, so that the occupied area at the time of installation can be reduced.

Meanwhile, in the first embodiment, the core assembly 110 is simple in structure, thereby further reducing the manufacturing cost. In addition, in the case of a choke transformer or a transformer, it is generally installed to adjust characteristic values such as an L value and a Q value It is effective to avoid the vicinity of the winding of the coil in order to avoid the loss of the air gap. In the case of the EE core, since the air gap is inevitably formed in the area where both E type cores meet, And at this time, a certain portion of the coil around the air gap, where the two E type cores meet, tends to fail to actually function. However, according to the first embodiment of the present invention, since voids are formed in a portion where the core assembly 110 and the focusing cover 160 are in contact with each other, this loss can be avoided, The amount of coil consumption can be further reduced and the volume of the inductor as a whole can be reduced.

8, the bobbin 140 is removed from the structure shown in FIG. 6, and the coil 150 is inserted into the core body 121, Which is directly wound around the windings. An insulating layer 130 made of an insulating material is coated on the surface of the core body 121 to remove the bobbin 140 and directly wind the coil 150 on the core body 121. [ 8, the insulating layer 130 is entirely coated over the core body 121 and the flanges 123 and 124. However, depending on the circumstances, only the surface portion of the core body 121, to which the coil 150 is wound, And may be coated. In addition, the insulating layer 130 may be formed in various ways besides the coating method. For example, the insulating layer 130 may be formed by inserting the core body 121 into a separately manufactured insulating member.

Here, the insulating layer 130 may be formed by coating with an insulating material such as liquid silicone, urethane, or an insulating paint, or may be formed by other methods such as winding an insulating tape or ejecting a tube or plastic.

8, since the bobbin 140 is replaced with the insulating layer 130 as compared with the first embodiment of FIG. 6, the fabrication process can be simplified to reduce manufacturing cost. The total volume of the inductor and the installation area thereof are smaller than those in the case of using the bobbin, and the additional effect of efficient use of resources such as reduction of the amount of the coil can be obtained.

The effect of removing the bobbin in the embodiment of FIG. 8 will be described in more detail. In the case of the cores based on the generally used E type core or the embodiment shown in FIG. 5, In order to achieve the proposition, a coil is wound around a bobbin which is an insulator, and a bobbin with a coil wound thereon is inserted into the core. This increases the dimension of a portion where the coil is wound by the minimum thickness of the bobbin, . Also, in a transformer, a certain cross-sectional area is required for a core used for stable focusing of a magnetic field line. In the case of designing a core to optimize the consumption amount of a coil, the length of the core is too large The cross-sectional area of a general core becomes a rectangular shape, which leads to a problem that the length of the coil must be increased accordingly.

However, as shown in the present invention, when the bobbin is removed and the coil is directly wound on the core having a circular section, the coil consumption can be reduced by about 30% compared to the conventional E-type core of the same size, Even if you do, you can save about 20% of the coil consumption compared to the existing E type.

More specifically, in the case of an E16 type core, the dimension of the central section is 4.0 * 8.2 mm, and the dimension of the bobbin section for winding the coil is 5.7 * 9.6 mm. When a coil having a diameter of 0.27 mm is wound around the bobbin by about 250 turns, the size of the coil bundle is about 10.2 * 14.3 mm, which is about 9,950 mm. However, the center section of the I-shaped or T-shaped core in which the bobbin to which the present invention is applied and the direct coil is wound is about 6.5 mm, and when the coil is wound with the same turn number, a coil bundle having an outer diameter of 11 mm is formed, It is possible to save about 31% of the coil compared with the case of using the bobbin in the existing E type core.

6, when the bobbin is used for an I-shaped or T-shaped core having a circular cross-section as in the present invention as shown in FIG. 6, the required diameter of the bobbin is 8.0 mm. In this case, the outer diameter of the coil bundle with the same turn number is 12.5 mm, and the required length of the coil wire is about 8,050 mm, which can save about 19% of the coil compared to the conventional E-type core, but consumes about 15% more wire than when removing the bobbin.

In the case where the bobbin is not used in the inductor having the magnetic focusing structure according to the present invention, the outer diameter of the core required can be reduced by about 1.6 mm. Even if an air gap is provided outside the flange, It can reduce the volume by about 30% and the installation area by about 15% compared to the existing E16 type core, contributing to miniaturization of the product to be applied.

In addition, the present invention proposes a new type of core, in which the thickness of the flange is adjusted so that the area through which the magnetic force lines pass is the second main feature of the present invention. The core shown in the present invention is a core through which magnetic force lines forming a closed loop from the core body toward the flange can pass through in the same cross sectional area, and FIG. 9 is a view showing the core of the core having the same cross- FIG.

9A is an EE-type core, which is formed so that the cross-sectional areas of the respective portions on the path of the magnetic force lines generated through the coils wound on the core are the same. The cross sectional area A1 of the center portion of the core, The sum of the cross sectional area of the core B1 and the cross sectional area of both sides of the core makes the closed loop of the magnetic force lines passing through the core all pass the same cross sectional area to improve the efficiency of the inductor.

However, in the case of the I-shaped core or the T-shaped core, the cross-sectional area of the core through which the magnetic flux runs is partially different. As shown in FIG. 9 (b) The cross-sectional area increases from the center B2 to the outer C2, that is, when the arc radius at the point through which the magnetic force line passes is R, the area through which the magnetic force lines pass is calculated as 2πR * (flange thickness) The cross-sectional area through which the magnetic field lines pass is doubled by 2πR * (flange thickness). Therefore, in the case of FIG. 9 (b), there is a problem that B2 is larger than A2 and C2 is much larger than B2.

In the present invention, the flange is formed so that the thickness becomes thinner from the center to the side so that the closed cross-sectional area of the inner circumference on the flange and the horizontal cross-sectional area of the core body are equal to each other so that the closed loop of the magnetic- As shown in FIG. 9 (c), the thickness becomes thinner toward the outer side from the central portion of the flange 123 '. Here, the horizontal sectional area A3 of the core body 121' and the inner circular arc of the flange 123 ' The vertical cross-sectional areas B3, C3, and the like are all formed to be the same, more preferably, the flange 123 'may be formed to satisfy the following expression (1).

[식 1]

[Formula 1]

Where t (r) is the flange thickness, r is the radius of the inner arc of the flange, and S is the horizontal cross-sectional area of the core body.

As described above, the present invention proposes a core in which a magnetic force line forming a closed loop can pass through the same cross-sectional area similarly to the E-E type core by applying a core in which the thickness of the flange is adjusted.

Furthermore, the core of the present invention has the same overall length as that of the conventional core, but can increase the number of windings or reduce the overall length of the core while having the same number of turns, thereby improving the performance of the inductor, Hereinafter, a cross sectional view of the core according to the present invention shown in FIG. 10 will be described with reference to FIG.

10 (a) shows a general I-shaped core. Flanges 123 and 124 are formed on the upper and lower portions of the core body 121 so that the entire length of the core 120 is H1 and the coil is wound (B) and (c) of FIG. 10 illustrate a new type of core 120 ', 120 "shown in the present invention.

10 (b) has the same overall length H1 as the general I-shaped core shown in FIG. 10 (a). As described in the embodiment of FIG. 9, the flange 123 ', 124') is formed so as to become thinner from the center to the side, so that the length of the region where the coil can be wound on the core 120 'is H3, relative to H2 in (a) It got longer. Therefore, the core 120 'according to the present invention shown in FIG. 10 (b) has the same overall length as the core 120 shown in FIG. 10 (a) do.

10 (c), the length of the region where the coil can be wound on the core 120 '' is the same H2 as the core 120 of FIG. 9 (a) The entire length H4 of the core 120 '' is formed to be smaller than the entire length of the core 120 shown in FIG. 9 (a) by forming the core 123 '', 124 ' H1. Therefore, when the core 120 '' as shown in FIG. 10 (c) is applied, the entire length of the core can be reduced while having the same number of turns as the core 120 shown in FIG. 9 (a) The total size of the inductor can be further reduced.

As described above, a new type of core proposed in the present invention is a core in which a magnetic force line extending from a body of a core toward a flange to form a closed loop can pass through the same cross-sectional area to improve the performance of the inductor, But it is possible to reduce the overall length of the core while increasing the number of rollers or having the same number of rollers.

11 shows various examples of the focusing cover of the inductor according to the present invention.

11 (a) shows a focusing cover of a cylindrical pipe structure as described above. In the present invention, in addition to a focusing cover of a simple cylindrical pipe structure, as shown in FIG. 11 (b) As shown in FIG. 11 (c), a plurality of grooves may be formed at predetermined intervals along the circumferential direction in the longitudinal direction from the top and bottom of the focusing cover Alternatively, as shown in FIG. 11 (d), a plurality of grooves may alternately be formed in the longitudinal direction alternating with the upper and lower ends of the focusing cover.

A plurality of support members having inner surfaces corresponding to longitudinal outer surfaces of the inserted core assemblies and spaced apart from each other along the outer periphery of the core assembly, and a connecting member for connecting support members between the support members, Preferably, the support member has a plurality of surfaces in a horizontal section and a surface adjacent to the core assembly is formed to correspond to an outer surface of the core assembly, and a plurality of the support members are arranged along the outer periphery of the core assembly Are spaced apart from each other by a predetermined distance, and the horizontal cross-sectional area of the entire focusing cover is formed to be a square. 11 (e), the supporting member has three faces in cross section, one face having an arc corresponding to the outer face of the core assembly, and two faces being formed at right angles to each other And the focusing cover is formed to be spaced apart from one another along the outer periphery of the core assembly into which the four supporting members are inserted, so that the outer periphery of the focusing cover as a whole has a quadrangular shape.

11 (b) to (e) to be applied in the present invention can be made into various shapes by eliminating certain non-cylindrical portions in consideration of a proper thickness. For example, It is preferable that the magnetic force lines forming the closed loop pass through the same cross-sectional area as in the case of the first embodiment, but it is not easy to manufacture the converging cover to a certain thickness or less due to limitations in the manufacturing process of the converging cover, There is a problem that the manufacturing cost rises sharply. The cross sectional area of the focusing cover becomes larger than the cross sectional area of the core through which the magnetic force lines pass due to the problems in the manufacturing process of the focusing cover. As the cross sectional area of the focusing cover becomes larger than necessary, It is possible to reduce the material loss for manufacturing the focusing cover by manufacturing the focusing cover in which the certain portion other than the complete cylindrical portion is removed in consideration of the appropriate thickness of the cross-sectional area through which the magnetic force lines pass. 11 (a), the thickness of the focusing cover shown in FIG. 11 (a) is a proper thickness in consideration of the cross-sectional area through which a substantial line of magnetic force passes, e) can have the same cross-sectional area as that of the converging cover shown in Fig. 11 (a), while the thickness of the converging cover is increased, so that the overall material loss of the converging cover can be substantially reduced.

In addition, as a certain portion of the focusing cover is removed, the heat generated in the inner coil can be easily generated into the atmosphere through this, so that the temperature of the coil can be lowered.

11 may be applied not only to the inductor having the bobbin shown in FIG. 6 but also to the inductor in which the bobbin shown in FIG. 7 is removed. In the following various embodiments according to the present invention Can be suitably applied.

In addition, the present invention proposes a fastening structure of a core assembly and a focusing cover so that the core assembly can be more stably fixed to the focusing cover. FIG. 12 shows an embodiment of fastening structure of the core assembly and the focusing cover in the inductor according to the present invention / RTI >

12A and 12B show various structures in which the cores 120a, 120b and 120c of the core assembly and the focusing covers 160a, 160b and 160c are combined. In FIGS. 12A and 12C, When the core assembly is inserted into the focusing cover, the end portions 127a and 127c of the focusing covers 160a and 160c and the end portions 163a, 163b, and 163c of the focusing covers 160a and 160c are coupled to each other, The portions are engaged with each other to fix the core assembly to the focusing cover. 12 (b), the coupling portion is formed so that the end portion 127b of the core 120b of the core assembly is fastened to the upper surface through hole 163b of the focusing cover 160b, so that the core assembly can be fixed to the focusing cover have.

The end portions 127a and 127c of the upper flanges 123a and 123c and the end portions 163a and 163b and 163c of the focusing covers 160a and 160c are engaged with each other to be engaged with each other, When the core assembly is inserted into the focusing cover through the coupling portion in which the end portion 127b of the core 120b of the core assembly is fastened to the upper surface through hole 163b, the core assembly can be easily assembled at the correct position, And a desired spacing between the ends of the focusing covers 160a, 160b and 160c and the lower flanges 124a, 124b and 124c of the core assembly allows the adjustment of the space created by the spacing acting as a kind of air gap It becomes easy. Hereinafter, the air gap will be described in more detail through embodiments according to the present invention.

Next, Fig. 13 shows a perspective view of a second embodiment of the inductor according to the present invention, and Fig. 14 shows a sectional view of the second embodiment of Fig.

The second embodiment shown in FIGS. 13 and 14 is the same as the first embodiment, except that the main structure of the focusing cover 260 differs from that of the first embodiment. And focus cover 260 will be mainly described.

In the inductor 200 of the second embodiment shown in FIGS. 13 and 14, the focusing cover 260 has an opening 262 at one end and a shielding portion 265 at the other end to have a cup structure as a whole, The core assembly 210 is inserted into the opening 262 of the focusing cover 260. When the focusing cover 260 is made of silicon steel or amorphous metal, it can be easily manufactured through drawing or the like.

In the second embodiment, the core 220 is a T-shaped core, and a flange 224 is formed only at one end of the core body 221. The core body 221 is connected to the bobbin 240 to which the coil 250 is wound, The core assembly 210 may be inserted into the core assembly 210. However, the present invention is not limited to this embodiment, and an I-type core having flanges formed on both ends of the core body may be applied. The flange may be formed to be smaller than the diameter of the focusing cover and may be inserted into the inside of the focusing cover or the upper flange may be formed to be smaller than the inner diameter of the focusing cover so that the lower flange is formed larger than the inner diameter of the focusing cover The opening of the focusing cover may be in the form of covering the lower flange.

15 is a cross-sectional view of a modified embodiment of the second embodiment shown in FIG. 14. In FIG. 15, the bobbin 240 shown in FIG. 14 is removed and the coil 250 is directly wound on the core body 221 An insulation layer 230 is formed on the core body 221 and the flange 224 for insulation between the core 220 and the coil 250. In this case, 15, the insulating layer 230 is formed entirely on the core body 221 and the flange 224, but an insulating layer may be formed on only a part of the core body along the region where the coil 250 is wound.

16 shows a perspective view of another modified embodiment of the second embodiment shown in Fig. 13. In Fig. 16, similarly to the second embodiment shown in Fig. 13, an opening 262 is formed at one end, A shield cover 260 having a cup structure as a whole is used and an inner surface of the shield cover 265 of the shield cover 260 is provided with an engagement groove 265 corresponding to the shape of the upper end of the core assembly 210 265 are formed.

The coupling groove 265 is formed on the inner surface of the shielding portion 265 of the focusing cover 260 so that the upper end of the core assembly 210 is inserted into the coupling groove 260 when the core assembly 210 is inserted into the focusing cover 260. [ 265 to fix the position of the core assembly 210 in the focusing cover 260, it is possible to stably maintain the position of the core assembly 210 even when the inductor swings or impacts.

16 shows a perspective view of a third embodiment of the inductor according to the present invention.

16A, the focusing cover 260a is a modified form of the cup-shaped focusing cover 260 of FIG. 13, and includes an opening 267a whose side is opened from the opening of the focusing cover 260a to the shielding portion And the shielding portion 265a has a plurality of fan-shaped shapes spreading from the center. In FIG. 16A, the shielding portion 265a has two fan-shaped openings extending from the same center, and a plurality of fan-shaped openings such as three or four openings from the same center may be formed.

The core 220a is a T-shaped core. The flange 224a corresponds to the shape of the shielding portion 265a of the focusing cover 265a and has a fan shape. The core body 220a is wound around the circular bobbin 240a in which the coil 250a is wound. And the core assembly is inserted into the focusing cover 260a so as to enclose a side portion of the coil.

 16B, the focusing cover 260b has a cross-shaped shielding portion 265b, and an opening portion 267b is formed on the side surface of the focusing cover 265b corresponding to the cross-shaped end of the shielding portion 265b have.

The flange 224b of the core 220b has a cross shape corresponding to the shape of the shielding portion 265b of the focusing cover 265b and has a rectangular bobbin 240b in which the coil 250b is wound. Here, the bobbin may have a circular shape, and when the bobbin is circular, the inner shape of the focusing cover is preferably formed corresponding to the circular bobbin.

17 is a perspective view of a modified embodiment of the third embodiment shown in Fig. 16, wherein Fig. 17 (a) is a modification of Fig. 16 (a) The core 220a corresponds to the shape of the focusing cover 265a and is the same as that of FIG. 16 (a). In FIG. 17 (a), the bobbin is removed and the core 220a The core assembly is constructed by winding the coil 250 directly on the core body 221a. Since it is desirable to insulate the core 220a from the coil 250, an insulating layer 230a is formed in a part of the core 220a. The insulating layer can be inferred from the above-mentioned contents. .

17 (b) is a modification of FIG. 16 (b), a cup-shaped focusing cover 265b having a cross-shaped shielding portion is applied. In FIG. 17 (b) the bobbin is removed and the coil 250 is directly wound on the core body 221b of the core 220b and the insulation layer 230b is formed for insulation between the core 220b and the coil 250. [ In FIG. 17 (b), the core body 221b is formed in a rectangular shape, which is optional, and the core body 221b may be formed in the form of a circular column.

It is possible to provide an inductor which effectively concentrates the magnetic field lines while saving the material for manufacturing the converging cover by applying the converging cover having such an opening portion.

Next, Fig. 18 shows a perspective view of a fourth embodiment of the inductor according to the present invention.

In the fourth embodiment of FIG. 18, the collecting covers 260d and 260e are formed in a sealed tubular structure having a space in which the shielding portions are formed at both ends of the circular pipe to receive the core assemblies 210d and 210e. 260d ", 260d", 260d ", 260d", 260d ", 260d", 260d ", 260d", 260d " 260e, 260e ', 260e' ', respectively, and two focusing cover pieces are coupled to each other with the core assemblies 210d and 210e interposed therebetween, and the core assemblies 210d and 210e are accommodated therein. . 18 (a) shows a focusing cover 260d that receives a core assembly 210d having a bobbin with a coil wound thereon. In FIG. 18 (b), the core assembly in which coils are wound on the straight core 210e, respectively. An engaging groove corresponding to an end of the core assembly 210e is formed in the upper surface and the lower surface of the focusing cover 260e in order to fix the core assembly 210e inside the focusing cover 260e as shown in FIG. So that the end of the core assembly 210e is inserted into the coupling groove and is fastened, so that the core assembly 210e can be stably fixed within the focusing cover 260e.

18, the shape of the focusing cover may be variously modified, and the number of pieces of the divided focusing cover may be divided into three or more pieces of the focusing cover in consideration of the shape of the core assembly .

19 shows a perspective view of a modified embodiment of the fourth embodiment shown in Fig. 18. In Fig. 19, the converging cover shown in the fourth embodiment of Fig. 18 has a plurality of openings Fig.

In FIG. 19, the upper and lower surfaces of the two focusing cover pieces 260f ', 260f', 260g ', and 260g' 'vertically divided in the longitudinal direction are formed to correspond to each other. And is formed in a V shape in FIG. 19 (b). The two cover cover pieces 260f ', 260f' ', 260g', and 260g '' are coupled to each other with the core assemblies 210f and 210g therebetween to form the cover covers 260f and 260g. That is, in FIG. 19 (a), the upper shielding portion and the lower shielding portion of the converging cover 260f formed by coupling the two focusing cover pieces 260f 'and 260f' 'correspond to each other to form a fan shape in which the center rotor is deployed , And an open portion is formed from the upper surface of the upper shield to the lower surface of the lower shield corresponding to the fan shape of the shield. 19B, the upper shielding portion and the lower shielding portion of the converging cover 260g, to which the two focusing cover pieces 260g 'and 260g' 'are coupled, are in the shape of a cross, corresponding to each other, A shape corresponding to the cross shape is formed in which the opening is formed from the upper surface as the upper shield to the lower surface as the lower shield.

19A, a core assembly 210f to which a bobbin is applied is used. In FIG. 19B, a core assembly 210g in which a coil is wound around a straight core is used. The coupling groove for stably fixing the core assembly 210g to the focusing cover 260g as shown in FIG. 19 (b) may be variously modified depending on the situation, .

20A and 20B show a perspective view of a fifth embodiment of the inductor according to the present invention. In FIGS. 20A and 20B, the focusing covers 360a and 360b have a rectangular shape, and the core assemblies 310a, 310b are inserted into the rectangular frames of the focusing covers 360a, 360b in the longitudinal direction to form inductors 300a, 300b.

20A and 20B, the straight cores 320a and 320b are applied so that the core assemblies 310a and 310b are inserted into the bobbins 340a and 340b on which the coils 350a and 350b are wound, 320a, and 320b.

21 shows a perspective view of a modified embodiment of the fifth embodiment shown in FIG. 20, wherein FIGS. 21 (a) and 21 (b) The core assemblies 310c and 310d are used to directly wind the coils 350c and 350d to the cores 320c and 320d and the insulating layers 330c and 330d are formed between the cores 320c and 320d and the coils 350c and 350d / RTI >

The fifth and sixth embodiments of the present invention shown in FIGS. 20 and 21 employ a condenser cover having a simpler structure, and a flanged core may be used. In addition to the circular or square pillars, The core body may be applied.

Next, an inductor having a self-focusing structure in which a gap flange of an air gap function or a winding guide function, which is a third main feature of the present invention, is applied will be described with reference to embodiments.

As described above, by forming a gap in an inductor such as a choke transformer, more magnetic energy can be stored in the inductor, so that even when a large current flows in the core, the inductor can be stably driven without reaching a saturated state In the present invention, an inductor that functions as a kind of air gap by forming a flange of a core with a non-magnetic material is proposed, wherein a flange, which is formed of a non-magnetic material different from a flange formed as a porcelain material, and functions as an air gap.

Further, the gap flange in the present invention may function as a winding guide for facilitating the winding of the coil and preventing the winding coil from escaping. As an optional function, whether the gap flange functions as a gap or as a winding guide, The gap flange may function only as a gap or function only as a winding guide or may function as both a gap and a winding guide.

FIG. 22 is a perspective view of a sixth embodiment of the inductor according to the present invention, and FIG. 23 is a sectional view of the sixth embodiment of FIG. 22. FIG.

The fifth embodiment of FIG. 22 is similar to the second embodiment of FIG. 13 except that the core assembly 410 is inserted into the cup-shaped focusing cover 460 and the core assembly 410 is provided with a gap flange 425 are formed.

The I-shaped core 420 of the core assembly 410 is composed of a core body 421 formed of a porcelain material, a lower flange 424 and a gap flange 425 formed of a non-magnetic material. The gap flange 425 By forming the non-magnetic material, the gap flange 425 itself functions as a kind of air gap.

That is, the core 420, the flange 424, and the focusing cover 460 form a magnetic-field line closed loop, and a gap flange (not shown) is formed between the core body 421 and the shielding portion 465 of the focusing cover 460 425 are positioned so that the gap flange 425 accumulates magnetic energy as a gap.

The inductance of the inductor 400 can be adjusted by regulating the reluctance of the gap flange 425 according to the thickness of the gap flange 425 since the thickness of the gap flange 425 is the size of the air gap .

23, the insulating layer 430 is formed on the core body 421 and the flange 424 and the coil 450 is directly wound on the core 420. However, the present invention is not limited thereto and may be a core assembly And various focus covers according to the present invention may be applied.

As described above, in the present invention, the inductance of the inductor 400 can be easily adjusted by adjusting the reluctance according to the thickness of the gap flange by forming the gap by applying the gap flange to the I-shaped or T- Further, the gap flange may be employed in the straight core or the T-shaped core to facilitate the coil winding and to function as a winding guide for preventing the coil from being separated from the winding.

The inductor to which the gap flange in the present invention is applied may be variously modified. Hereinafter, some modified embodiments will be described in detail.

24 shows a perspective view of a seventh embodiment of the inductor according to the present invention.

24A, the focusing cover 560 includes an upper focusing cover 560a and a lower focusing cover 560b. Each of the upper focusing cover 560a and the lower focusing cover 560b has a cup shape, Shielding portions 565a and 565b are formed at the other end of the core assembly 510. The upper and lower portions of the core assembly 510 are inserted into the upper focusing cover 560a and the lower focusing cover 560b, The upper focusing cover 560a and the lower focusing cover 560b are configured to entirely surround the core assembly 510. [

Gap flanges 525 and 527 are formed at both ends of the core of the core assembly 510 so that the gap between the core assembly 510 and the upper fly cover 560a and the lower flyer cover 560b, An air gap is formed through the openings 525 and 527. Further, the core can be provided with a winding guide at both ends to facilitate the winding of the coil on the core through the gap flanges 525 and 527, and to prevent the winding coil from escaping.

In FIG. 24 (a), the enclosure cover 560 having a closed tubular structure in which the core assembly 510 is accommodated may be composed of a horizontally divided upper focusing cover 560a and a lower focusing cover 560b. 24 (b), a closed cover 560 'of a closed tubular structure in which the core assembly 510 is received is divided into vertically divided left focusing cover 560a' and right focusing cover 560b ' And the left focusing cover 560a 'and the right focusing cover 560b' are coupled with each other through the core assembly 510 to form a focusing cover 560 '.

In the seventh embodiment of FIG. 24, gap flanges are formed at both ends of the core. However, considering the characteristics of the inductors required, only one gap flange may be selectively formed, and a flange of a ceramic material may be selectively formed.

25 shows a perspective view of an eighth embodiment of the inductor according to the present invention.

The eighth embodiment shown in Fig. 25 is a focusing cover 660a, 660b to which a shielding portion 665a, 665b of a fan shape or a cross shape is applied similarly to the third embodiment of Figs. 16 and 17, Gap flanges 625a and 625b are formed on the cores 620a and 620b of the core assembly to adjust magnetoresistance through the gap flanges 625a and 625b.

26 shows a perspective view of a ninth embodiment of the inductor according to the present invention. In the same manner as in the embodiment of FIG. 19, two focusing cover pieces 660c 'and 660c' ' The two cover cover pieces 660c 'and 660c' 'are coupled to each other with the core assembly 610c interposed therebetween to form a focusing cover 660c. The core assembly 610c A gap flange is applied at both ends of the flange.

27 shows a perspective view of a tenth embodiment of the inductor according to the present invention. The tenth embodiment shown in FIG. 27 is similar to the fifth embodiment shown in FIGS. 20 and 21, The core assemblies 710a, 710b, and 710c are inserted in the lengthwise direction in the inside of the rectangular frame cover 760a, 760b, and 760c, to which the focusing covers 760a, 760b, and 760c are applied And the inductors 700a, 700b, and 700c are formed. Gap flanges 725a, 727a, 725b, 727b, 725c, and 727c are formed at both ends of the cores 720a, 720b, and 720c, and shapes of the gap flanges 725a, 727a, 725b, 727b, Circular, square, or the like. In particular, in FIG. 27C, the core assembly 710c is formed in an elliptical shape in cross section, and the coil space can be utilized by utilizing the inner space of the focusing cover corresponding to the shape of the focusing cover of the rectangular frame have.

24 to 27 may include a core assembly to which a bobbin is applied, or an assembly in which a bobbin is removed and a coil is wound directly on the core.

By applying the gap flange to the core assembly and the focusing cover in this manner, it is possible to adjust the magnetoresistance through the gap flange or to prevent the escape of the coil wound as a winding guide.

Further, as a fourth main feature according to the present invention, the gap flange may be used to divide the primary coil and the secondary coil. In this regard, FIG. 28 shows a perspective view of the eleventh embodiment of the inductor according to the present invention .

28, the core assembly 810 includes a first coil 850a and a second coil 850b, and the first coil 850a and the second coil 850b are interrupted And a gap flange 825b of the first flange 810b. And a core assembly 810 including a first coil 850a and a second coil 850b is inserted into a focusing cover 860. [ 28, gap flanges 825a and 825c are also applied to the upper and lower ends of the core assembly 810. However, a flange of a ceramic material may be selectively applied to the upper and lower ends of the core assembly 810 In addition, the shape of the focusing cover 860 can be applied to various types of focusing covers as described above in addition to the cylindrical pipe structure.

In the present invention, a method of manufacturing an inductor having a self-focusing structure as described above is presented. Hereinafter, a method of manufacturing an inductor having a self-focusing structure will be described as a fifth main feature of the present invention .

29 shows a process embodiment of a method of manufacturing an inductor according to the present invention.

In the method of manufacturing an inductor according to the present invention, a core body, a flange, a focusing cover and the like can be selectively manufactured by winding a steel plate having a porcelain shape in a roll form. As shown in FIG. 29A, A core body 920a in the form of a drum core having a constant diameter in a section taken in a predetermined number of turns in the form of a roll is manufactured and the core body 920a having porosity such that the core body 920a has a through- The flanges 920b and 920c are manufactured by winding the steel plate 905 a predetermined number of times in the form of a roll and the steel plate 920b and 920c having porosity so as to have a through space in consideration of the cross sectional diameters of the core body 920a and the flanges 920b and 920c 907 are wound a predetermined number of times to manufacture a focusing cover 960. Here, the cross-sectional diameters of the core body 920a and the flanges 920b and 920c can be selected according to the performance of the inductor and the applicable conditions, and can be easily adjusted according to the number of turns of the steel sheet. In addition, the core body 920a is not limited to a circular shape in cross section, but may be formed in various polygonal shapes such as a quadrangle, a pentagon, etc., and the flange and the focusing cover may be formed in various shapes corresponding to the shape of the core body.

Further, as the core body 920a is manufactured by winding a steel sheet in the form of a roll, a hole may be formed at the center of the core body 920a. The inner space of the core body 920a thus formed is filled with a magnetic material It is desirable to fill up. Further, the through-hole formed at the center of the core body 920a may be used as a wiring path of the coil wound around the core body.

When the core body 920a, the flanges 920b and 920c and the focusing cover 960 are selectively prepared, flanges 920b and 920b are formed on the upper and lower ends of the core body 920a as shown in FIG. 29 (b) 920c are inserted into the core 920 to manufacture the core 920 and the core 920 is wound on the coil 950 to manufacture the core assembly 910. [

The process of inserting and inserting the flanges 920b and 920c into the core body 920a is optional. In the case where the flanges 920b and 920c are not used, the core body 920a itself may be a straight core, It may be a T-shaped core in a case where the core bodies 920b and 920c are sandwiched only at either the upper end or the lower end of the core body 920a.

When the core assembly 910 is prepared as described above, an inductor having a self-focusing structure can be manufactured by inserting the core assembly 910 into the focusing cover 960 as shown in FIG. 29 (c) .

Further, it is an optional process to manufacture the core body 920a, the flanges 920b and 920c, or the focusing cover 960 by winding the corrugated steel sheet in a roll form as shown in FIG. 29 (a) May be manufactured using the ceramic steel sheet.

The core assembly in the present invention can be manufactured in various forms and configurations, and FIG. 30 shows various modified embodiments of a process for manufacturing a core assembly in a manufacturing method of an inductor according to the present invention.

30A, the core 920a is inserted into the insulating member 930 and the flange 920b is selectively inserted into the upper and lower ends of the core body 920a to manufacture the core 920 ' The coil 950 is wound on the core 920 'to manufacture the assembly 910'. The insulating member 930 is an insulating layer formed between the core body 920a and the coil 950. The insulating member 930 may be made of a plastic injection molded product or a tube made of an insulating material having a through space through which the core body 920a is inserted. The flange 920b may be formed on the insulating member 930 so that the flanges 920b and 920c do not flow down more stably.

30B illustrates a case where an insulating layer is formed through an insulating material coating, and an insulating layer is formed of an insulating layer 930a by coating an insulating material around the core body 920a. Then, the core 920 '' is manufactured by sandwiching the flanges 920b and 920c selectively at the upper and lower ends of the core body 920a, and the coil 950 is wound thereon to manufacture the core assembly 910 ''.

The process of forming the insulation layer shown in the embodiment of FIG. 30 is optional and can be applied according to circumstances. For example, in the case of a low frequency inductor, the coil may be wound directly on the core without applying an insulating layer. The flange is also optional and can be applied depending on the situation, taking into account the characteristics of the inductor required.

The manufacturing method of the inductor having the self-focusing structure according to the present invention can manufacture the core by winding the steel sheet in the form of a roll, thereby eliminating the dangerous and complicated pressing process. Thus, It is possible to reduce the manufacturing cost, and in particular, it is possible to selectively control the thickness of the steel sheet forming the core and the winding roll in the roll form, so that the characteristics of the inductor can be adjusted by adjusting the core itself without depending on the winding of the coil.

Further, by applying a cylindrical cylindrical core, the consumption of the coil relative to the winding of the coil can be further reduced as compared with the case of using the existing angled E-shaped or T-shaped core.

The present invention further provides a hybrid inductor including the inductor having the self-focusing structure and the inductor for controlling the trigger of the switching element. Hereinafter, a hybrid inductor according to the sixth aspect of the present invention will be described. Hereinafter, the embodiment will be described.

The hybrid inductor according to the present invention includes the inductor having the self-focusing structure according to the present invention. The inductor having the self-focusing structure will not be described in detail with reference to the above description.

Generally, an electronic ballast is provided with a so-called oscillator using a toroidal core to trigger two switching elements, and also uses an inductor using a toroidal core in various electronic apparatuses as a transformer and a filter.

In the present invention, the inductor having such a self-focusing structure that can be used for various inductors using the toroidal core as a transformer or a choke transformer and the choke transformer as described above can be constituted as one package, A method for reducing the number is disclosed.

31 shows a first embodiment of a hybrid inductor according to the present invention.

In the first embodiment of the hybrid inductor shown in FIG. 31, the inductor having the self-focusing structure according to the present invention described above includes a core assembly 1110 and a focusing cover 1160 that are formed of a first inductor 1100.

The focusing cover 1160 is a cylindrical pipe structure in which the focusing cover 1160 is used as the sleeve core of the inductor so that the coil 1250 is wound in the toroidal shape in the longitudinal direction of the focusing cover 1160 to form the second inductor 1200).

That is, the hybrid inductor 1000 according to the present invention includes the core assembly 1110 and the focusing cover 1160 constituting the first inductor 1100, and the coil cover 1160 and the focusing cover 1160, The first inductor 1100 and the second inductor 1200 constitute a hybrid inductor 1000 in a package form.

In the first embodiment shown in FIG. 31, the core assembly 1110 in which the bobbin is removed and the coil 1150 is wound directly on the core 1120 is constituted as a core assembly to which a bobbin is applied have.

FIG. 32 shows the direction of magnetic force lines in the first embodiment of the hybrid inductor according to the present invention shown in FIG. 31. Referring to FIGS. 31 and 32, the operation principle of the hybrid inductor according to the present invention will be described. do.

A magnetic field is generated by the current flow in the coil, where the change in the magnetic field applied to the coil produces an induced current in a direction to counteract the change in the magnetic field.

31, the magnetic field B _P is generated in accordance with the direction of the current I _P flowing through the coil of the core assembly 1100 of the first inductor 1100 as shown in FIG. 32, and the second inductor The magnetic field B _S is generated in accordance with the direction of the current I _S flowing through the coil 1250 of the magnetic field generator 1200.

Since the magnetic field BP generated by the core assembly 1100 of the first inductor 1100 coincides with the direction of the coil 1250 wound around the second inductor 1200, And does not affect the toroidal coil 1250. The magnetic field B _S generated by the second inductor 1200 is also coincident with the direction of the coil 1150 of the core assembly 1110 of the first inductor 1100 so that no magnetic field is generated in the coil 1150 of the core assembly 1110 It does not affect.

Accordingly, in the case of the hybrid inductor 1000 having the first inductor 1100 having the self-focusing structure according to the present invention as shown in FIG. 31 and the second inductor 1200 coupled to the one inductor, The first inductor 1100 constituted by the core assembly 1110 and the second inductor 1200 located outside the core assembly 1110 do not affect each other and can operate individually.

33 shows a second embodiment of a hybrid inductor according to the present invention,

33, the structure of the core assembly 1110a of the first inductor 1100a is the same as that of the inductor having the self-focusing structure according to the present invention. The focusing cover 1160a A focusing cover having a plurality of grooves formed in the longitudinal direction and spaced apart from the upper and lower portions by a predetermined distance is applied. The coil cover 1250a of the second inductor 1200a is wound in a toroidal shape in the portion 1161a where the groove cover 1160a is formed and the groove cover 1160a is used as the sleeve core of the second inductor 1200a. do. By winding the coil in the groove of the focusing cover 1160a as described above, it is possible to stably maintain the position of the coil by preventing the coil from being separated, and by cutting the material by matching the positions of the grooves, Production can be made possible, and waste of the material can be prevented.

Here, liquid crystal silicon, urethane or insulating paint is applied to the focusing cover 1160a, which is used as the sleeve core 1160a by winding the coil 1160a for insulation between the coil 1250a of the second inductor 1200a and the sleeve core 1160a, Or the like may be coated to form an insulating layer, or an insulating layer may be formed by a plastic case, an insulating tape, a tube, or another method.

Furthermore, in addition to the focusing cover shown in FIG. 33, various types of focusing covers as described with reference to FIG. 11 can be applied to the sleeve core of the second inductor 1200a.

34 shows a third embodiment of a hybrid inductor according to the present invention.

34, since the core assemblies 1110b of the first inductor 1100b can be applied to the core assemblies described above, their description will be omitted.

34, the focusing cover 1160b has four supporting members 1163 and a supporting member 1163 which have a rounded surface corresponding to the outer surface of the core assembly 1110b at the outer periphery of the core assembly 1110b, And a connecting member 1164 connecting between the supporting members 1163 between the supporting members 1163. The sectional view taken from the upper part is a quadrangular shape as a whole.

The supporting member 1163 and the connecting member 1164 are used as a sleeve core of the second inductor 1200b and the core 1250b is wound on the connecting member 1164 in a toroidal shape.

The coil 1250b of the second inductor is wound to insulate the coil 1250b of the second inductor from the connecting member 1164 and the connection member 1164 used as the sleeve core is made of liquid silicon, urethane, The insulating layer may be formed by coating the insulating material, or the insulating layer may be formed by other methods such as a plastic case, an insulating tape or a tube.

In FIG. 34, four supporting members 1163 are positioned on the outer periphery of the four corners of the core assembly 1110b, and are generally rectangular when viewed from above. However, the present invention is not limited to this, A triangular shape, or a pentagon with five supporting members positioned thereon, and a plurality of supporting members may be positioned to form a polygonal shape.

34C shows a core assembly 1110b from which a bobbin has been removed. However, a core assembly using a bobbin may be applied as needed.

35 shows a fourth embodiment of a hybrid inductor according to the present invention.

35, the core assembly 1310 located inside the focusing cover 1360 can be applied to the core assembly. In FIG. 35, an inductor ring 1461 is positioned on the focusing cover 1360 The inductor ring 1461 is connected to the upper end of the focusing cover 1360 by a plurality of supporting legs 1465 and is supported by the focusing cover 1360. A coil 1450 wound in a toroidal shape in the inductor ring 1461 and the inductor ring 1461 constitutes the second inductor 1400.

That is, in the hybrid inductor according to the fourth embodiment of FIG. 35, the core assembly 1310 and the focusing cover 1360 constitute the first inductor 1300 at the lower end, and the inductor ring 1461 and the support legs 1465 And a coil 1450 wound around the inductor ring 1461 constitute a second inductor 1400. The coil 1460 is wound around the sleeve core 1460 and the inductor ring 1461,

35B, the core 1320 of the first inductor 1300 includes a core body 1321 formed of a ceramic material, a flange 1324 formed at the lower end of the core body 1321, And a gap flange 1325 as shown in FIG.

The hybrid inductor in which the first inductor 1300 and the second inductor 1400 are formed as a package as shown in FIG. 35 uses the upper part of the first inductor 1300 as the space of the second inductor 1400, Can be further improved.

The hybrid inductor according to the present invention as shown in FIGS. 31 to 35 may be selectively provided with a bobbin having a coil wound thereon. Alternatively, an insulating layer may be partially formed in the core and the coil may be wound thereon. And a core having a flange with a thickness controlled according to FIG. 10 may be applied. Further, the inductance of the inductor may be adjusted by applying a gap flange to the hybrid inductors of FIGS. 31 to 35 as well.

The foregoing description is merely illustrative of the technical idea of the present invention and various changes and modifications may be made by those skilled in the art without departing from the essential characteristics of the present invention. Therefore, the embodiments of the present invention are not intended to limit the scope of the present invention but to limit the scope of the present invention. The scope of protection of the present invention should be construed according to the following claims, and all technical ideas within the scope of equivalents thereof should be construed as being included in the scope of the present invention.

100, 200, 400: inductor,
110, 110a, 210, 410: core assembly,
120, 220, 420: core,
121, 221, 421: core body,
123, 124, 224, 424: flange,
425, 525, 527: a gap flange,
130, 230, 430: insulating layer,
140, 240: bobbin,
150, 250, 450: coil,
160, 260, 460, 560: focusing cover,
560a: upper focusing cover, 560b: lower focusing cover,
1000: Hybrid inductor,
1100, 1100a, 1100b, 1300: a first inductor
1200, 1200a, 1200b, 1400: a second inductor.

Claims (32)

A core assembly including a core having a core body of a predetermined length and a coil wound around the core body; And
The core assembly being formed to contain a porcelain material and inserted into the core assembly so as to surround at least a portion of the coil at an outer angle of the core assembly so as to restrict external diffusion of the magnetic force lines generated in accordance with the current flow of the coils, And a focusing cover for applying a current to the inductor. The method according to claim 1,
The core assembly includes:
Wherein the core body includes a core having a flange formed of a porcelain material at one or both ends in the lengthwise direction of the core body and having a vertical cross-section of I-type or T-type. 3. The method of claim 2,
Wherein the flange is formed to have a thickness thinner toward the side from the center portion so that the vertical cross-sectional area of the inner circumference on the flange and the horizontal cross-sectional area of the core body are equal to each other. The method according to claim 1,
The core assembly includes:
Wherein the core body includes a core having a gap flange formed of a nonmagnetic material at one or both ends in the longitudinal direction of the core body and having a vertical cross-section of I-type or T-type. The method according to claim 1,
The core assembly includes:
Wherein the core body has a flange formed of a porcelain material on one of both ends in the longitudinal direction of the core body and a gap flange formed of a nonmagnetic material on the other of the flanges. 6. The method according to any one of claims 2 to 5,
The core assembly includes:
A bobbin inserted into the center of the core body; And
And a coil wound around the bobbin. 6. The method according to any one of claims 2 to 5,
The core assembly includes:
An insulating layer formed on at least a part of the core; And
And a coil wound around a portion of the core on which the insulating layer is formed. 6. The method according to any one of claims 1 to 5,
The focusing cover
Wherein the coil assembly is formed with a circular or polygonal pipe structure having both ends penetrating to form an opening and surrounding the outer periphery of the coil with the core assembly inserted therein. 9. The method of claim 8,
The focusing cover
And a plurality of converging cover pieces vertically divided in the longitudinal direction are coupled. 9. The method of claim 8,
The focusing cover
Wherein a plurality of through holes are formed at predetermined intervals along a side surface of the inductor. 9. The method of claim 8,
The focusing cover
A plurality of grooves are formed at regular intervals in the longitudinal direction from the upper side or the lower side of the side surface,
Wherein a plurality of grooves are formed alternately spaced apart from each other in the longitudinal direction at regular intervals. 6. The method according to any one of claims 1 to 5,
The focusing cover
Wherein an opening is formed at one end and a shield is formed at the other end, and the core assembly is inserted into the opening to surround the outer periphery of the coil. 13. The method of claim 12,
The focusing cover
An upper focusing cover formed in a cup structure into which an upper end of the core assembly is inserted; And
And a lower focusing cover formed in a cup structure into which a lower end of the core assembly is inserted. 13. The method of claim 12,
The focusing cover
And a plurality of openings are formed on the side surfaces from the one end to the other end. 13. The method of claim 12,
The focusing cover
Wherein the shielding portion is formed in a plurality of fan shapes or cross shapes extending from the center to an outer periphery,
And the opening portion is formed corresponding to the shape of the shielding portion. 16. The method according to any one of claims 12 to 15,
An engaging groove corresponding to an upper end shape of the core assembly is formed on the inner surface of the shielding portion of the focusing cover,
And an upper end of the core assembly is inserted into and engaged with the coupling groove. 6. The method according to any one of claims 1 to 5,
The focusing cover
A shielding portion is formed at both ends of a circular or polygonal pipe to form a sealed tubular structure having a space for accommodating the core assembly,
And a plurality of converging cover pieces vertically divided in the longitudinal direction are coupled. 18. The method of claim 17,
The focusing cover
And a plurality of openings are formed on the side surfaces from the upper surface to the lower surface. 6. The method according to any one of claims 1 to 5,
The focusing cover
And has a rectangular frame structure having a predetermined thickness,
Wherein the core assembly is inserted into the focusing cover and is inserted into the rectangular frame of the focusing cover in the longitudinal direction. 6. The method according to any one of claims 1 to 5,
The focusing cover
A plurality of support members having surfaces corresponding to longitudinal outer surfaces of the core assembly and spaced apart from each other along an outer angle of the core assembly; And
And a connection member for connecting the support members between the support members. 18. The method of claim 17,
Wherein the support member has a plurality of surfaces in a horizontal section and a surface adjacent to the core assembly is formed to correspond to an outer surface of the core assembly,
Wherein the plurality of support members are spaced apart from each other along the outer periphery of the core assembly so that the outer edge of the horizontal cross section of the focusing cover has a quadrangular shape. 6. The method according to any one of claims 2 to 5,
The end of the flange or the gap flange and the end of the focusing cover are mutually corresponding to each other so as to maintain a distance to a certain portion between the core assembly and the focusing cover while fixing the core assembly to a predetermined position on the inside of the focusing cover And an engaging portion that is engaged with the engaging portion is formed. The method according to claim 4 or 5,
The core assembly includes:
A first core body on which a first coil is wound;
A second core body on which a second coil is wound; And
And a gap flange positioned between the first coil and the second coil. A first inductor composed of the inductor of any one of claims 1 to 10 or 20 to 22;
And a second inductor including a toroidal coil wound in the longitudinal direction on the focusing cover. 25. The method of claim 24,
Wherein the first inductor comprises the inductor of claim 11,
And the toroidal coil of the second inductor is wound in the groove of the focusing cover. 25. The method of claim 24,
And an insulating layer coated on a surface of the focusing cover,
Wherein the toroidal coil is wound on an insulating layer. 25. The method of claim 24,
Wherein the first inductor is composed of the inductor of claim 20 or 21,
And the toroidal coil of the second inductor is wound on the connecting member. A first inductor composed of the inductor of any one of claims 1 to 18 or 20 to 22; And
And a second inductor spaced apart from an upper portion of the focusing cover, the inductor ring being connected to the focusing cover with a plurality of support legs, and a coil wound around the inductor ring in a toroidal shape. A core body manufacturing step of fabricating a core body having a round or polygonal cross section with a predetermined number of turns of a steel plate having a porosity;
A core assembly manufacturing step of winding the core around the core body at an intermediate portion of the core body to manufacture a core assembly;
A focusing cover manufacturing step of manufacturing a focusing cover containing a porcelain material and having an opening corresponding to an end surface of the core assembly; And
And inserting the core assembly into the focusing cover so as to surround at least a portion of the coil at an outer angle of the core assembly. 30. The method of claim 29,
The focusing cover manufacturing step includes:
Wherein the core assembly is inserted into the core assembly so that the core assembly has a through space that surrounds the core assembly. 32. The method according to claim 29 or 30,
Further comprising a flange manufacturing step of fabricating a flange having a predetermined number of turns of a ceramic plate having a porosity so as to have a through space corresponding to a cross-sectional diameter of the core body,
The core assembly manufacturing step may include:
Coupling the flange to the core body by sandwiching the flange on at least one of an upper end or a lower end of the core body; And
And forming a coil wound around the core body at an intermediate portion of the core body. 30. The method of claim 29,
The core body manufacturing step may include:
Preparing a core body having a circular or polygonal cross section with a predetermined number of turns of a steel plate having a porosity; And
And inserting the core body into an insulating member having an outer surface of the core body coded with an insulating material or having a through hole corresponding to a diameter of the core body.

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