TWI679659B - Choke and inductive component and the fabrication method thereof - Google Patents
Choke and inductive component and the fabrication method thereof Download PDFInfo
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Abstract
一種扼流器,包括一磁芯以及一中空線圈。磁芯包括一第一磁芯體以及一第二磁芯體。第一磁芯體包括一中柱。第二磁芯體為一平板且具有一開口,且中柱的一端適於置入開口內並與開口相接合。中空線圈套設於中柱上。 A choke includes a magnetic core and a hollow coil. The magnetic core includes a first magnetic core body and a second magnetic core body. The first magnetic core body includes a center pillar. The second magnetic core body is a flat plate and has an opening, and one end of the center pillar is suitable for being inserted into the opening and engaging with the opening. A hollow coil is sleeved on the middle post.
Description
本發明是有關於一種被動元件,且特別是有關於一種扼流器。 The invention relates to a passive element, and in particular to a choke.
扼流器的功用在於穩定電路中的電流並達到濾除雜訊的效果,作用與電容器類似,同樣是以儲存、釋放電路中的電能來調節電流的穩定性,而且相較於電容是以電場(電荷)的形式來儲存電能,扼流器則是以磁場的形式來達成。 The function of the choke is to stabilize the current in the circuit and achieve the effect of filtering noise. The role is similar to that of a capacitor. It also stores and releases the electrical energy in the circuit to adjust the stability of the current. (Charge) to store electrical energy, and chokes are achieved in the form of magnetic fields.
圖1為習知之扼流器的俯視示意圖。請參考圖1,習知之扼流器100具有一環形磁芯(toroidal core)110與纏繞於環形磁芯110上的一導線120。扼流器100的製作方法如下所述:首先,將磁性粉末(未繪示)壓合成環形磁芯110。然後,以600℃以上的溫度燒結環形磁芯110。之後,以人工的方式將導線120纏繞於環形磁芯110上。然而,扼流器100需以人工的方式纏繞導線120於環形磁芯110上,而無法以自動化方式生產,因此,扼流器100的製程需耗費相當大的人力成本。 FIG. 1 is a schematic top view of a conventional choke. Please refer to FIG. 1, a conventional choke 100 includes a toroidal core 110 and a wire 120 wound on the toroidal core 110. The manufacturing method of the choke 100 is as follows: First, a magnetic powder (not shown) is pressed into a ring-shaped magnetic core 110. Then, the toroidal magnetic core 110 is sintered at a temperature of 600 ° C or higher. After that, the conductive wire 120 is wound around the toroidal magnetic core 110 in a manual manner. However, the choke 100 needs to manually wind the wire 120 on the toroidal core 110 and cannot be produced in an automated manner. Therefore, the manufacturing process of the choke 100 requires a considerable labor cost.
另一種扼流器為組合式扼流器,其採用以黏膠來組裝組合式磁芯。然於組裝時,若黏膠的膠量控制不佳或磁芯之組裝面的表面不平整,則易造成組裝後黏膠的厚度產生不一致的現象,而使扼流器的電感值變異 性大,進而造成良率下降。為了解決上述問題,進而提出加強組裝精準度及增加磁芯的組裝面的特殊表面處理程序,但卻因此增加扼流器的製造成本。 Another type of choke is a combined choke, which uses a glue to assemble a combined magnetic core. However, during assembly, if the amount of adhesive is poorly controlled or the surface of the magnetic core assembly surface is uneven, it is easy to cause inconsistencies in the thickness of the adhesive after assembly, and the inductance of the choke will vary. High sex, which in turn leads to a decrease in yield. In order to solve the above problems, a special surface treatment procedure is proposed to enhance the assembly accuracy and increase the assembly surface of the magnetic core, but the manufacturing cost of the choke is therefore increased.
本發明之一目的,在於提出一種扼流器,其組裝穩定性高,電感值變異性小。 It is an object of the present invention to provide a choke which has high assembly stability and small variability in inductance value.
本發明之另一目的,在於提出一種扼流器,其利用自動化設備將導線纏繞成中空線圈,可有效降低導線於繞線製程中所耗費的人力成本。 Another object of the present invention is to provide a choke, which uses automatic equipment to wind a wire into a hollow coil, which can effectively reduce the labor cost of the wire in the winding process.
本發明之另一目的,在於提出一種扼流器,其可控制第二磁芯體相對於第一磁芯體的位置來搭配不同線圈,以調整感量,使得不同感量之扼流器可使用相同的磁芯,而節省模具費用。 Another object of the present invention is to provide a choke, which can control the position of the second magnetic core body relative to the first magnetic core body to match different coils to adjust the inductance, so that the chokes with different inductances can be used. Uses the same magnetic core and saves mold costs.
本發明之另一目的,在於提出一種扼流器,其具有導線槽時,可有效縮小扼流器的外觀寬度及線圈之端部的距離,且可使線路板上之焊墊間距縮小。 Another object of the present invention is to provide a choke, which can effectively reduce the appearance width of the choke and the distance between the ends of the coils when the wire groove is provided, and can reduce the pad spacing on the circuit board.
本發明之另一目的,在於提出一種扼流器,其將開口設置於具有組裝面之第二磁芯體或底板上,使中柱會朝組裝面突出,而使突出的中柱不致影響扼流器的外觀。 Another object of the present invention is to provide a choke, which is provided with an opening on a second magnetic core body or a bottom plate having an assembly surface, so that the center pillar protrudes toward the assembly surface, so that the protruding center pillar does not affect the choke. The appearance of the flow device.
本發明之另一目的,在於提出一種扼流器,其具有殼體、封裝體、磁性殼體或磁芯具有側壁部,可用來取代磁性膠,而有效避免磁性膠溢膠或垂流之問題。 Another object of the present invention is to provide a choke having a housing, a package, a magnetic housing, or a magnetic core with a side wall portion, which can be used to replace the magnetic glue and effectively avoid the problem of overflowing or vertical flow of the magnetic glue .
本發明提出一種扼流器,其包括一磁芯以及一中空線圈。磁芯包括一第一磁芯體以及一第二磁芯體。第一磁芯體包括一中柱。第二磁芯體為一平板且具有一開口,且中柱的一端適於置入開口內並與開口相接合。中空線圈套設於中柱上。 The invention provides a choke, which includes a magnetic core and a hollow coil. The magnetic core includes a first magnetic core body and a second magnetic core body. The first magnetic core body includes a center pillar. The second magnetic core body is a flat plate and has an opening, and one end of the center pillar is suitable for being inserted into the opening and engaging with the opening. A hollow coil is sleeved on the middle post.
在本發明之一實施例中,上述之第二磁芯體具有一接合面與一相對於接合面的組裝面。中柱的一端適於從接合面置入於開口內,且開口位於第二磁芯體之中心且連通接合面與組裝面。 In one embodiment of the present invention, the second magnetic core body has a joint surface and an assembly surface opposite to the joint surface. One end of the center pillar is adapted to be inserted into the opening from the joint surface, and the opening is located at the center of the second magnetic core body and communicates the joint surface and the assembly surface.
在本發明之一實施例中,上述之中柱的一端實質上與組裝面切齊。 In one embodiment of the present invention, one end of the middle pillar is substantially aligned with the assembly surface.
在本發明之一實施例中,上述之中柱的一端穿過開口而突出於組裝面。 In an embodiment of the present invention, one end of the above-mentioned middle post passes through the opening and protrudes from the assembly surface.
在本發明之一實施例中,上述之中空線圈具有兩端部,兩端部配置於組裝面上。 In one embodiment of the present invention, the hollow coil has two ends, and the two ends are disposed on an assembly surface.
在本發明之一實施例中,上述之第二磁芯體更具有二導線槽,位於第二磁芯體的邊緣,且這些端部穿過這些導線槽。 In an embodiment of the present invention, the second magnetic core body further includes two lead grooves, which are located at the edges of the second magnetic core body, and the ends pass through the lead grooves.
在本發明之一實施例中,上述之扼流器更包括一材料層。材料層配置於開口的內壁且位於中柱與開口的之間。 In one embodiment of the present invention, the choke further includes a material layer. The material layer is disposed on the inner wall of the opening and between the center pillar and the opening.
在本發明之一實施例中,上述之材料層為一磁性膠。 In one embodiment of the present invention, the material layer is a magnetic glue.
在本發明之一實施例中,上述之第一磁芯體更包括一頂板。頂板連接於中柱之一端,且中柱與頂板為一體成形。中空線圈位於第一磁芯體的頂板與第二磁芯體之間。 In an embodiment of the present invention, the first magnetic core body further includes a top plate. The top plate is connected to one end of the center pillar, and the center pillar and the top plate are integrally formed. The hollow coil is located between the top plate of the first magnetic core body and the second magnetic core body.
在本發明之一實施例中,上述之扼流器更包括一磁性膠。磁性膠包覆中空線圈。 In one embodiment of the present invention, the choke further includes a magnetic glue. Magnetic glue covers the hollow coil.
在本發明之一實施例中,上述之扼流器更包括一磁性膠與一具有一開口端的殼體。殼體為一桶狀結構。磁芯與中空線圈配置於殼體內,且第二磁芯體配置於開口端且暴露出第二磁芯體的一組裝面。磁性膠配置於殼體與中空線圈間的空間內。 In one embodiment of the present invention, the choke further includes a magnetic glue and a casing having an open end. The shell is a barrel-shaped structure. The magnetic core and the hollow coil are disposed in the housing, and the second magnetic core body is disposed at the open end and exposes an assembly surface of the second magnetic core body. The magnetic glue is arranged in a space between the casing and the hollow coil.
在本發明之一實施例中,上述之第二磁芯體更具有至少一位於第二磁芯體之邊緣的注入孔,磁性膠適於由注入孔填充於殼體內。 In an embodiment of the present invention, the second magnetic core body further has at least one injection hole located at an edge of the second magnetic core body, and the magnetic glue is suitable for filling the casing with the injection hole.
在本發明之一實施例中,上述之扼流器更包括一封裝體,套設於第一磁芯體的中柱上,封裝體包括中空線圈與一磁性材料,磁性材料包覆中空線圈的周圍。 In one embodiment of the present invention, the choke described above further includes a package, which is sleeved on the center pillar of the first magnetic core. The package includes a hollow coil and a magnetic material, and the magnetic material covers the hollow coil. around.
在本發明之一實施例中,上述之扼流器更包括一磁性殼體。磁性殼體具有兩開口端、一上表面以及一相對於上表面的下表面,其中這些開口端分別位於上表面與下表面且相互連通,中空線圈配置於磁性殼體內,且第一磁芯體的中柱貫穿磁性殼體的這些開口端,第二磁芯體配置於磁性殼體的下表面上。 In one embodiment of the present invention, the choke further includes a magnetic case. The magnetic case has two open ends, an upper surface, and a lower surface opposite to the upper surface. The open ends are respectively located on the upper surface and the lower surface and communicate with each other. The hollow coil is disposed in the magnetic case and the first magnetic core body. The central post of the penetrant penetrates these open ends of the magnetic case, and the second magnetic core body is disposed on the lower surface of the magnetic case.
在本發明之一實施例中,上述之第一磁芯具有一頂板,其中頂板連接於中柱之一端。第一磁芯體之頂板具有一底部與二側壁部。這些側壁部配置於底部的相對兩側邊,且這些側壁部的延伸方向實質上垂直於底部的延伸方向。 In one embodiment of the present invention, the first magnetic core has a top plate, and the top plate is connected to one end of the center pillar. The top plate of the first magnetic core body has a bottom portion and two side wall portions. These side wall portions are disposed on opposite sides of the bottom portion, and the extending direction of the side wall portions is substantially perpendicular to the extending direction of the bottom portion.
在本發明之一實施例中,上述之第二磁芯體配置於這些側壁部之間。 In one embodiment of the present invention, the second magnetic core body is disposed between the side wall portions.
在本發明之一實施例中,上述之第二磁芯體直接配置於中空線圈上。 In one embodiment of the present invention, the second magnetic core body is directly disposed on the hollow coil.
本發明提出一種扼流器,其包括一磁芯、至少一導線以及一殼體。磁芯具有一中柱。導線纏繞於磁芯之中柱上。殼體為具有一開口端之桶狀結構,其中磁芯與導線配置於殼體內,且開口端暴露出磁芯的一組裝面。 The invention provides a choke, which includes a magnetic core, at least one wire, and a casing. The magnetic core has a center pillar. The wire is wound on the core post. The casing is a barrel-shaped structure with an open end, wherein the magnetic core and the lead are arranged in the casing, and an open end exposes an assembly surface of the magnetic core.
在本發明之一實施例中,上述之磁芯包括一頂板以及一具有組裝面的底板。中柱配置於頂板與底板之間,且頂板、底板與中柱之間形成一繞線空間。導線位於繞線空間內。 In one embodiment of the present invention, the magnetic core includes a top plate and a bottom plate having an assembly surface. The center pillar is arranged between the top plate and the bottom plate, and a winding space is formed between the top plate, the bottom plate and the center pillar. The wires are located in the winding space.
在本發明之一實施例中,上述之磁芯包括一具有組裝面的底板,底板具有至少一位於底板之邊緣的注入孔,磁性膠適於由注入孔填充於殼體內。 In an embodiment of the present invention, the magnetic core includes a bottom plate having an assembly surface, the bottom plate has at least one injection hole located at an edge of the bottom plate, and the magnetic glue is suitable for filling the casing with the injection hole.
在本發明之一實施例中,上述之磁芯包括一中柱及一具有組裝面之底板,其中底板具有一開口,中柱的一端適於置入開口內並與開口相接合。導線為一中空線圈,中空線圈套設於中柱上。 In an embodiment of the present invention, the above magnetic core includes a center pillar and a bottom plate with an assembly surface, wherein the bottom plate has an opening, and one end of the center pillar is suitable for being inserted into the opening and engaging the opening. The conducting wire is a hollow coil, and the hollow coil is sleeved on the pillar.
在本發明之一實施例中,上述之底板直接配置於中空線圈上。 In one embodiment of the present invention, the above-mentioned bottom plate is directly disposed on the hollow coil.
本發明提出一種扼流器,其包括一磁芯以及一封裝體。磁芯包括一中柱。封裝體套設於磁芯的中柱上,且包括一中空線圈與一磁性材料,其中磁性材料包覆中空線圈。 The invention provides a choke, which includes a magnetic core and a package. The magnetic core includes a center pillar. The package is sleeved on the core post of the magnetic core and includes a hollow coil and a magnetic material, wherein the magnetic material covers the hollow coil.
在本發明之一實施例中,上述之封裝體是以射出成型或壓模成型使磁性材料包覆中空線圈。 In one embodiment of the present invention, the above-mentioned package body is made of a magnetic material to cover the hollow coil by injection molding or compression molding.
在本發明之一實施例中,上述之磁芯更包括一頂板。中柱與頂板為一體成形,且中柱的一端套設於封裝體內。 In one embodiment of the present invention, the magnetic core further includes a top plate. The center pillar and the top plate are integrally formed, and one end of the center pillar is sleeved in the package body.
在本發明之一實施例中,上述之磁芯更包括一頂板。中柱與頂板為一體成形,且中柱的一端穿過於封裝體而與封裝體遠離頂板的一表面實質上切齊。 In one embodiment of the present invention, the magnetic core further includes a top plate. The center pillar is integrally formed with the top plate, and one end of the center pillar passes through the package body and is substantially aligned with a surface of the package body away from the top plate.
在本發明之一實施例中,上述之磁芯更包括一頂板以及一底板。頂板與中柱為一體成形,且中柱的一端穿過於封裝體而與封裝體遠離頂板的一表面實質上切齊,底板覆蓋中柱的一端與封裝體的表面。 In one embodiment of the present invention, the magnetic core further includes a top plate and a bottom plate. The top plate and the center pillar are integrally formed, and one end of the center pillar passes through the package and is substantially aligned with a surface of the package far from the top plate, and the bottom plate covers one end of the center pillar and the surface of the package.
在本發明之一實施例中,上述之磁芯更包括一頂板以及一底板。頂板與中柱為一體成形。底板具有一開口、一接合面與一相對於接合面的組裝面。中柱的一端穿過於封裝體而從接合面置入於開口內,且中柱的一端實質上與組裝面切齊。 In one embodiment of the present invention, the magnetic core further includes a top plate and a bottom plate. The top plate and the center pillar are integrally formed. The bottom plate has an opening, a joint surface and an assembly surface opposite to the joint surface. One end of the center pillar passes through the package and is inserted into the opening from the joint surface, and one end of the center pillar is substantially aligned with the assembly surface.
本發明提出一種扼流器,其包括一磁芯以及一中空線圈。磁芯包括一第一磁芯體以及一第二磁芯體。第一磁芯體包括一頂板與一中柱。 頂板具有一底部與一側壁部。側壁部環繞底部的周圍配置,且側壁部的延伸方向實質上垂直於底部的延伸方向,側壁部包圍中柱。第二磁芯體為一平板並具有一開口,且中柱的一端適於置入於開口內。中空線圈套設於中柱上,且位於第一磁芯體的頂板與第二磁芯體之間,其中中空線圈的高度小於頂板的側壁部的高度,側壁部至少與部分之中空線圈相接觸。 The invention provides a choke, which includes a magnetic core and a hollow coil. The magnetic core includes a first magnetic core body and a second magnetic core body. The first magnetic core body includes a top plate and a center pillar. The top plate has a bottom portion and a side wall portion. The side wall portion is arranged around the periphery of the bottom portion, and the extending direction of the side wall portion is substantially perpendicular to the extending direction of the bottom portion, and the side wall portion surrounds the center pillar. The second magnetic core body is a flat plate and has an opening, and one end of the center pillar is suitable for being inserted into the opening. The hollow coil is sleeved on the center pillar and is located between the top plate of the first magnetic core body and the second magnetic core body. The height of the hollow coil is less than the height of the side wall portion of the top plate. The side wall portion is in contact with at least part of the hollow coil. .
在本發明之一實施例中,上述之中柱與頂板為一體成形。 In one embodiment of the present invention, the middle pillar and the top plate are integrally formed.
在本發明之一實施例中,上述之第二磁芯體具有一接合面與一相對於接合面的組裝面,且中柱的一端適於從接合面置入於開口內,開口位於第二磁芯體之中心且連通接合面與組裝面。 In an embodiment of the present invention, the second magnetic core body has a joint surface and an assembly surface opposite to the joint surface, and one end of the center pillar is adapted to be inserted into the opening from the joint surface, and the opening is located in the second The center of the magnetic core body connects the joint surface and the assembly surface.
在本發明之一實施例中,上述之中柱的一端實質上與組裝面切齊。 In one embodiment of the present invention, one end of the middle pillar is substantially aligned with the assembly surface.
在本發明之一實施例中,上述之中柱的一端穿過開口而突出於組裝面。 In an embodiment of the present invention, one end of the above-mentioned middle post passes through the opening and protrudes from the assembly surface.
在本發明之一實施例中,上述之第一磁芯體更包括至少一導線槽。導線槽配置於頂板的側壁部。 In an embodiment of the present invention, the first magnetic core body further includes at least one wire groove. The lead groove is disposed on a side wall portion of the top plate.
在本發明之一實施例中,上述之扼流器更包括一材料層。材料層配置於開口的內壁,且位於中柱與開口之間。 In one embodiment of the present invention, the choke further includes a material layer. The material layer is disposed on the inner wall of the opening and is located between the center pillar and the opening.
在本發明之一實施例中,上述之第二磁芯體直接配置於中空線圈上。 In one embodiment of the present invention, the second magnetic core body is directly disposed on the hollow coil.
基於上述,由於本發明之扼流器是先利用自動化設備將導線纏繞成中空線圈後,再將此中空線圈套設於第一磁芯體的中柱上,並使中柱的一端置入第二磁芯體的開口內,此時中空線圈位於第一磁芯體的頂板與第二磁芯體之間,而完成其組裝。相較於習知技術而言,本發明之扼流器除了可以有效降低導線於繞線製程中所耗費的人力成本外,亦可以提高組裝穩定性並降低電感值的變異性。 Based on the above, since the choke of the present invention uses an automatic device to wind the wire into a hollow coil, the hollow coil is sleeved on the center pillar of the first magnetic core, and one end of the center pillar is placed in the first Inside the openings of the two magnetic core bodies, the hollow coil is located between the top plate of the first magnetic core body and the second magnetic core body at this time to complete its assembly. Compared with the conventional technology, the choke of the present invention can not only effectively reduce the labor cost of the wires in the winding process, but also improve the assembly stability and reduce the variability of the inductance value.
為讓本發明之上述特徵和優點能更明顯易懂,下文特舉實施例,並配合所附圖式作詳細說明如下。 In order to make the above features and advantages of the present invention more comprehensible, embodiments are described below in detail with reference to the accompanying drawings.
100、300a、300c~300f、400a~400c、500a~500e、600a、600b、700a‧‧‧扼流器 100, 300a, 300c ~ 300f, 400a ~ 400c, 500a ~ 500e, 600a, 600b, 700a‧‧‧ choke
110‧‧‧環形磁芯 110‧‧‧ Toroidal Core
120、420‧‧‧導線 120, 420‧‧‧ wires
310、310’、410a~410c、510a~510d、610‧‧‧磁芯 310, 310 ’, 410a ~ 410c, 510a ~ 510d, 610‧‧‧ core
311、311’、611、611’、711a‧‧‧第一磁芯體 311, 311 ’, 611, 611’, 711a‧‧‧ the first magnetic core
312、414、414’、414”、512a~512e、614、614’、714a‧‧‧中柱 312, 414, 414 ’, 414”, 512a ~ 512e, 614, 614 ’, 714a‧‧‧
312a、312b、513b~513e、614a、614a’‧‧‧一端 312a, 312b, 513b ~ 513e, 614a, 614a’‧‧‧
314、314’、412、412’、514b~514e、612、612’‧‧‧頂板 314, 314 ’, 412, 412’, 514b ~ 514e, 612, 612’‧‧‧
314a、612a、612a’‧‧‧底部 314a, 612a, 612a’‧‧‧ bottom
314b、612b、612b’、712a‧‧‧側壁部 314b, 612b, 612b ’, 712a‧‧‧ sidewall
315、315’、617、617’、717a‧‧‧第二磁芯體 315, 315 ’, 617, 617’, 717a‧‧‧ second core
315a、416a、518a、617a‧‧‧接合面 315a, 416a, 518a, 617a
315b、416b、518b、617b‧‧‧組裝面 315b, 416b, 518b, 617b‧‧‧Assembly surface
316、517、619‧‧‧開口 316, 517, 619‧‧‧ opening
317a、317b、616‧‧‧導線槽 317a, 317b, 616‧‧‧ wire duct
318、416c‧‧‧注入孔 318, 416c‧‧‧ injection hole
320、522、620‧‧‧中空線圈 320, 522, 620‧‧‧ hollow coil
322、324‧‧‧端部 322, 324‧‧‧
323‧‧‧繞線部 323‧‧‧winding department
330‧‧‧材料層 330‧‧‧material layer
340、440‧‧‧磁性膠 340, 440‧‧‧ Magnetic Adhesive
350、430‧‧‧殼體 350, 430‧‧‧shell
352、432‧‧‧開口端 352, 432‧‧‧ open end
360‧‧‧磁性殼體 360‧‧‧Magnetic case
360a‧‧‧上表面 360a‧‧‧ Top surface
360b‧‧‧下表面 360b‧‧‧ lower surface
362a、362b‧‧‧開口端 362a, 362b‧‧‧ open end
416、416’、416”、516d、516e‧‧‧底板 416, 416 ’, 416”, 516d, 516e‧‧‧ floor
370、520‧‧‧封裝體 370, 520‧‧‧ package
520a‧‧‧表面 520a‧‧‧ surface
524‧‧‧磁性材料 524‧‧‧ Magnetic Materials
526‧‧‧穿孔 526‧‧‧perforation
S‧‧‧繞線空間 S‧‧‧winding space
圖1為習知之扼流器的俯視示意圖。 FIG. 1 is a schematic top view of a conventional choke.
圖2A為本發明之一實施例之扼流器的示意圖。 FIG. 2A is a schematic diagram of a choke according to an embodiment of the present invention.
圖2B為圖2A之扼流器的分解示意圖。 FIG. 2B is an exploded view of the choke of FIG. 2A.
圖2C為圖2A之扼流器的仰視示意圖。 FIG. 2C is a schematic bottom view of the choke of FIG. 2A.
圖3為本發明之另一實施例之扼流器的剖面示意圖。 FIG. 3 is a schematic cross-sectional view of a choke according to another embodiment of the present invention.
圖4為本發明之另一實施例之扼流器的立體示意圖。 FIG. 4 is a schematic perspective view of a choke according to another embodiment of the present invention.
圖5為本發明之另一實施例之扼流器的剖面示意圖。 FIG. 5 is a schematic cross-sectional view of a choke according to another embodiment of the present invention.
圖6A為本發明之另一實施例之扼流器的剖面示意圖。 FIG. 6A is a schematic cross-sectional view of a choke according to another embodiment of the present invention.
圖6B為圖6A之磁性殼體的立體示意圖。 FIG. 6B is a schematic perspective view of the magnetic casing of FIG. 6A.
圖7為本發明之另一實施例之扼流器的剖面示意圖。 FIG. 7 is a schematic cross-sectional view of a choke according to another embodiment of the present invention.
圖8A為本發明之另一實施例之扼流器的剖面示意圖。 8A is a schematic cross-sectional view of a choke according to another embodiment of the present invention.
圖8B為圖8A之扼流器的分解示意圖。 FIG. 8B is an exploded view of the choke of FIG. 8A.
圖8C為圖8A之扼流器的立體示意圖。 FIG. 8C is a schematic perspective view of the choke of FIG. 8A.
圖8D為圖8A之扼流器的另一分解示意圖。 FIG. 8D is another exploded view of the choke of FIG. 8A.
圖8E為圖8A之扼流器的又一分解示意圖。 FIG. 8E is another exploded view of the choke of FIG. 8A.
圖9為本發明之另一實施例之扼流器的剖面示意圖。 FIG. 9 is a schematic cross-sectional view of a choke according to another embodiment of the present invention.
圖10A至圖10D為圖9之磁芯的四種變化結構的剖面示意圖。 10A to 10D are schematic cross-sectional views of four modified structures of the magnetic core of FIG. 9.
圖11A為本發明之另一實施例之扼流器的示意圖。 FIG. 11A is a schematic diagram of a choke according to another embodiment of the present invention.
圖11B為圖11A之扼流器的分解示意圖。 FIG. 11B is an exploded view of the choke of FIG. 11A.
圖11C為本發明之另一實施例之扼流器的示意圖。 FIG. 11C is a schematic diagram of a choke according to another embodiment of the present invention.
圖11D為本發明之另一實施例之扼流器的示意圖。 FIG. 11D is a schematic diagram of a choke according to another embodiment of the present invention.
圖12為扼流器的磁路示意圖。 Fig. 12 is a schematic diagram of a magnetic circuit of a choke.
圖2A為本發明之一實施例之扼流器的示意圖,圖2B為圖2A之扼流器的分解示意圖,圖2C為圖2A之扼流器的仰視示意圖。請先同時參考圖2A與圖2B,在本實施例中,扼流器300a包括一磁芯310以及一中空線圈320,其中磁芯310包括一第一磁芯體311以及一第二磁芯體315。 FIG. 2A is a schematic view of a choke according to an embodiment of the present invention, FIG. 2B is an exploded view of the choke of FIG. 2A, and FIG. 2C is a bottom view of the choke of FIG. 2A. Please refer to FIG. 2A and FIG. 2B at the same time. In this embodiment, the choke 300a includes a magnetic core 310 and a hollow coil 320, wherein the magnetic core 310 includes a first magnetic core body 311 and a second magnetic core body 315.
第一磁芯體311包括一中柱312與一頂板314,其中中柱312之一端312b連接於頂板314以構成一T字型結構,中柱312與頂板314為一體成形。第二磁芯體315為一平板,且具有一接合面315a、一相對於接合面315a的組裝面315b、一開口316以及二配置於開口316的相對兩側邊且位於第二磁芯體315之邊緣的導線槽317a、317b。開口316位於第二磁芯體315之中心且連通接合面315a與組裝面315b,其中第一磁芯體311之中柱312的一端312a適於從接合面315a置入於開口316內並與開口316相接合。中柱312的一端312a與開口316的接合方式可為緊配結合或黏膠接合。在本實施例中,頂板314、第二磁芯體315以及開口316的截面形狀皆為圓形,而中柱312為一圓柱,但不以此為限,舉例來說,頂板314、第二磁芯體315以及開口316的形狀亦可皆為矩形,而中柱312為一矩形柱。 The first magnetic core body 311 includes a center pillar 312 and a top plate 314. One end 312b of the center pillar 312 is connected to the top plate 314 to form a T-shaped structure. The center pillar 312 and the top plate 314 are integrally formed. The second magnetic core body 315 is a flat plate, and has a joint surface 315a, an assembly surface 315b opposite to the joint surface 315a, an opening 316, and two opposite sides of the opening 316 and located on the second magnetic core body 315. The lead grooves 317a, 317b. The opening 316 is located at the center of the second magnetic core body 315 and communicates the joint surface 315a and the assembly surface 315b. One end 312a of the pillar 312 in the first magnetic core body 311 is adapted to be inserted into the opening 316 from the joint surface 315a and communicate with the opening 316 joints. The joining manner of the one end 312a of the center pillar 312 and the opening 316 may be a tight fit bonding or an adhesive bonding. In this embodiment, the cross-sectional shapes of the top plate 314, the second magnetic core body 315, and the opening 316 are all circular, and the center pillar 312 is a cylinder, but not limited thereto. For example, the top plate 314, the second The shape of the magnetic core body 315 and the opening 316 may also be rectangular, and the center pillar 312 is a rectangular pillar.
磁芯310材質為鐵氧體(ferrite)材料、鐵或低磁損材料。鐵氧體(ferrite)材料包括鎳鋅鐵氧體(Ni-Zn ferrite)或錳鋅鐵氧體(Mn-Zn ferrite)。低磁損材料例如是含鐵合金,其中含鐵合金可為鐵矽鋁合金、鐵鎳鉬合金、鐵鎳合金或非晶質(Amorous)合金。值得注意的是,採用低磁損材料作為 磁芯310,可提高導磁率並達到低鐵損。本實施例中,磁芯310之第一磁芯體311與第二磁芯體315採用鐵氧體(ferrite)材料,磁芯310的導磁率例如是75以上,詳細地說,磁芯310是利用一鐵氧體粉末(ferrite powder)混合黏合劑,經過加壓成型並燒結(firing)而形成,黏合劑包括聚甲基丙烯合成樹脂(Polymethylallyl(PMA)Synthesize resin)。 The material of the magnetic core 310 is a ferrite material, iron, or a low magnetic loss material. Ferrite materials include nickel-zinc ferrite (Ni-Zn ferrite) or manganese-zinc ferrite (Mn-Zn ferrite). The low magnetic loss material is, for example, an iron-containing alloy, and the iron-containing alloy may be an iron-silicon aluminum alloy, an iron-nickel molybdenum alloy, an iron-nickel alloy, or an amorphous (Amorous) alloy. It is worth noting that low magnetic loss materials are used as The magnetic core 310 can improve magnetic permeability and achieve low iron loss. In this embodiment, the first core body 311 and the second core body 315 of the magnetic core 310 are made of ferrite. The magnetic permeability of the magnetic core 310 is, for example, 75 or more. In detail, the magnetic core 310 is A ferrite powder (ferrite powder) is used to mix a binder, which is formed by pressure molding and firing. The binder includes polymethylallyl (PMA) Synthesize resin.
在此必須說明的是,第一磁芯體311與第二磁芯體315於製程的過程中,易因製程公差的影響而於中柱312與開口316的接合處產生一間距,請參考圖2C,意即開口316的直徑大於中柱312的直徑。因此,於本實施例中,可選擇性地塗佈一材料層330於開口316的內壁,意即材料層330位於中柱312與開口316之間,來降低組裝時中柱312與開口316間的間距對感值的影響,以提高組裝穩定性並降低感值變異性。此外,材料層330例如是樹脂膠體或磁性膠體。 值得注意的是,材料層330可直接作為中柱312的一端312a與開口316以黏膠接合時之黏著劑。 It must be noted here that during the manufacturing process of the first magnetic core body 311 and the second magnetic core body 315, a gap is easily generated at the joint of the center pillar 312 and the opening 316 due to the influence of process tolerances. Please refer to the figure 2C, which means that the diameter of the opening 316 is larger than the diameter of the center pillar 312. Therefore, in this embodiment, a material layer 330 can be selectively coated on the inner wall of the opening 316, which means that the material layer 330 is located between the center pillar 312 and the opening 316, so as to reduce the center pillar 312 and the opening 316 during assembly. The effect of the spacing between the two values on the sense value to improve the stability of the assembly and reduce the variability of the sense value. The material layer 330 is, for example, a resin colloid or a magnetic colloid. It is worth noting that the material layer 330 can be directly used as an adhesive when one end 312a of the center pillar 312 and the opening 316 are adhesively bonded.
中空線圈320套設於第一磁芯體311的中柱312上,且位於第一磁芯體311的頂板314與第二磁芯體315的接合面315a之間。詳細而言,本實施例是利用自動化設備將導線繞製成中空線圈320,其中導線例如為圓線(最小截面積為圓形)或扁線(最小截面積為矩形),且導線例如是由銅線外包覆漆包層所組成,而漆包層為一絕緣層。具體而言,中空線圈320具有兩端部322、324以及位於兩端部322、324間的繞線部323,且繞線部323纏繞於第一磁芯體311的中柱312上,而兩端部322、324穿過第二磁芯體315的導線槽317a、317b而配置於組裝面315b上。中空線圈320的兩端部322、324可直接作為外部電極或連接 導線架(lead frame)作為外部電極,外部電極可以以穿孔固定(through-hole mount)方式或表面黏著(surface mount)方式與外部電路電性連接。 The hollow coil 320 is sleeved on the center post 312 of the first magnetic core body 311 and is located between the top plate 314 of the first magnetic core body 311 and the joint surface 315 a of the second magnetic core body 315. In detail, in this embodiment, the conductive wire is wound into a hollow coil 320 by using an automated device. The conductive wire is, for example, a round wire (the minimum cross-sectional area is circular) or a flat wire (the minimum cross-sectional area is rectangular). The copper wire is covered with an enameled layer, and the enameled layer is an insulating layer. Specifically, the hollow coil 320 has two end portions 322 and 324 and a winding portion 323 located between the two end portions 322 and 324. The winding portion 323 is wound around the center pillar 312 of the first magnetic core body 311, and two The end portions 322 and 324 pass through the lead grooves 317 a and 317 b of the second magnetic core body 315 and are disposed on the assembly surface 315 b. Both ends 322, 324 of the hollow coil 320 can be directly used as external electrodes or connected A lead frame is used as an external electrode, and the external electrode can be electrically connected to an external circuit in a through-hole mount method or a surface mount method.
值得一提的是,第二磁芯體315是直接壓合於中空線圈320上,使第二磁芯體315直接配置於中空線圈320上,因此可藉由中空線圈320的高度來定位第二磁芯體315位置。而本實施例之第一磁芯體311之中柱312的一端312a實質上與第二磁芯體315的組裝面315b切齊,但於其他實施例中,請參考圖3,第一磁芯體311之中柱312的一端312a穿過第二磁芯體315的開口316且突出於組裝面315b,仍屬於本發明可採用的技術方案,不脫離本發明所欲保護的範圍。而圖3中,中柱312突出於組裝面315b的高度低於中空線圈320之兩端部322、324延伸至導線槽317a、317b外的長度,以避免中柱312影響端部322、324與外部電路的電性連接。 It is worth mentioning that the second magnetic core body 315 is directly pressed onto the hollow coil 320, so that the second magnetic core body 315 is directly disposed on the hollow coil 320. Therefore, the second magnetic core body 315 can be positioned by the height of the hollow coil 320 The magnetic core body 315 position. While one end 312a of the pillar 312 in the first magnetic core body 311 in this embodiment is substantially aligned with the assembly surface 315b of the second magnetic core body 315, but in other embodiments, please refer to FIG. 3, the first magnetic core One end 312a of the pillar 312 in the body 311 passes through the opening 316 of the second magnetic core body 315 and protrudes from the assembly surface 315b, which still belongs to the technical solution of the present invention and does not depart from the scope of the present invention. In FIG. 3, the height of the center pillar 312 protruding from the assembly surface 315b is lower than the length of the two ends 322, 324 of the hollow coil 320 extending beyond the wire grooves 317a, 317b to prevent the center pillar 312 from affecting the ends 322, 324 and Electrical connection of external circuit.
此外,本實施例之扼流器300a可選擇性地填充一磁性膠340於第一磁芯體311與第二磁芯體315之間並包覆中空線圈320的繞線部323與部份之端部322、324,使未被包覆之端部322、324作為與外部電路電性連接用。磁性膠340包括一樹脂材料與一磁性粉狀材料,其中磁性粉狀材料占磁性膠340之總重量的70百分比以上,且磁性膠340的導磁率例如為6以上,但不以此為限。樹脂材料可選自聚醯胺6(Polyamide 6,PA6)、聚醯胺12(Polyamide 12,PA12)、聚苯硫醚(Polyphenylene Sulfide,PPS)、聚對苯二甲酸丁二酯(polybutyleneterephthalate,PBT)或乙烯-丙烯酸乙酯共聚物(ethylene-ethyl acrylate copolymer,EEA)其中之一。磁性粉狀材料可為金屬軟磁材料或鐵氧體粉末(Ferrite),其中金屬軟磁材料可選自鐵粉(Iron)、鐵鋁矽合金(FeAlSi Alloy)、鐵鉻矽合金(FeCrSi Alloy)或不鏽鋼其中之一。 In addition, the choke 300a of this embodiment can selectively fill a magnetic glue 340 between the first magnetic core body 311 and the second magnetic core body 315 and cover the winding portion 323 and a part of the hollow coil 320. The end portions 322 and 324 are used to electrically connect the uncovered end portions 322 and 324 to an external circuit. The magnetic glue 340 includes a resin material and a magnetic powder material, wherein the magnetic powder material accounts for more than 70% of the total weight of the magnetic glue 340, and the magnetic permeability of the magnetic glue 340 is, for example, 6 or more, but is not limited thereto. The resin material may be selected from Polyamide 6, PA6, Polyamide 12, PA12, Polyphenylene Sulfide (PPS), Polybutyleneterephthalate (PBT) ) Or ethylene-ethyl acrylate copolymer (EEA). The magnetic powder material may be a metal soft magnetic material or a ferrite powder, wherein the metal soft magnetic material may be selected from iron powder, FeAlSi Alloy, FeCrSi Alloy, or stainless steel. one of them.
由於本實施例之扼流器300a是先利用自動化設備將導線纏繞成中空線圈320後,再將中空線圈320圈套設於第一磁芯體311的中柱312上,再將中柱312的一端312a置入第二磁芯體315的開口316內,而完成組裝。相較於習知扼流器100,本實施例之扼流器300a可以有效降低導線於繞線製程中所耗費的人力成本。 Since the choke 300a of this embodiment uses an automatic device to wind the wire into a hollow coil 320, the hollow coil 320 is set on the center post 312 of the first magnetic core body 311, and then one end of the center post 312 312a is placed in the opening 316 of the second magnetic core body 315 to complete the assembly. Compared with the conventional choke 100, the choke 300a of this embodiment can effectively reduce the labor cost of the wire during the winding process.
此外,本發明可利用控制第二磁芯體315相對於第一磁芯體311的位置來搭配不同中空線圈,以調整感量,使得不同感量之扼流器可使用相同的磁芯,而節省模具費用。再者,將開口316設置於具有組裝面315b之第二磁芯體315上,使利用第二磁芯體315的位置調整感值時,中柱312可朝組裝面315b突出,而使突出的中柱312不致影響扼流器300a的外觀。另外,由於第二磁芯體315具有導線槽317a、317b可供中空線圈320的兩端部322、324穿過,因此可縮小兩端部322、324的距離及扼流器300a外觀的寬度,且當兩端部322、324做為外部電極時,可有效縮小與線路板之焊墊(pad)的間距。 In addition, the present invention may use different hollow coils to control the position of the second magnetic core body 315 relative to the first magnetic core body 311 to adjust the inductance, so that chokes of different inductances can use the same magnetic core, and Save mold costs. Furthermore, the opening 316 is provided on the second magnetic core body 315 having the assembly surface 315b, so that when the position of the second magnetic core body 315 is used to adjust the sensing value, the center pillar 312 can protrude toward the assembly surface 315b, so that the protruding The center pillar 312 does not affect the appearance of the choke 300a. In addition, since the second magnetic core body 315 has lead grooves 317a and 317b through which both ends 322 and 324 of the hollow coil 320 can pass, the distance between the ends 322 and 324 and the width of the appearance of the choke 300a can be reduced. And when the two end portions 322 and 324 are used as external electrodes, the distance from the pads of the circuit board can be effectively reduced.
圖4為本發明之另一實施例之扼流器的立體示意圖。請同時參考圖2A與圖4,圖4之扼流器300c與圖2A之扼流器300a相似,其不同之處在於:圖4之扼流器300c更包括一具有一開口端352的殼體350,且第二磁芯體315’更具有至少一位於第二磁芯體315’之邊緣的注入孔318(圖4中僅示意繪示兩個),其中殼體350為一桶狀結構,磁芯310’與中空線圈320配置於殼體350內,且第二磁芯體315’配置於開口端352,且開口端352暴露出第二磁芯體315’的組裝面315b,而磁性膠340適於經由注入孔318填充於殼體350內,以配置於殼體350與中空線圈320間的空間內,並包覆中空線圈320、第一磁芯體311的中柱312與頂板314以及部分第二磁芯體315’。 FIG. 4 is a schematic perspective view of a choke according to another embodiment of the present invention. Please refer to FIG. 2A and FIG. 4 at the same time. The choke 300c of FIG. 4 is similar to the choke 300a of FIG. 2A. The difference is that the choke 300c of FIG. 4 further includes a housing having an open end 352. 350, and the second magnetic core body 315 'further has at least one injection hole 318 (only two are schematically shown in FIG. 4) located at the edge of the second magnetic core body 315', wherein the casing 350 is a barrel structure, The magnetic core 310 'and the hollow coil 320 are disposed in the housing 350, and the second magnetic core body 315' is disposed at the open end 352, and the open end 352 exposes the assembly surface 315b of the second magnetic core body 315 ', and the magnetic glue 340 is suitable to be filled in the housing 350 through the injection hole 318 to be disposed in the space between the housing 350 and the hollow coil 320, and to cover the hollow coil 320, the center pillar 312 and the top plate 314 of the first magnetic core body 311, and Part of the second magnetic core body 315 '.
由於本實施例之扼流器300c具有殼體350,因此磁性膠340填充時,不會有溢流或垂流的問題(尤其是扼流器300c的高度越高,如10釐米(mm)以上時),扼流器300c的外觀亦較為美觀且可遮蔽磁性膠340之龜裂(因樹脂材料與銅線熱膨脹係數不同,而造成扼流器表面有裂紋)及防止生銹。此外,殼體350的材質若為金屬或磁性材料時,則扼流器300c亦具有防止電磁干擾的效果。若殼體350的材質為金屬時,可提供散熱使扼流器300c整體溫度下降,進而提升效率。 Because the choke 300c of this embodiment has a housing 350, there is no problem of overflow or vertical flow when the magnetic glue 340 is filled (especially the higher the height of the choke 300c, such as 10 cm (mm) or more ), The appearance of the choke 300c is also more beautiful, and can shield the crack of the magnetic glue 340 (the surface of the choke is cracked due to the different thermal expansion coefficient of the resin material and the copper wire) and prevent rust. In addition, when the material of the case 350 is a metal or a magnetic material, the choke 300c also has an effect of preventing electromagnetic interference. When the material of the casing 350 is metal, heat can be provided to reduce the overall temperature of the choke 300c, thereby improving efficiency.
圖5為本發明之另一實施例之扼流器的剖面示意圖。請同時參考圖2A與圖5,圖5之扼流器300d與圖2A之扼流器300a相似,其不同之處在於:圖5之扼流器300d的製作是先採用射出成型(injection molding)或壓模成型(press molding)的方式將磁性膠340包覆於中空線圈320的周圍以形成一封裝體370,接著,封裝體370套設於中柱312上,使第一磁芯體311的中柱312的一端312a穿過中空線圈320及第二磁芯體315,並與第二磁芯體315的組裝面315b切齊,而完成扼流器300d的組裝。由於本實施例之扼流器300d的製作是先將磁性膠340包覆於中空線圈320形成封裝體370後,再組裝於磁芯310上,因此可以避免溢膠或垂流的問題。而且,透過射出及壓模成型形成磁性膠,使得封裝體370中磁性膠的密度可提高進而提高導磁率,故於達到相同感值的條件下,扼流器300d可較扼流器300a、300c具有較小的體積。 FIG. 5 is a schematic cross-sectional view of a choke according to another embodiment of the present invention. Please refer to FIG. 2A and FIG. 5 at the same time. The choke 300d of FIG. 5 is similar to the choke 300a of FIG. 2A. The difference is that the choke 300d of FIG. 5 is manufactured by injection molding. The magnetic glue 340 is wrapped around the hollow coil 320 to form a package 370 by press molding or press molding. Then, the package 370 is set on the center pillar 312 to make the first magnetic core 311 One end 312a of the center pillar 312 passes through the hollow coil 320 and the second magnetic core body 315 and is aligned with the assembly surface 315b of the second magnetic core body 315 to complete the assembly of the choke 300d. Because the choke 300d of this embodiment is manufactured by first covering the hollow coil 320 with the magnetic glue 340 to form a package 370, and then assembling the magnetic core 310, problems of overflowing or vertical flow can be avoided. In addition, the magnetic glue is formed through injection molding and compression molding, so that the density of the magnetic glue in the package 370 can be increased and the magnetic permeability can be improved. Therefore, under the condition of achieving the same inductance value, the choke 300d can be compared with the chokes 300a and 300c. Has a smaller volume.
圖6A為本發明之另一實施例之扼流器的剖面示意圖,圖6B為圖6A之磁性殼體的立體示意圖。請同時參考圖2A、圖6A與圖6B,圖6A之扼流器300e與圖2A之扼流器300a相似,其不同之處在於:圖6A之扼流器300e藉由一磁性殼體360來取代圖2A的磁性膠340,其中磁性殼體360具有一上表面360a、一 相對於上表面360a的下表面360b以及二開口端362a、362b,開口端362a、362b分別位於上表面360a與下表面360b,且開口端362a、362b互相連通。詳細而言,中空線圈320配置於磁性殼體360內,且第一磁芯體311的中柱312貫穿磁性殼體360的這些開口端362a、362b,使第一磁芯體311的頂板314承靠磁性殼體360的上表面360a,而第二磁芯體315配置於磁性殼體360的下表面360b上。由於本實施例之扼流器300e是藉由磁性殼體360來取代磁性膠340,因此不會有溢膠或垂流的問題。 FIG. 6A is a schematic cross-sectional view of a choke according to another embodiment of the present invention, and FIG. 6B is a schematic perspective view of the magnetic case of FIG. 6A. Please refer to FIG. 2A, FIG. 6A and FIG. 6B at the same time. The choke 300e of FIG. 6A is similar to the choke 300a of FIG. 2A. The difference is that the choke 300e of FIG. 6A is provided by a magnetic housing 360. Instead of the magnetic glue 340 of FIG. 2A, the magnetic casing 360 has an upper surface 360a, a With respect to the lower surface 360b and the two open ends 362a and 362b of the upper surface 360a, the open ends 362a and 362b are located on the upper surface 360a and the lower surface 360b, respectively, and the open ends 362a and 362b communicate with each other. In detail, the hollow coil 320 is disposed in the magnetic case 360, and the center post 312 of the first magnetic core body 311 penetrates these open ends 362a and 362b of the magnetic case 360, so that the top plate 314 of the first magnetic core body 311 bears. Abutting on the upper surface 360a of the magnetic case 360, and the second magnetic core body 315 is disposed on the lower surface 360b of the magnetic case 360. Since the choke 300e of this embodiment replaces the magnetic glue 340 by the magnetic case 360, there is no problem of overflowing glue or vertical flow.
圖7為本發明之另一實施例之扼流器的剖面示意圖。請同時參考圖2A與圖7,圖7之扼流器300f與圖2A之扼流器300a相似,其不同之處在於:圖7之扼流器300f的第一磁芯體311’之頂板314’具有一底部314a與二側壁部314b,其中這些側壁部314b配置於底部314a的相對兩側邊,且這些側壁部314b的延伸方向實質上垂直於底部314a的延伸方向。這些側壁部314b之延伸方向平行於中柱312之延伸方向,側壁部314b之高度可與中柱312之高度相同,且第二磁芯體315配置於這些側壁部314b之間。而磁性膠340填充於第一磁芯體311之這些側壁部314b之間,並包覆中空線圈320的繞線部323與部份之端部(圖未示)。本實施例之扼流器300f藉由側壁部314b的設置,因此可改善磁性膠340溢膠或垂流的問題。 FIG. 7 is a schematic cross-sectional view of a choke according to another embodiment of the present invention. Please refer to FIG. 2A and FIG. 7 at the same time. The choke 300f of FIG. 7 is similar to the choke 300a of FIG. 2A, except that the top plate 314 of the first magnetic core body 311 'of the choke 300f of FIG. It has a bottom portion 314a and two side wall portions 314b, wherein the side wall portions 314b are disposed on opposite sides of the bottom portion 314a, and the extending direction of the side wall portions 314b is substantially perpendicular to the extending direction of the bottom portion 314a. The extending direction of the side wall portions 314b is parallel to the extending direction of the center pillar 312. The height of the side wall portion 314b may be the same as the height of the center pillar 312, and the second magnetic core body 315 is disposed between the side wall portions 314b. The magnetic glue 340 is filled between the side wall portions 314b of the first magnetic core body 311, and covers the winding portion 323 and a portion of an end portion (not shown) of the hollow coil 320. Since the choke 300f of this embodiment is provided with the side wall portion 314b, the problem of overflow or vertical flow of the magnetic glue 340 can be improved.
圖8A為本發明之另一實施例之扼流器的剖面示意圖,圖8B為圖8A之扼流器的分解示意圖,圖8C為圖8A之扼流器的立體示意圖。在此必須說明的是,為了方便說明起見,圖8B省略繪示磁性膠340。請同時參考圖8A、圖8B與圖8C,在本實施例中,扼流器400a包括一磁芯410a、至少一導線420以及一殼體430。詳細而言,磁芯410a包括一頂板412、一中柱414以及一底板416,且底 板416具有一接合面416a、一相對於接合面416a的組裝面416b與至少一注入孔416c(圖8C中示意繪示兩個),其中中柱414配置於頂板412與底板416之間,且頂板412、中柱414以及底板416之間形成一繞線空間S。磁芯410a材質及製作方法與磁芯310相同,故在此不再贅述。在本實施例中,磁芯410a之頂板412、中柱414以及底板416為一體成形且構成一鼓型磁芯(drum-core)結構。 8A is a schematic cross-sectional view of a choke according to another embodiment of the present invention, FIG. 8B is an exploded schematic view of the choke of FIG. 8A, and FIG. 8C is a perspective schematic view of the choke of FIG. 8A. It must be noted here that, for convenience of description, FIG. 8B omits the illustration of the magnetic glue 340. Please refer to FIG. 8A, FIG. 8B and FIG. 8C at the same time. In this embodiment, the choke 400a includes a magnetic core 410a, at least one wire 420, and a casing 430. In detail, the magnetic core 410a includes a top plate 412, a center pillar 414, and a bottom plate 416. The plate 416 has a joint surface 416a, an assembly surface 416b opposite to the joint surface 416a, and at least one injection hole 416c (two are shown schematically in FIG. 8C), wherein the center pillar 414 is disposed between the top plate 412 and the bottom plate 416, and A winding space S is formed between the top plate 412, the center pillar 414, and the bottom plate 416. The material and manufacturing method of the magnetic core 410a are the same as those of the magnetic core 310, so they are not repeated here. In this embodiment, the top plate 412, the center pillar 414, and the bottom plate 416 of the magnetic core 410a are integrally formed and constitute a drum-core structure.
導線420纏繞於中柱414上且位於繞線空間S內,其中導線420例如可為圓線(最小截面積為圓形)或扁線(最小截面積為矩形),且導線420例如是由銅線外包覆漆包層所組成,而漆包層為一絕緣層。此外,導線420可具有位於最內層之第一多個繞線圈與位於最外層之第二多個繞線圈,導線420可具有兩直線形端部420a,420b,其中,兩直線形端部420a,420b分別連接至該第一多個繞線圈與該第二多個繞線圈之底部磁芯體設置於該下表面之下方且分別與該第一多個繞線圈之最下層之繞線圈以及該第二多個繞線圈之最下層之繞線圈相接觸,該兩直線形端部420a,420b分別由該磁芯體410a之上方延伸至該磁芯體410a之底面之下方以作為該具有電感之元件之兩引腳以連接一外部電路。此外,導線420可利用自動化設備將導線420纏繞於磁蕊410a的中柱414上,且本實施例並未限定導線420的數量,意即導線420可為一條或是多條。 The conductive wire 420 is wound on the center pillar 414 and is located in the winding space S. The conductive wire 420 may be, for example, a round wire (the minimum cross-sectional area is circular) or a flat wire (the minimum cross-sectional area is rectangular). The wire is covered by an enamelled layer, which is an insulating layer. In addition, the conducting wire 420 may have a first plurality of winding coils located at the innermost layer and a second plurality of winding coils located at the outermost layer. The conducting wire 420 may have two linear end portions 420a, 420b, of which two linear end portions 420a 420b is respectively connected to the bottom multiple cores of the first plurality of winding coils and the second plurality of winding coils, which are disposed below the lower surface and are respectively connected to the bottommost winding coil of the first plurality of winding coils and the The lowermost windings of the second plurality of windings are in contact with each other. The two linear end portions 420a, 420b extend from above the magnetic core body 410a to below the bottom surface of the magnetic core body 410a, respectively. The two pins of the component are connected to an external circuit. In addition, the wires 420 can be wound on the center pillar 414 of the magnetic core 410a by using an automated device, and the number of the wires 420 is not limited in this embodiment, which means that the wires 420 can be one or more.
殼體430為具有一開口端432之桶狀結構,其中磁芯410a與導線420配置於殼體430內,且開口端432暴露出磁芯410a之底板416的組裝面416b。 The housing 430 is a barrel-shaped structure having an open end 432. The magnetic core 410a and the lead wires 420 are disposed in the housing 430, and the open end 432 exposes the assembly surface 416b of the bottom plate 416 of the magnetic core 410a.
此外,本實施例之扼流器400a更包括一磁性膠440,其中磁性膠440適於經由注入孔416c填充於殼體430內,以填滿繞線空間S且包覆導線420與部份磁芯410a。磁性膠440之材質與磁性膠340相同,故在此不再贅述。 In addition, the choke 400a of this embodiment further includes a magnetic glue 440, wherein the magnetic glue 440 is adapted to be filled in the housing 430 through the injection hole 416c to fill the winding space S and cover the wire 420 and a part of the magnetic Core 410a. The material of the magnetic glue 440 is the same as that of the magnetic glue 340, so it will not be repeated here.
由於本實施例之扼流器400a具有殼體430,因此磁性膠430填充時,不會有溢流或垂流的問題,且扼流器400a的外觀亦較為美觀且可遮蔽磁性膠之龜裂及防止生銹。此外,殼體430的材質若為金屬或磁性材料時,則扼流器400a可具有防止電磁干擾的效果。若殼體430的材質為金屬時,可提供散熱使扼流器400a整體溫度下降,進而提升效率。 Since the choke 400a of this embodiment has a housing 430, there is no problem of overflow or vertical flow when the magnetic glue 430 is filled, and the appearance of the choke 400a is also beautiful and can shield the crack of the magnetic glue And prevent rust. In addition, if the material of the housing 430 is a metal or a magnetic material, the choke 400 a can have an effect of preventing electromagnetic interference. If the material of the casing 430 is metal, heat can be provided to reduce the overall temperature of the choke 400a, thereby improving efficiency.
值得一提的是,本發明並不限定磁芯410a的形態,於其他實施例中,請參考圖8D,扼流器400b的磁芯410b亦可由一頂板412’、一中柱414’以及一底板416’所組成,其中中柱414’與頂板412’為一體成形,底板416’利用黏合方式與中柱414’之一端相連接,或者中柱414’、頂板412’與底板416’均利用黏合方式相連接,而導線420為一中空線圈並套設於中柱414’上。請參閱圖8E,扼流器400c的磁芯410c亦可是由一中柱414”及一底板416”所組成,其中,導線420為一中空線圈並套設於中柱414”上,仍屬於本發明可採用的技術方案,不脫離本發明所欲保護的範圍。 It is worth mentioning that the present invention does not limit the shape of the magnetic core 410a. In other embodiments, please refer to FIG. 8D. The magnetic core 410b of the choke 400b may also include a top plate 412 ', a center pillar 414', and a The bottom plate 416 'is composed of the center pillar 414' and the top plate 412 ', and the bottom plate 416' is connected to one end of the center pillar 414 'by an adhesive method, or the center pillar 414', the top plate 412 'and the bottom plate 416' are all used. The wires are connected in an adhesive manner, and the wire 420 is a hollow coil and is sleeved on the center pillar 414 '. Please refer to FIG. 8E. The magnetic core 410c of the choke 400c may also be composed of a center pillar 414 "and a bottom plate 416", wherein the wire 420 is a hollow coil and is sleeved on the center pillar 414 ", which still belongs to the present invention. The technical solutions that can be adopted in the invention do not depart from the scope of the present invention.
圖9為本發明之另一實施例之扼流器的剖面示意圖。請參考圖9,在本實施例中,扼流器500a包括一磁芯510a以及一封裝體520,其中磁芯510a包括一中柱512a,而封裝體520套設於磁芯510a的中柱512a上,且封裝體520包括一中空線圈522與一包覆中空線圈522的磁性材料524。封裝體520是以射出成型(injection molding)或壓模成型(press molding)的方式使磁性材料524包覆中空線圈522的周圍而形成,且封裝體520具有一穿孔526以供設置磁芯510a之中柱512a。在本實施例中,封裝體520的高度等於中柱512b的長度,使中柱512b之兩端與封裝體520之表面切齊。磁芯510a之材質與磁芯310相同,中空線圈 522與中空線圈320相同,磁性材料524之材質與磁性膠340相同,故在此不再贅述。 FIG. 9 is a schematic cross-sectional view of a choke according to another embodiment of the present invention. Please refer to FIG. 9. In this embodiment, the choke 500 a includes a magnetic core 510 a and a package 520, wherein the magnetic core 510 a includes a center pillar 512 a, and the package 520 is sleeved on the center pillar 512 a of the magnetic core 510 a. The package 520 includes a hollow coil 522 and a magnetic material 524 covering the hollow coil 522. The package body 520 is formed by injecting molding or press molding by covering the hollow coil 522 with a magnetic material 524, and the package body 520 has a perforation 526 for providing a magnetic core 510a. Center pillar 512a. In this embodiment, the height of the package 520 is equal to the length of the center pillar 512b, so that both ends of the center pillar 512b are aligned with the surface of the package 520. The material of the magnetic core 510a is the same as that of the magnetic core 310, and the hollow coil 522 is the same as the hollow coil 320, and the material of the magnetic material 524 is the same as that of the magnetic glue 340, so it is not repeated here.
本實施例之扼流器500a的製作是先形成封裝體520,再將磁芯510a的中柱512a穿過中空線圈522,而形成扼流器500a。而本實施例之扼流器500a可達到之功效與扼流器300d相同,故在此不贅述。 In the manufacture of the choke 500a of this embodiment, a package 520 is first formed, and then the central post 512a of the magnetic core 510a is passed through the hollow coil 522 to form the choke 500a. However, the effect achieved by the choke 500a of this embodiment is the same as that of the choke 300d, so it will not be repeated here.
有關磁芯510a之結構並不限於圖9揭示之結構,磁芯510a亦可為圖10A至圖10D所揭示之結構。詳細地說,如圖10A所示,扼流器500b的磁芯510b更包括一頂板514b,其中中柱512b與頂板514b為一體成形,且中柱512b的一端513b套設於封裝體520內,意即中柱512b的一端513b並未暴露於封裝體520外,且封裝體520的高度大於中柱512b的長度。如圖10B所示,扼流器500c的磁芯510c更包括一頂板514c,其中中柱512c與頂板514c為一體成形,且中柱512c的一端513c穿過於封裝體520而與封裝體520遠離頂板514c的一表面520a實質上切齊。如圖10C所示,扼流器500d的磁芯510d更包括一頂板514d以及一底板516d,其中頂板514d與中柱512d為一體成形,且中柱512d的一端513d穿過於封裝體520而與封裝體520遠離頂板514d的一表面520a實質上切齊,而底板516d覆蓋中柱512d的一端513d與封裝體520的表面520a。如圖10D所示,扼流器500e的磁芯510e更包括一頂板514e以及一底板516e,其中頂板514e與中柱512e為一體成形,且底板516e具有一開口517、一接合面518a與一相對於接合面518a的組裝面518b。中柱512e的一端513e穿過於封裝體520而從接合面518a置入於開口517內,且中柱512e的一端513e實質上與組裝面518b切齊。 The structure of the magnetic core 510 a is not limited to the structure disclosed in FIG. 9, and the magnetic core 510 a may also be the structure disclosed in FIGS. 10A to 10D. In detail, as shown in FIG. 10A, the magnetic core 510b of the choke 500b further includes a top plate 514b, wherein the center pillar 512b and the top plate 514b are integrally formed, and one end 513b of the center pillar 512b is sleeved in the package 520. That is, one end 513b of the center pillar 512b is not exposed outside the package 520, and the height of the package 520 is greater than the length of the center pillar 512b. As shown in FIG. 10B, the magnetic core 510c of the choke 500c further includes a top plate 514c, wherein the center pillar 512c and the top plate 514c are integrally formed, and one end 513c of the center pillar 512c passes through the package 520 and is separated from the package 520 away from the top plate. A surface 520a of 514c is substantially aligned. As shown in FIG. 10C, the magnetic core 510d of the choke 500d further includes a top plate 514d and a bottom plate 516d. The top plate 514d and the center pillar 512d are integrally formed, and one end 513d of the center pillar 512d passes through the package body 520 and is packaged with the package. A surface 520a of the body 520 away from the top plate 514d is substantially aligned, and a bottom plate 516d covers one end 513d of the center pillar 512d and the surface 520a of the package 520. As shown in FIG. 10D, the magnetic core 510e of the choke 500e further includes a top plate 514e and a bottom plate 516e. The top plate 514e and the center pillar 512e are integrally formed, and the bottom plate 516e has an opening 517, a joint surface 518a and an opposite surface. Assembly surface 518b on the joint surface 518a. One end 513e of the center pillar 512e passes through the package 520 and is inserted into the opening 517 from the joint surface 518a, and one end 513e of the center pillar 512e is substantially aligned with the assembly surface 518b.
圖11A為本發明之另一實施例之扼流器的示意圖,圖11B為圖11A之扼流器的分解示意圖。請同時參考圖11A與圖11B,在本實施例中,扼流器600a 包括一磁芯610以及一中空線圈620。詳細而言,磁芯610包括一第一磁芯體611以及一第二磁芯體617。第一磁芯體611包括一頂板612、一中柱614以及至少一導線槽616(圖11A中示意地繪示二個),其中中柱614與頂板612為一體成形,且頂板612具有一底部612a與一環繞底部612a周圍配置的側壁部612b,側壁部612b包圍中柱614。中柱614的直徑小於頂板612之底部612a一邊的長度,且側壁部612b的延伸方向實質上垂直於底部612a的延伸方向。側壁部612b之延伸方向平行於中柱614之延伸方向。導線槽616配置於頂板612的側壁部612b,且導線槽616的寬度可依配置中空線圈620的線徑設計。 FIG. 11A is a schematic diagram of a choke according to another embodiment of the present invention, and FIG. 11B is an exploded schematic diagram of the choke of FIG. 11A. Please refer to FIG. 11A and FIG. 11B together. In this embodiment, the choke 600a It includes a magnetic core 610 and a hollow coil 620. In detail, the magnetic core 610 includes a first magnetic core body 611 and a second magnetic core body 617. The first magnetic core body 611 includes a top plate 612, a center pillar 614, and at least one wire groove 616 (two are schematically shown in FIG. 11A), wherein the center pillar 614 and the top plate 612 are integrally formed, and the top plate 612 has a bottom 612a and a side wall portion 612b disposed around the bottom portion 612a. The side wall portion 612b surrounds the center pillar 614. The diameter of the center pillar 614 is smaller than the length of one side of the bottom portion 612a of the top plate 612, and the extending direction of the side wall portion 612b is substantially perpendicular to the extending direction of the bottom portion 612a. The extending direction of the side wall portion 612b is parallel to the extending direction of the center pillar 614. The lead groove 616 is disposed on the side wall portion 612 b of the top plate 612, and the width of the lead groove 616 can be designed according to the wire diameter of the hollow coil 620.
第二磁芯體617為一平板且具有一接合面617a、一相對於接合面617a的組裝面617b以及一開口619。開口619位於第二磁芯體617之中心且連通接合面617a與組裝面617b。中柱614的一端614a適於從接合面617a置入於開口619內。特別是,頂板612之側壁部612b之高度可與中柱614之高度相同,且第二磁芯體617配置於側壁部612b之間。本實施例之磁芯610材質與磁芯310相同,故在此不再贅述。在本實施例中,中柱614例如為一圓柱,第二磁芯體617、開口619、頂板612之底部612a的形狀皆例如為一圓形,且開口619的直徑大於或等於中柱617的直徑。 The second magnetic core body 617 is a flat plate and has a joint surface 617a, an assembly surface 617b opposite to the joint surface 617a, and an opening 619. The opening 619 is located at the center of the second magnetic core body 617 and communicates the joint surface 617a and the assembly surface 617b. One end 614a of the center pillar 614 is adapted to be inserted into the opening 619 from the joint surface 617a. In particular, the height of the side wall portion 612b of the top plate 612 may be the same as the height of the center pillar 614, and the second magnetic core body 617 is disposed between the side wall portions 612b. The material of the magnetic core 610 in this embodiment is the same as that of the magnetic core 310, so it will not be repeated here. In this embodiment, the center pillar 614 is, for example, a cylinder, and the shape of the second magnetic core body 617, the opening 619, and the bottom 612a of the top plate 612 is, for example, a circle, and the diameter of the opening 619 is greater than or equal to that of the center pillar 617. diameter.
中空線圈620套設於中柱614上,且位於第一磁芯體611的頂板612與第二磁芯體617之間,其中中空線圈620的高度小於頂板612的側壁部612b的高度,且側壁部612b至少與部分之中空線圈620相接觸。有關中空線圈620之製作方法、材料與結構與中空線圈320相同,故在此不贅述。 The hollow coil 620 is sleeved on the center pillar 614 and is located between the top plate 612 of the first magnetic core body 611 and the second magnetic core body 617. The height of the hollow coil 620 is smaller than the height of the side wall portion 612b of the top plate 612, and the side wall The portion 612b is in contact with at least a part of the hollow coil 620. The manufacturing method, material, and structure of the hollow coil 620 are the same as those of the hollow coil 320, so they will not be repeated here.
值得一提的是,本實施例之第二磁芯體617是直接壓合於中空線圈620上,使第二磁芯體617直接配置於中空線圈620上,因此可藉由中空線圈620 的高度來定位第二磁芯體617位置,而於本實施例中,第一磁芯體611之中柱614一端614a實質上與第二磁芯體617的組裝面617b切齊,但於其他實施例中,第一磁芯體611之中柱614一端614a可穿過第二磁芯體617的開口619而突出於組裝面617b,其中中柱614突出於組裝面617b的高度低於中空線圈620之兩末端延伸至導線槽616外的長度,仍屬於本發明可採用的技術方案,不脫離本發明所欲保護的範圍。 It is worth mentioning that the second magnetic core body 617 in this embodiment is directly pressed on the hollow coil 620, so that the second magnetic core body 617 is directly disposed on the hollow coil 620, so the hollow coil 620 can be used. Position of the second magnetic core body 617 in this embodiment. In this embodiment, one end 614a of the pillar 614 in the first magnetic core body 611 is substantially aligned with the assembly surface 617b of the second magnetic core body 617, but in other places In the embodiment, one end 614a of the pillar 614 in the first magnetic core body 611 can pass through the opening 619 of the second magnetic core body 617 and protrude from the assembly surface 617b. The height of the central pillar 614 protruding from the assembly surface 617b is lower than the hollow coil. The length of the two ends of 620 extending outside the wire groove 616 still belongs to the technical solution that can be adopted in the present invention, without departing from the scope of the present invention.
此外,於本實施例中,可選擇性地塗佈一材料層630於中柱614與開口619的交接處,來降低組裝時中柱614與開口619之間的間距對感值的影響。 此外,材料層630例如是樹脂膠體或磁性膠體。當然,於較佳實施例中,第一磁芯體611之中柱614的直徑等於第二磁芯體617之開口619的直徑。 In addition, in this embodiment, a material layer 630 may be selectively applied at the junction between the center pillar 614 and the opening 619 to reduce the influence of the distance between the center pillar 614 and the opening 619 on the sensing value during assembly. The material layer 630 is, for example, a resin colloid or a magnetic colloid. Of course, in the preferred embodiment, the diameter of the post 614 in the first magnetic core body 611 is equal to the diameter of the opening 619 of the second magnetic core body 617.
另外,本發明並不限定第一磁芯體611與第二磁芯體617的形態,雖然此處所提及的第一磁芯體611之頂板612的底部612a形狀為圓形,而第二磁芯體617的形狀為圓形,但於其他實施例中,請參考圖11C,第一磁芯體611’之頂板612’的底部612a’亦可以是矩形,而側壁部612b’環繞底部612a’之矩形周圍配置,第二磁芯體617’設置於側壁部612b’內且形狀是圓形,仍屬於本發明可採用的技術方案,不脫離本發明所欲保護的範圍。 In addition, the present invention does not limit the shapes of the first magnetic core body 611 and the second magnetic core body 617, although the bottom 612a of the top plate 612 of the first magnetic core body 611 mentioned here is circular, and the second The shape of the magnetic core body 617 is circular, but in other embodiments, please refer to FIG. 11C. The bottom portion 612a 'of the top plate 612' of the first magnetic core body 611 'may also be rectangular, and the side wall portion 612b' surrounds the bottom portion 612a. It is arranged around a rectangular shape, and the second magnetic core body 617 'is disposed in the side wall portion 612b' and has a circular shape, which still belongs to the technical solution of the present invention and does not depart from the scope of the present invention.
本實施例之扼流器600a是先利用自動化設備將導線纏繞成中空線圈620後,再將中空線620圈套設於第一磁芯體611的中柱614上,並使中柱614的一端614a置入第二磁芯體617的開口619內,此時中空線圈620位於第一磁芯體611的頂板612與第二磁芯體617之間,而完成組裝。相較於習知技術而言,本實施例之扼流器600a可以有效降低導線於繞線製程中所耗費的人力成本外,亦 可有選擇性的塗佈材料層630於中柱614與開口619的交接處,來提高組裝穩定性並降低電感值變異性。 In the choke 600a of this embodiment, the wire is wound into a hollow coil 620 by using an automatic device, and then the hollow wire 620 is looped on the center pillar 614 of the first magnetic core 611, and one end 614a of the center pillar 614 is set. It is placed in the opening 619 of the second magnetic core body 617, and the hollow coil 620 is located between the top plate 612 of the first magnetic core body 611 and the second magnetic core body 617, and the assembly is completed. Compared with the conventional technology, the choke 600a of this embodiment can effectively reduce the labor cost of the wire in the winding process. A selective coating material layer 630 may be provided at the junction between the center pillar 614 and the opening 619 to improve assembly stability and reduce inductance variability.
由於本實施例之扼流器600a是利用頂板612的側壁部612b來包覆中空線圈620的周圍以取代磁性膠,因此除了不會有溢膠或垂流的問題外,亦可減少製程步驟進而降低製造成本。此外,可利用控制第二磁芯體617相對於第一磁芯體611的位置來搭配不同中空線圈,以調整感量,使得不同感量之扼流器可使用相同的磁芯,而節省模具費用。再者,將開口619設置於具有組裝面617b之第二磁芯體617上,使利用第二磁芯體617的位置調整感值時,中柱614可朝組裝面617b突出,而使突出的中柱617不致影響扼流器600a的外觀。 Since the choke 600a of this embodiment uses the side wall portion 612b of the top plate 612 to cover the periphery of the hollow coil 620 to replace the magnetic glue, in addition to the problem of overflowing glue or vertical flow, the process steps can be reduced and further Reduce manufacturing costs. In addition, different hollow coils can be used to control the position of the second magnetic core body 617 relative to the first magnetic core body 611 to adjust the inductance, so that chokes of different inductances can use the same magnetic core, thereby saving the mold. cost. Furthermore, the opening 619 is provided on the second magnetic core body 617 having the assembly surface 617b, and when the position of the second magnetic core body 617 is used to adjust the sensing value, the center pillar 614 can protrude toward the assembly surface 617b, so that the protruding The center pillar 617 does not affect the appearance of the choke 600a.
另外,圖11D為本發明之另一實施例之扼流器的剖面示意圖。請同參考圖11A與圖11D,圖11D之扼流器600b與圖11A之扼流器600a相似,其不同之處在於,圖11D之扼流器600b的磁芯610’之第一磁芯體611’之側壁部612b’之高度低於中柱614’之高度,中柱614’的一端614a’適於從第二磁芯體617之接合面617a置入於開口619內且第二磁芯體617之兩端配置於側壁部612b’上,亦即第二磁芯體617可藉由側壁部612b’定位。本實施例中,亦利用側壁部612b’來取代磁性膠,因此除了不會有溢膠或垂流的問題外,亦可減少製程步驟進而降低製造成本。 In addition, FIG. 11D is a schematic cross-sectional view of a choke according to another embodiment of the present invention. Please refer to FIG. 11A and FIG. 11D. The choke 600b of FIG. 11D is similar to the choke 600a of FIG. 11A. The difference is that the first core body of the magnetic core 610 'of the choke 600b of FIG. 11D The height of the side wall portion 612b 'of 611' is lower than the height of the center pillar 614 '. One end 614a' of the center pillar 614 'is adapted to be inserted into the opening 619 from the joint surface 617a of the second magnetic core body 617 and the second magnetic core. Both ends of the body 617 are disposed on the side wall portion 612b ', that is, the second magnetic core body 617 can be positioned by the side wall portion 612b'. In this embodiment, the side wall portion 612b 'is also used instead of the magnetic glue, so in addition to the problem of overflowing or vertical flow, the number of manufacturing steps can be reduced and the manufacturing cost can be reduced.
以下將提出實測結果來比較習知圖1之扼流器100與本實施例之部分扼流器300a、300c、300d、600a、600b。 The measured results will be presented below to compare the conventional choke 100 of FIG. 1 with some of the chokes 300a, 300c, 300d, 600a, and 600b of this embodiment.
[第一組實測結果] [First set of measured results]
本實測是比較磁芯的材料相同且體積相近之習知之扼流器100與本實施例圖2A之扼流器300a。表一為電源供應器輸出12伏特轉5伏特所得之扼流器100與三個 相同之扼流器300a的實驗數據。表二為電源供應器輸出12伏特轉3.3伏特所得之扼流器100與三個相同之扼流器300a的實驗數據。 This actual measurement compares the conventional choke 100 with the same material and similar volume of the magnetic core and the choke 300a of FIG. 2A in this embodiment. Table 1 is the choke 100 and three chokes obtained from the power supply output 12 volts to 5 volts. Experimental data of the same choke 300a. Table 2 shows the experimental data of choke 100 and three identical chokes 300a obtained from the power supply outputting 12 volts to 3.3 volts.
根據圖表一與表二可知,扼流器100與扼流器300a在相同的電流下,扼流器300a之效率均比習知之扼流器100高。換言之,扼流器300a之磁芯310的設計相較於習知扼流器100之磁芯設計佳。 According to Table 1 and Table 2, it can be known that the efficiency of the choke 300a is higher than that of the conventional choke 100 under the same current of the choke 100 and the choke 300a. In other words, the design of the magnetic core 310 of the choke 300a is better than that of the conventional choke 100.
[第二組實測結果] [Second set of measured results]
本實測是比較磁芯的材料相同且體積相近之習知之扼流器100與本實施例圖4之扼流器300c。表三為電源供應器輸出12伏特轉5伏特所得之扼流器100與四個相同之扼流器300c的實驗數據,表四為電源供應器輸出12伏特轉3.3伏特所得之扼流器100與四個相同之扼流器300c的實驗數據。 This actual measurement compares the conventional choke 100 with the same material and similar volume of the magnetic core and the choke 300c of FIG. 4 in this embodiment. Table 3 shows the experimental data of the choke 100 and the four identical chokes 300c obtained from the power supply outputting 12 volts to 5 volts. Table 4 shows the choke 100 and the choke 100 obtained from the power supply outputting 12 volts to 3.3 volts. Experimental data for four identical chokes 300c.
表三
根據表三與表四可知,扼流器100與扼流器300c在相同的電流下,扼流器300c於輕載重(50%載重)之效率均比習知之扼流器100高。 According to Tables 3 and 4, it can be known that at the same current of the choke 100 and the choke 300c, the efficiency of the choke 300c at light load (50% load) is higher than that of the conventional choke 100.
[第三組實測結果] [The third group of measured results]
本實測是比較磁芯的材料相同且體積相近之習知之扼流器100與本實施例圖5之扼流器300d。表五表示為電源供應器輸出12伏特轉3.3伏特所得之扼流器200與扼流器300d的實驗數據。 This actual measurement compares the conventional choke 100 with the same material and similar volume of the magnetic core and the choke 300d of FIG. 5 in this embodiment. Table 5 shows the experimental data of the choke 200 and the choke 300d obtained from the power supply outputting 12 volts to 3.3 volts.
根據表五可知,扼流器100與扼流器300d在相同的電流下,扼流器300d於輕載重之效率均比習知之扼流器100高。 According to Table 5, under the same current of the choke 100 and the choke 300d, the efficiency of the choke 300d at light load is higher than that of the conventional choke 100.
[第四組實測結果] [The fourth group of measured results]
本實測是針對中柱312與開口316之接合處的單邊間距對扼流器300a之初始感量的影響作實驗,其中第二磁芯體315的厚度為2.5釐米(mm)。表六為單邊間距對扼流器300a之初始感量的實驗數據。 The actual measurement is to perform an experiment on the influence of the unilateral distance between the junction of the center pillar 312 and the opening 316 on the initial inductance of the choke 300a. The thickness of the second magnetic core 315 is 2.5 cm (mm). Table 6 shows the experimental data of the initial inductance of the choke 300a with one-sided pitch.
根據表六可知,當單邊間距為0.1釐米(mm)時,初始感量下降6.91%;當單邊間距越大時(例如為0.4釐米(mm)),初始感量下降越大(17.51%)。也就是說,於扼流器300a的製造過程中,中柱312與開口316的接合處所產生的間距會影響感值的變異性。 According to Table 6, it can be seen that when the unilateral distance is 0.1 cm (mm), the initial sensitivity decreases by 6.91%; when the unilateral distance is larger (for example, 0.4 cm (mm)), the initial sensitivity decreases (17.51%). ). That is to say, during the manufacturing process of the choke 300a, the pitch generated at the junction of the center pillar 312 and the opening 316 will affect the variability of the sensing value.
以下將針對中柱312與開口316的接合處填充材料層340對扼流器310a之初始感量作實驗,其中第二磁芯體315的厚度為2.5釐米(mm)。表七為材料層厚度對初始感量的實驗數據。 In the following, experiments will be performed on the initial inductance of the choke 310a by the filling material layer 340 at the junction of the center pillar 312 and the opening 316. The thickness of the second magnetic core body 315 is 2.5 centimeters (mm). Table 7 shows the experimental data of the thickness of the material layer on the initial sensitivity.
根據表七可知,當磁性材料層330厚度從0.1釐米(mm)增厚至0.4釐米(mm)時,感量變化量仍小於5%,也就是說,相對於圖18而言,材料層330厚度對初始感量的影響比中柱312與開口316的接合處所產生的間距對初始感量的影響小。換言之,可藉由選擇性地填充材料層330來降低因製程公差所產生之感值的變異性。 According to Table 7, it can be seen that when the thickness of the magnetic material layer 330 is increased from 0.1 cm (mm) to 0.4 cm (mm), the change in the amount of inductance is still less than 5%, that is, compared to FIG. 18, the material layer 330 The effect of the thickness on the initial sensitivity is smaller than the effect of the spacing generated at the junction of the center pillar 312 and the opening 316 on the initial sensitivity. In other words, the variability of the sensed value due to the process tolerance can be reduced by selectively filling the material layer 330.
以下以第二磁芯體315的厚度為3釐米(mm)進行實驗,表八為材料層厚度對初始感量的實驗數據。 In the following, experiments are performed with the thickness of the second magnetic core 315 being 3 centimeters (mm). Table 8 shows the experimental data of the thickness of the material layer on the initial sensing amount.
根據表八及比較表七可知,當第二磁芯體315從2.5釐米(mm)增加至3釐米(mm)時,感量變化量較2.5釐米(mm)時僅提高0.81%,而材料層330厚度0.4釐米(mm)時,感量影響仍小於5%,也就是說,中柱312與開口316的接合處塗佈材料層330比增加第二磁芯體315的厚度對感量影響更佳有效。 According to Table 8 and Comparison Table 7, it can be known that when the second magnetic core body 315 is increased from 2.5 cm (mm) to 3 cm (mm), the amount of change in inductance is only 0.81% higher than that when 2.5 cm (mm), and the material layer When the thickness of the 330 is 0.4 centimeters (mm), the influence of the sensitivity is still less than 5%, that is, the coating material layer 330 at the joint of the center pillar 312 and the opening 316 has a greater impact on the sensitivity than increasing the thickness of the second magnetic core 315 Good effect.
[第五組實測結果] [Fifth set of measured results]
本實測為針對圖11A之扼流器600a的有無導線槽616對感量的影響作模擬,其中中空線圈620的線徑為1釐米(mm),線圈5.5圈,直流阻抗0.5歐姆(mΩ)。由模擬的結果可知,當扼流器600a無導線槽616時,感量約為3.3微亨利(μH); 當扼流器600a有導線槽616時,感量約為3.43微亨利(μH),也就是說,有無導線槽616,感量差為4%。 This actual measurement is to simulate the influence of the presence or absence of the wire slot 616 of the choke 600a of FIG. 11A on the inductance. The hollow coil 620 has a wire diameter of 1 cm (mm), a coil of 5.5 turns, and a DC impedance of 0.5 ohm (mΩ). It can be known from the simulation results that when the choke 600a has no wire groove 616, the inductance is about 3.3 microhenry (μH); When the choke 600a has a wire groove 616, the inductance is about 3.43 microhenry (μH), that is, with or without the wire groove 616, the difference in inductance is 4%.
接著,針對導線槽616的寬度對感量的影響作實驗,其中扼流器600a之第一磁芯體611的材質為鐵矽鋁合金,且其導磁率為125。表九為導線槽間距對感量的實驗數據。 Next, an experiment is performed on the influence of the width of the wire groove 616 on the inductance. The material of the first magnetic core body 611 of the choke 600a is an iron-silicon aluminum alloy, and its magnetic permeability is 125. Table 9 shows the experimental data of the distance between the wire grooves and the inductance.
根據表九可知,導線槽616的間距由1.6mm至4.8mm,扼流器600a之感量的下降率在3%以下。可見導線槽616之設置對感量的影響小。 According to Table 9, it can be known that the pitch of the wire groove 616 is from 1.6 mm to 4.8 mm, and the decrease rate of the inductance of the choke 600a is less than 3%. It can be seen that the arrangement of the wire groove 616 has a small influence on the amount of inductance.
[第六組實測結果] [Sixth group of measured results]
以下針對圖11A之扼流器600a與圖11D之扼流器600b進行等效磁路之實驗,其中這些扼流器之磁芯的材料與體積大小皆相同。圖12為扼流器的磁路示意圖,為了方便說明起見,圖12僅繪示磁芯之第一磁芯體與第二磁芯體,圖12(a)圖代表第二磁芯體717a位於第一磁芯體711a的中柱714a與側壁部712a上,且第二磁芯體717a無開口,(b)圖代表扼流器600a,即第二磁芯體617配置於側壁部612b之間,(c)圖代表扼流器600b,即第二磁芯體617之兩端配置於側壁部612b’上。細 虛線表示間距(僅繪示單邊),而粗虛線表示等效磁路路徑(僅繪示單邊)。表十為單邊間距對等效磁路之導磁率的實驗數據。 In the following, an equivalent magnetic circuit experiment is performed with respect to the choke 600a of FIG. 11A and the choke 600b of FIG. 11D, where the material and volume of the magnetic core of these chokes are the same. FIG. 12 is a schematic diagram of a magnetic circuit of a choke. For convenience of explanation, FIG. 12 only shows a first core body and a second core body of the core, and FIG. 12 (a) represents a second core body 717a. It is located on the center pillar 714a and the side wall portion 712a of the first core body 711a, and the second core body 717a has no opening. (B) represents the choke 600a, that is, the second core body 617 is disposed on the side wall portion 612b. Meanwhile, (c) represents the choke 600b, that is, both ends of the second magnetic core body 617 are disposed on the side wall portion 612b '. fine The dashed line indicates the pitch (only one side is shown), and the thick dashed line indicates the equivalent magnetic path (only one side is shown). Table 10 shows the experimental data of the magnetic permeability of the equivalent magnetic circuit with one-sided spacing.
根據表十可知,單邊間距對導磁率的影響,扼流器600a為最小,扼流器600b次之,扼流器700a最大。可見,本發明提出之扼流器600a及扼流器600b可有效降低單邊間距對導磁率的影響,而使扼流器600a、600b相較於扼流器700a具有較大之感值。 According to Table 10, it is known that the influence of the single-sided pitch on the magnetic permeability is the smallest in the choke 600a, the second in the choke 600b, and the largest in the choke 700a. It can be seen that the choke 600a and the choke 600b proposed by the present invention can effectively reduce the influence of the single-sided distance on the magnetic permeability, and make the chokes 600a and 600b have a larger value than the choke 700a.
綜上所述,本發明之扼流器300a、300c~300f、400a~400c、500a~500e、600a、600b至少具有下列優點: In summary, the chokes 300a, 300c ~ 300f, 400a ~ 400c, 500a ~ 500e, 600a, 600b of the present invention have at least the following advantages:
1.扼流器的組裝穩定性高,降低感值變異性。 1. The choke assembly has high stability and reduces the variability of the sense value.
2.本發明之扼流器的效率大於習知之扼流器的效率。 2. The efficiency of the choke of the present invention is greater than that of the conventional choke.
3.可利用自動化設備將導線纏繞成中空線圈,可有效降低導線於繞線製程中所耗費的人力成本。 3. The wire can be wound into a hollow coil by using automatic equipment, which can effectively reduce the labor cost of the wire in the winding process.
4.可控制第二磁芯體相對於第一磁芯體的位置來搭配不同線圈,以調整感量,使得不同感量之扼流器可使用相同的磁芯,而節省模具費用。 4. The position of the second magnetic core body relative to the first magnetic core body can be controlled to match different coils to adjust the inductance, so that the chokes of different inductances can use the same magnetic core, thereby saving mold costs.
5.扼流器具有導線槽時,可有效縮小扼流器的外觀寬度及線圈之端部的距離,且可使線路板上之焊墊間距縮小。 5. When the choke has a wire groove, it can effectively reduce the appearance width of the choke and the distance between the ends of the coil, and can reduce the pad spacing on the circuit board.
6.將開口設置於具有組裝面之第二磁芯體或底板上,使中柱會朝組裝面突出,而使突出的中柱不致影響扼流器的外觀。 6. Set the opening on the second magnetic core body or bottom plate with the assembly surface, so that the center pillar will protrude toward the assembly surface, so that the protruding center pillar will not affect the appearance of the choke.
7.扼流器具有殼體、封裝體、磁性殼體或磁芯具有側壁部,可用來取代磁性膠,而有效避免磁性膠溢膠或垂流之問題。 7. The choke has a housing, a package, a magnetic housing, or a magnetic core with a side wall portion, which can be used to replace the magnetic glue and effectively avoid the problem of overflowing or vertical flow of the magnetic glue.
雖然本發明已以實施例揭露如上,然其並非用以限定本發明,任何所屬技術領域中具有通常知識者,在不脫離本發明之精神和範圍內,當可作些許之更動與潤飾,故本發明之保護範圍當視後附之申請專利範圍所界定者為準。 Although the present invention has been disclosed as above with the examples, it is not intended to limit the present invention. Any person with ordinary knowledge in the technical field can make some modifications and retouching without departing from the spirit and scope of the present invention. The protection scope of the present invention shall be determined by the scope of the attached patent application.
Claims (12)
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