TWI438797B - Hot/cold forming and assembling magnetic component - Google Patents

Description

Cold and hot pressed combined magnetic components

The invention combines the advantages and characteristics of the cold press forming and the hot press forming magnetic element, and combines the cold press forming with the high density mandrel on the body of the thermocompression magnetic element to obtain the final high magnetic induction combined magnetic element.

The magnetic inductive component used in the market has a basic structure in which a current-carrying coil is placed around the core rod, and a magnetic shielding material is packaged around the core rod and the current-carrying coil. The general manufacturing method is roughly divided into a cold pressing method and a hot pressing method, so-called cold. The pressing method firstly forms the core rod and the magnetic shielding material by cold pressing, and then assembles together with the current-carrying coil to form a cold-pressed magnetic element; and the hot pressing method forms the core rod and the magnetic shielding material by hot pressing. Subsequent assembly with the current-carrying coil to form a thermocompressive magnetic element.

As is known, there are significant differences in the characteristics of magnetic components produced by hot pressing technology and cold pressing technology. The hot pressing technology is formed by hot pressing of a semi-fluid powder injection mold, which has the requirements of complex design shape, high mechanical strength and low. The advantage of magnetic line loss, while the cold pressing technology forcibly presses the powder into a stamping die, which has the advantages of high magnetic material weight ratio and low manufacturing cost. Therefore, a single hot pressing method or a cold pressing method is used for the magnetic element. The disadvantage of being reversed beyond its advantages.

In view of the absence of conventional hot-pressed or cold-pressed magnetic components, the cold-and-hot-pressed magnetic components of the present invention have been researched and developed, which combines the advantages of cold-pressing and hot-pressing magnetic components to obtain a final high magnetic induction combined magnetic component.

Before explaining the technical content of the present invention, the materials or processes to which the present invention is applied are first defined or described as follows: a mandrel: generally refers to a magnetic sensitive material coated by a coil in a general magnetic component, which may be a single individual or as needed With the components, there are different shapes such as T-shaped and rod-shaped.

Magnetic powder: The magnetic powder referred to in the present invention may include iron powder, iron-iron alloy powder (Fe-Si), ferrite powder (ferrite), iron-aluminum-niobium alloy powder (Sendust), Or other magnetic materials such as Hi-Flux, Molypermalloy Powder, Amorphous magnetic powder or the like, or the aforementioned composite materials.

Hot-pressed magnetic powder: The hot-pressed magnetic powder referred to in the present invention is a hot-flowing plastic raw material such as polycarbonate (PC), styrene resin (PS), polyethylene (PE), nylon. (Nylon), polypropylene (PP), technical details can be found in the contents of Taiwan Patent No. 098110688, US No. 12/559580 and China No. 200910151966.4.

Coil: The coil referred to in the present invention is a coil of surface-insulated copper wire wound into a single or multiple turns to generate an applied magnetic field by a carrier current.

Assembling: As described in the present invention, the holes, the card shoots, and the positioning design for each component combination are reserved in advance, and are mechanically or manually combined. The glues sold in the general market can be used for bonding between the components. Such as epoxy resin, silicone rubber, instant glue.

Hot pressing technology: mainly by heating and pressing, the hot-pressed magnetic powder is heated to soften and melt, and the powder flows into the mold for forming, which can form 3D complex forming such as corner, hollow and minute size, and the product does not need annealing and size. Accuracy, the disadvantage is that the manufacturing cost is expensive.

Cold pressing technology: Refers to powder press-forming (Press), which is mainly formed by mechanical pressure molding, and then finished by annealing and sintering. The advantage is that the manufacturing cost is low. The disadvantage is that the product needs to be annealed, the size variation is large, and 3D complexity cannot be performed. Forming.

The technical differences between the technical features of the present invention and the general cold-pressed combined magnetic element and the hot-pressed combined magnetic element are summarized as follows:

* General magnetic components create air gaps in the path of magnetic lines of force, delaying the occurrence of magnetic saturation.

It can be seen from the above comparative analysis that the present invention combines the prior art hot pressing technology with the advantages of complex design, high mechanical strength and low magnetic flux loss, and the cold pressing technology with the advantages of high magnetic material weight ratio and low manufacturing cost, and innovative several bodies and cores. The rod combination morphology is applied to the development of new magnetic components to obtain a combined magnetic component with a final high magnetic induction.

As shown in the first to sixth figures of the present invention, the cold and hot-pressed combined magnetic component of the present invention is mainly composed of a rod-shaped mandrel (Rob Shape) (1) and a current-carrying coil. (Coil) (2), paired with a pair of lead pads (3) and a hot body (Hot Forming Body) (4) four accessories.

The rod-shaped core rod (1) is composed of magnetic powder and is formed by cold pressing technology, and mainly provides a magnetic element to induce a magnetic field source, which is loaded into a rod-shaped mandrel space (Rod Space) of the hot-pressed body (4) ( 41) The rod-shaped mandrel (1) may be a rod-shaped core rod (1) or a T-shaped core (T shape) (1A) containing a monomer.

The current-carrying coil (2) is a coil wound by an insulated copper wire, which has a load current and generates an external magnetic field function.

The pair of copper sheets (3) are mainly made of conductive copper sheets, and one end of each of the attached copper sheets is electrically connected to one end of the current-carrying coil (2), and one end protrudes from the hot-pressing body (4). As a current input and output electrode.

The hot-pressed body (4) is made of hot-pressed magnetic powder and is made by hot pressing technology, mainly by magnetic powder coated with current-carrying coil (2) and partially attached copper sheet (3) and reserved. The rod-shaped mandrel space (41) of the rod-shaped mandrel (1) is placed, wherein the rod-shaped mandrel space (41) may also be a T-shaped mandrel space (T shape) (41A).

As shown in the third and sixth figures, the present invention incorporates a rod-shaped mandrel (1) or a T-shaped mandrel (1A) into a rod-shaped mandrel space (41) of a hot-pressed body (4) or In the T-shaped mandrel space (41A), and the two ends or one end of the rod-shaped mandrel (1) are exposed, according to the combination of the invention, the cold and hot-pressed composite magnetic component is finished, and the copper sheets are attached at both ends (3) After the current is applied, the current-carrying coil (2) will generate an applied magnetic field, and the rear mandrel (1) will produce A magnetic field (M) (shown in the dotted line on the figure) is generated to become an electromagnetic inductance component with energy storage function.

As shown in the seventh to ninth drawings, the T-shaped core rod (1A) of the present invention comprises a disc-shaped core rod (11) and a cylindrical core rod (12), and a grooved disc core provided with a groove (131). Rod (13) and cylindrical mandrel (12), perforated disc core rod (14) with through hole (141) and cylindrical core rod (12) two-component combination T-shaped core rod (1A)

As shown in the tenth and tenth figures, two T-shaped core rods (1A) with opposite directions are combined and an air gap (A) can be formed between the two core rods.

The above description shows the magnetic element of the hot-pressed body (4) of the present invention combined with a single rod-shaped core rod (1) or a T-shaped core rod (1A). As shown in Fig. 12, the hot-pressed body (4) of the present invention is implemented. In the case of a single integrated hot-pressing body (4A), a plurality of rod-shaped mandrel spaces (41) or T-shaped mandrel spaces (41A) can be made to make the same or different mandrel space design, and each mandrel space The composite core can be combined with the current-carrying coil and the pair of copper strips to form a combined cold and hot-pressed magnetic component. Therefore, the present invention comprises a plurality of different core-bar combinations.

(1)‧‧‧ Rod core rod

(1A)‧‧‧T-type mandrel

(11)‧‧‧ disc core rod

(12)‧‧‧Cylinder mandrel

(13)‧‧‧ Grooved disc core rod

(131)‧‧‧ Groove

(14)‧‧‧Perforated disc core rod

(141)‧‧‧through holes

(2) ‧‧‧ current carrying coil

(3)‧‧‧ Attached copper

(4) ‧‧‧Hot-pressed body

(41)‧‧‧ Rod core space

(41A)‧‧‧T core space

(A) ‧ ‧ air gap

(M)‧‧‧Induced magnetic field

The first figure is a perspective view of a magnetic component of a rod-shaped core rod combination according to the present invention.

The second figure is an exploded perspective view of the magnetic component of the rod-shaped core rod combination of the present invention.

The third figure is a cross-sectional view of a magnetic element in the form of a rod-shaped core rod assembly of the present invention.

The fourth figure is a perspective view of the magnetic component of the T-shaped core bar combination of the present invention.

The fifth figure is an exploded perspective view of the magnetic component of the T-shaped core bar combination of the present invention.

Figure 6 is a cross-sectional view showing the magnetic element of the T-shaped core rod combination of the present invention.

7 to 9 are exploded perspective views of the present invention in which a plurality of components are combined into various T-shaped core rods.

Figure 11 is a cross-sectional view showing a magnetic element in which two T-shaped core rods are combined in the present invention.

The eleventh figure is a cross-sectional view showing a magnetic element in which two T-shaped core rods are combined and an air gap is formed between the two core rods.

The twelfth figure is a perspective view of a composite magnetic element composed of a plurality of rod-shaped core rods and a T-shaped core rod of the hot-pressing body of the present invention.

(1A)‧‧‧T-type mandrel

(2) ‧‧‧ current carrying coil

(3)‧‧‧ Attached copper

(4) ‧‧‧Hot-pressed body

(41A)‧‧‧T core space

Claims (2)

A cold and hot-pressed combined magnetic component is mainly composed of the following components: two rod-shaped core rods (1), which are composed of magnetic powder, are formed by cold pressing technology, and are loaded into a rod of a hot-pressed body (4) In the Rod Space (41), an air gap (A) is formed between the two rod core rods (1); a current carrying coil (2), which is wound by an insulated copper wire; The pair of copper sheets (3) are mainly made of conductive copper sheets, and one end of each attached copper sheet is electrically connected to one end of the current-carrying coil (2), and the other end of each attached copper sheet protrudes from the hot-pressing body. (4) In addition, as a current input and output electrode; a hot-pressed body (4) is composed of hot-pressed magnetic powder, which is made by hot pressing technology, and is covered with magnetic powder (2) and partially attached. A copper plate (3) is attached and a rod-shaped mandrel space (41) capable of being inserted into the rod-shaped core rod (1) is reserved; the hot-pressed body (4) is covered with a current-carrying coil (2), not included The current-carrying coil (2) is directly above the center and directly below the center of the current-carrying coil (2), and has a through-bar type mandrel space exposing the inside of the current-carrying coil (2); the above-mentioned rod-shaped core rod (1) is added to the stick Adhesive into the hot pressing body In the rod-shaped mandrel space (41) of (4), a combination of cold and hot-pressed magnetic elements is combined. A cold and hot pressed combined magnetic component is mainly composed of the following components: two T-shaped core rods (1), which are composed of magnetic powder and are formed by cold pressing technology, and are loaded into the hot pressing body (4) In the mandrel space (41A), an air gap (A) is formed between the two T-shaped core rods (1A); a current-carrying coil (2), which is wound by an insulated copper wire; a pair of attached copper pieces (3), mainly made of a conductive copper piece, each of which is attached with a copper piece and a current-carrying coil (2) One end is electrically connected, and the other end of each attached copper piece protrudes out of the hot pressing body (4) as a current input and output electrode; a hot pressing body (4) is composed of hot pressed magnetic powder, which is hot pressed Made of technology, the current-carrying coil (2) is partially covered with magnetic powder and a portion of the copper sheet (3) is attached and a T-shaped mandrel space (41A) capable of being placed in the T-shaped core rod (1) is reserved; The pressing body (4) covers the outer side surface of the current-carrying coil (2), directly above the center of the uncoated current-carrying coil (2) and directly below the center of the current-carrying coil (2), and has an exposed current-carrying coil (2) The T-shaped mandrel space above the internal and current-carrying coils (2); the T-shaped mandrel (1) is added into the rod-shaped mandrel space (41) of the hot-pressed body (4), according to Combine cold and hot pressed combined magnetic components.