WO1992005568A1 - Inductive device and method of manufacture - Google Patents

Inductive device and method of manufacture Download PDF

Info

Publication number
WO1992005568A1
WO1992005568A1 PCT/US1991/006254 US9106254W WO9205568A1 WO 1992005568 A1 WO1992005568 A1 WO 1992005568A1 US 9106254 W US9106254 W US 9106254W WO 9205568 A1 WO9205568 A1 WO 9205568A1
Authority
WO
WIPO (PCT)
Prior art keywords
core
filler material
inductive device
selection
gap
Prior art date
Application number
PCT/US1991/006254
Other languages
French (fr)
Inventor
Helen Gogny
Donald Westra
James G. Boyter
Original Assignee
Coilcraft, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Coilcraft, Inc. filed Critical Coilcraft, Inc.
Publication of WO1992005568A1 publication Critical patent/WO1992005568A1/en

Links

Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00Fixed inductances of the signal type 
    • H01F17/04Fixed inductances of the signal type  with magnetic core
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206Manufacturing of magnetic cores by mechanical means
    • H01F41/0246Manufacturing of magnetic circuits by moulding or by pressing powder
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/12Insulating of windings
    • H01F41/127Encapsulating or impregnating

Definitions

  • the present invention relates generally to inductor devices and to
  • the protruding core edges are minimized to thereby improve the
  • part blocks of molded thermoplastic resin containing magnetic particles are
  • particles is used to fill the mold and completely surround the coil.
  • inductive device used in connection with the present invention.
  • Figure IB depicts the bobbin of Figure IA having a winding wrapped
  • Figure IC is a perspective view of the assembled inductive device
  • Figure 2 is a cross sectional view of the inductive device of Figure IC
  • Figure 3 is a cross sectional view of another embodiment of an
  • Figure 4 is a cross sectional view of another embodiment of an
  • Figure 5 is a cross sectional view of yet another embodiment of an
  • Figure 6 is a cross sectional view of a further embodiment of an
  • Figure 7 is a cross sectional view of still another embodiment of an
  • Figure 8 is a cross sectional view of an additional embodiment of an
  • core 12 is shown assembled to a magnetically inert substrate base 14
  • a wire 16 is wound
  • sleeve are usually composed of ferrite or iron materials to thereby close the
  • the bobbin core is
  • This inserted material is preferably of a formable
  • this material are selected particles of either magnetic or non-magnetic
  • magnetic materials are ferrite or iron particles, and examples of such non ⁇
  • magnetic materials are aluminum or brass.
  • winding 50a-50f is wound about a core member 52a-52f.
  • This space or "gap" is then filled with a
  • vehicle of hardenable material having selected particles dispersed therein
  • examples of such a hardenable material are adhesives
  • thermoplastic resins and epoxies thermoplastic resins and epoxies. Particles dispersed in the vehicle may be
  • a magnetic material such as a ferrite or iron particles
  • inductance or they may be a non-magnetic material, such as aluminum or
  • brass to decrease the inductance, or they may be a combination of these
  • particles or the selected combination of particles may be adjusted and the

Abstract

An assembly and method of manufacture is described for an inductive device in which the effect of a gap in its enclosure is controlled. This is accomplished by assembling a winding (16) on a core (12), placing a shell (18), sleeve or other closure member over the winding, and then injecting a measured amount of a hardenable vehicle (40) containing particles having selected magnetic properties into the gap (30) existing between the closure member and the core.

Description

INDUCTIVE DEVICE AND METHOD OF MANUFACTURE
BACKGROUND OF THE INVEN ION
Field of the Invention
The present invention relates generally to inductor devices and to
methods of manufacturing such devices. More particularly, this invention
relates to methods of controlling the effect on the flux lines caused by gaps
or spaces in the enclosing magnetic shell surrounding the winding.
Description of the Prior Art
Production of inductive devices has typically involved the winding of
a length of wire around a center core. To improve the inductance
characteristics of these devices the coil is surrounded by a casing or
enclosure of magnetic material to close the flux paths. Such a device is
described in U.S. Patent No. 4,498,067. In that reference, a shell is
polished at its edges and fitted to edges protruding from the core of the
coil. By improving the fit of the shell, the spaces between the shell and
the protruding core edges are minimized to thereby improve the
inductance.
Another approach is described in U.S. Patent No. 4,769,900; counter¬
part blocks of molded thermoplastic resin containing magnetic particles are
fitted to surround the coil. By custom molding these blocks, a close fit is obtained thereby minimizing any gaps which would degrade the inductance
characteristics. A similar molding technique has also been used to fully
encompass the coil. In U.S. Patent No. 3,201,729 and U.S. Patent No.
3,255,512 a coil is placed within a mold and a resin containing magnetic
particles is used to fill the mold and completely surround the coil.
Notwithstanding these prior attempts, accuracy and economy have
remained elusive for miniaturized inductive devices. Polishing of mating
surfaces is expensive and unreliable for mass production. Molding
techniques have also proven to be expensive and the desired inductive
characteristics of the finished product are difficult to control.
SUMMARY OF THE INVENTION
Accordingly, it is a principal objective of this invention to provide a
method for the production of an inductive device of the type having a
winding on a core and an enclosing shell, which process yields an
economical yet accurate inductive device. This is accomplished by
assembling a winding on a core, placing a shell or sleeve closure member
over the winding to mate with extending portions of the core and thereby
fully encompass the winding, and then injecting an adhesive or epoxy
containing particles having selected magnetic properties into the small gap
existing between the closure member and the core.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure IA depicts a bobbin core member of one embodiment of an
inductive device used in connection with the present invention.
Figure IB depicts the bobbin of Figure IA having a winding wrapped
thereon.
Figure IC is a perspective view of the assembled inductive device
having a sleeve placed over the bobbin and winding.
Figure 2 is a cross sectional view of the inductive device of Figure IC
showing the gap between the sleeve and the bobbin core filled with
material containing particles having magnetic properties.
Figure 3 is a cross sectional view of another embodiment of an
inductive device employing the gap control techniques of the present
invention.
Figure 4 is a cross sectional view of another embodiment of an
inductive device employing the gap control techniques of the present
invention.
Figure 5 is a cross sectional view of yet another embodiment of an
inductive device employing the gap control techniques of the present
invention. Figure 6 is a cross sectional view of a further embodiment of an
inductive device employing the gap control techniques of the present
invention.
Figure 7 is a cross sectional view of still another embodiment of an
inductive device employing the gap control techniques of the present
invention.
Figure 8 is a cross sectional view of an additional embodiment of an
inductive device employing the gap control techniques of the present
invention.
While the invention will be described in connection with a preferred
embodiment, it will be understood that it is not the intent to limit the
invention to that embodiment. On the contrary, it is the intent to cover
all alternatives, modifications, and equivalents as may be included within
the spirit and scope of the invention as defined by the appended claims.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning now to the drawings, there is shown in Figures IA, IB and
IC the progressive assembly of one example of an inductive device in
accordance with the present invention. Particularly, in Figure IA a bobbin
core 12 is shown assembled to a magnetically inert substrate base 14
(typically of a ceramic, plastic or phenol composition). A wire 16 is wound
onto the bobbin (Figure IB) and terminated on the substrate; and a sleeve
18 is fitted over the wire wound bobbin (Figure IC). The sleeve engages
the bobbin to form an enclosure surrounding the winding; and the core and
sleeve are usually composed of ferrite or iron materials to thereby close the
magnetic flux lines developed by the device. Typically, the bobbin core is
adhered to the substrate base and the sleeve is adhered to the lower
portion of the bobbin.
Following this assembly, it is well known in the manufacturing industry
that a small gap 30 circumscribing the upper part 32 of the bobbin exists
between the sleeve and the bobbin, and that this space interrupts the flux
lines and degrades the inductance characteristics of the device. Perhaps
more importantly, the existence of this gap makes the manufacture of
inductive devices of the desired characteristics and tolerance difficult to
achieve. In accordance with the present invention, a filler material 40 carrying
selected particles of a desired magnetic characteristic dispersed
therethrough is inserted into the gap to thereby provide a determinable
effect on the flux lines. This inserted material is preferably of a formable
or flowable type in the nature of an adhesive, plastic resin or epoxy which
hardens or may be hardened once it is in place. Distributed throughout
this material are selected particles of either magnetic or non-magnetic
properties, or a combination thereof, of such size, quantity and ratio as to
provide desired requisite magnetic properties. An example of such
magnetic materials are ferrite or iron particles, and examples of such non¬
magnetic materials are aluminum or brass. By selecting a particular grain
size, a concentration of particles or a desired combination of particles, then
for a given configuration of an inductive device, the effect of the gap in the
enclosing casing may be effectively controlled by inserting therein a
measured quantity of the filler material to yield fairly precise manufacturing
tolerances for the characteristics of the inductor.
Control of the flux characteristics of the encasing shell of an inductive
device by the selection of a quantity of filler material containing a
prescribed concentration, grain size, and type or ratio of particles is further
exemplified by the embodiments shown in Figures 3-8. In each case a
winding 50a-50f is wound about a core member 52a-52f. When the sleeve,
shell or other encasing enclosure 54a-54f is added to mate with portions of the core member, a space 56a-56f is created which adversely affects the
characteristics of the device. This space or "gap" is then filled with a
vehicle of hardenable material having selected particles dispersed therein
in accordance with the above described principles of the present invention.
As before, examples of such a hardenable material are adhesives,
thermoplastic resins and epoxies. Particles dispersed in the vehicle may be
of a magnetic material, such as a ferrite or iron particles, to increase the
inductance or they may be a non-magnetic material, such as aluminum or
brass, to decrease the inductance, or they may be a combination of these
types. During manufacture, the quantity of the particles, the size of the
particles or the selected combination of particles may be adjusted and the
amount of material inserted into the gap area may be controlled to achieve
the desired inductive characteristics for the device.
From the foregoing description, it will be apparent that modifications
can be made to the apparatus and method for using same without
departing from the teachings of the present invention. Accordingly, the
scope of the invention is only to be limited as necessitated by the
accompanying claims.

Claims

1. An inductive device comprising a core, a winding on said core, a
closure member for engaging said core and thereby substantially
enclosing said winding, a gap between portions of said closure member
and said core, and filler material having selected magnetic properties
positioned in said gap.
2. The inductive device of Claim 1 wherein said filler material is a
flowable material which is hardenable once positioned and contains
particles dispersed throughout, said particles being selected to have
desired magnetic properties.
3. The inductive device of Claim 2 wherein said filler material contains
a mixture of particles of differing magnetic properties dispersed in said
filler material in a predetermined ratio.
4. The inductive device of Claim 1 wherein said core exhibits a bobbin
construction and said closure member comprises a sleeve arranged to
envelop said bobbin and to mate with the ends thereof, and wherein
said filler material comprises an epoxy resinous material containing
particles of ferrite composition dispersed throughout which is injected
into gaps between said sleeve and the ends of said bobbin.
5. An inductive device constructed by the assembly of a core, a winding
wrapped on said core, a closure member arranged to engage said core
and thereby substantially enclose said winding, said engagement of said
closure member and said core leaving a gap between portions of said
core and said closure member; and wherein said assembly is further
constructed by inserting filler material into selected gap portions for
affecting the magnetic properties of said device, said filler material
being inserted by injecting into said gap a quantity of flowable material
containing particles of selected magnetic properties, which flowable
material is hardenable once in position.
6. The inductive device of Claim 5 wherein said assembly is further
constructed by determining the magnetic effect required by said filler
material to produce the desired characteristics of the inductive device,
and selecting particles for dispersal in said filler material, which particles will produce said desired effect, and dispersing said particles
within said filler material prior to inserting said filler material.
7. The inductive device of Claim 6 wherein said particle selection includes
one or more of the following criteria; selection of particle type by its
magnetic characteristics, selection of particle size, selection of a ratio
of particle types, and selection of particle concentration in said filler
material.
8. The inductive device of Claim 6 wherein said core exhibits a bobbin
construction and said closure member comprises a sleeve arranged to
envelop said bobbin and to mate with the ends thereof, and wherein
said filler material comprises an epoxy resinous material containing
particles of ferrite composition dispersed throughout which is injected
into the gap between said sleeve and the ends of said bobbin.
9. A method of manufacturing an inductive device comprising the steps
of winding a coil onto a core, placing a closure member in engagement
with said core thereby substantially enclosing said winding but leaving
a gap between portions of said closure member and said core, and
injecting into said gap a quantity of flowable material containing
particles of selected magnetic properties.
10. The method of manufacturing an inductive device of Claim 9 wherein
said particle selection includes one or more of the following criteria;
selection of particle type by its magnetic characteristics, selection of
particle size, selection of a ratio of particle types, and selection of
particle concentration in said filler material.
11. The method of manufacturing an inductive device of Claim 10 wherein
said core exhibits a bobbin construction and said closure member
comprises a sleeve arranged to envelop said bobbin and to mate with
the ends thereof, and wherein said filler material comprises an epoxy
resinous material containing particles of ferrite composition dispersed
throughout, which is injected into gaps between said sleeve and said
bobbin ends.
12. In the manufacturing of an inductive device having a winding on a
core, a closure member in engagement with said core and thereby
substantially enclosing said winding, and a gap between portions of
said closure member and said core, a method of controlling the
magnetic effect of said gap comprising the step of injecting into said
gap a measured quantity of flowable filler material containing particles
of selected magnetic properties.
13. The method of manufacturing of an inductive device of Claim 12
further comprising first determining the desired effect of said filler
material and then selecting particles for dispersal therein to yield the
requisite effect for a measured amount of injected filler material.
14. The method of manufacturing an inductive device of Claim 13 wherein
said particle selection includes one or more of the following criteria;
selection of particle type by its magnetic characteristics, selection of
particle size, selection of ratio of particle types, and selection of particle
concentration in said filler material.
15. The method of manufacturing of an inductive device of Claim 12
wherein said core exhibits a bobbin construction and said closure
member comprises a sleeve arranged to envelop said bobbin and to
mate with the ends thereof, and wherein said filler material comprises
an epoxy resinous material containing particles of ferrite composition
dispersed throughout, which is injected into the gap between said sleeve
and the end of said bobbin.
PCT/US1991/006254 1990-09-21 1991-08-29 Inductive device and method of manufacture WO1992005568A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US58590490A 1990-09-21 1990-09-21
US585,904 1990-09-21

Publications (1)

Publication Number Publication Date
WO1992005568A1 true WO1992005568A1 (en) 1992-04-02

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1991/006254 WO1992005568A1 (en) 1990-09-21 1991-08-29 Inductive device and method of manufacture

Country Status (2)

Country Link
CN (1) CN1062051A (en)
WO (1) WO1992005568A1 (en)

Cited By (17)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6204744B1 (en) * 1995-07-18 2001-03-20 Vishay Dale Electronics, Inc. High current, low profile inductor
WO2002017336A1 (en) * 2000-08-24 2002-02-28 Koninklijke Philips Electronics N.V. Method of manufacturing a substantially closed core, core, and magnetic coil
NL1017426C2 (en) * 2001-02-22 2002-08-23 Tno Method for manufacturing an electromagnetic coil, device obtained with the method and actuator.
US6690255B2 (en) 2002-02-21 2004-02-10 Coilcraft, Incorporated Electronic component
US6717500B2 (en) 2001-04-26 2004-04-06 Coilcraft, Incorporated Surface mountable electronic component
US7034645B2 (en) 1999-03-16 2006-04-25 Vishay Dale Electronics, Inc. Inductor coil and method for making same
USRE39453E1 (en) 1999-10-28 2007-01-02 Coilcraft, Incorporated Low profile inductive component
US7263761B1 (en) 1995-07-18 2007-09-04 Vishay Dale Electronics, Inc. Method for making a high current low profile inductor
US7623014B2 (en) 2008-02-22 2009-11-24 Cyntec Co., Ltd. Choke coil
US7791445B2 (en) 2006-09-12 2010-09-07 Cooper Technologies Company Low profile layered coil and cores for magnetic components
US7921546B2 (en) 1995-07-18 2011-04-12 Vishay Dale Electronics, Inc. Method for making a high current low profile inductor
US8378777B2 (en) 2008-07-29 2013-02-19 Cooper Technologies Company Magnetic electrical device
US8941457B2 (en) 2006-09-12 2015-01-27 Cooper Technologies Company Miniature power inductor and methods of manufacture
US9318251B2 (en) 2006-08-09 2016-04-19 Coilcraft, Incorporated Method of manufacturing an electronic component
US9558881B2 (en) 2008-07-11 2017-01-31 Cooper Technologies Company High current power inductor
US9589716B2 (en) 2006-09-12 2017-03-07 Cooper Technologies Company Laminated magnetic component and manufacture with soft magnetic powder polymer composite sheets
US9859043B2 (en) 2008-07-11 2018-01-02 Cooper Technologies Company Magnetic components and methods of manufacturing the same

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KR100686711B1 (en) * 2005-12-28 2007-02-26 주식회사 이수 Surface mount type power inductor
CN104425099A (en) * 2013-09-05 2015-03-18 重庆美桀电子科技有限公司 Assembled-type inductance element and manufacturing method thereof
CN108414110A (en) * 2018-02-09 2018-08-17 陈景超 Induction temperature sensing device and temp measuring method, cooker and calutron

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JPS54114716A (en) * 1978-02-28 1979-09-07 Tdk Corp Transformer
US4717901A (en) * 1984-03-23 1988-01-05 Siemens Aktiengesellschaft Electronic component, especially for a chip inductance

Cited By (24)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7263761B1 (en) 1995-07-18 2007-09-04 Vishay Dale Electronics, Inc. Method for making a high current low profile inductor
US7986207B2 (en) 1995-07-18 2011-07-26 Vishay Dale Electronics, Inc. Method for making a high current low profile inductor
US7921546B2 (en) 1995-07-18 2011-04-12 Vishay Dale Electronics, Inc. Method for making a high current low profile inductor
US6460244B1 (en) 1995-07-18 2002-10-08 Vishay Dale Electronics, Inc. Method for making a high current, low profile inductor
US6204744B1 (en) * 1995-07-18 2001-03-20 Vishay Dale Electronics, Inc. High current, low profile inductor
US7345562B2 (en) 1995-07-18 2008-03-18 Vishay Dale Electronics, Inc. Method for making a high current low profile inductor
US7034645B2 (en) 1999-03-16 2006-04-25 Vishay Dale Electronics, Inc. Inductor coil and method for making same
USRE39453E1 (en) 1999-10-28 2007-01-02 Coilcraft, Incorporated Low profile inductive component
WO2002017336A1 (en) * 2000-08-24 2002-02-28 Koninklijke Philips Electronics N.V. Method of manufacturing a substantially closed core, core, and magnetic coil
WO2002067277A1 (en) * 2001-02-22 2002-08-29 Nederlandse Organisatie Voor Toegepast Natuurwetenschappelijk Onderzoek Tno Method for manufacturing an electromagnetic coil, device obtained with the method, and actuator
NL1017426C2 (en) * 2001-02-22 2002-08-23 Tno Method for manufacturing an electromagnetic coil, device obtained with the method and actuator.
US6717500B2 (en) 2001-04-26 2004-04-06 Coilcraft, Incorporated Surface mountable electronic component
US6690255B2 (en) 2002-02-21 2004-02-10 Coilcraft, Incorporated Electronic component
US9318251B2 (en) 2006-08-09 2016-04-19 Coilcraft, Incorporated Method of manufacturing an electronic component
US10319507B2 (en) 2006-08-09 2019-06-11 Coilcraft, Incorporated Method of manufacturing an electronic component
US11869696B2 (en) 2006-08-09 2024-01-09 Coilcraft, Incorporated Electronic component
US7791445B2 (en) 2006-09-12 2010-09-07 Cooper Technologies Company Low profile layered coil and cores for magnetic components
US8941457B2 (en) 2006-09-12 2015-01-27 Cooper Technologies Company Miniature power inductor and methods of manufacture
US9589716B2 (en) 2006-09-12 2017-03-07 Cooper Technologies Company Laminated magnetic component and manufacture with soft magnetic powder polymer composite sheets
US7623014B2 (en) 2008-02-22 2009-11-24 Cyntec Co., Ltd. Choke coil
US9558881B2 (en) 2008-07-11 2017-01-31 Cooper Technologies Company High current power inductor
US9859043B2 (en) 2008-07-11 2018-01-02 Cooper Technologies Company Magnetic components and methods of manufacturing the same
US8378777B2 (en) 2008-07-29 2013-02-19 Cooper Technologies Company Magnetic electrical device
US8910373B2 (en) 2008-07-29 2014-12-16 Cooper Technologies Company Method of manufacturing an electromagnetic component

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