Choke construction

Abstract

A choke coil configuration includes: a coil defining a first axis and a second axis perpendicular to each other, the coil including a plurality of first leads along the first axis, a plurality of second leads along the second axis, a plurality of third leads along the first axis, a plurality of fourth leads along the second axis, a plurality of fifth leads along the first axis, a plurality of sixth leads along the second axis, and a seventh lead along the first axis, the first leads connecting to the second leads, the second leads connecting to the third leads, the third leads connecting to the fourth leads, the fourth leads connecting to the fifth leads, the fifth leads connecting to the sixth leads, and the sixth leads connecting to the seventh lead; and a body comprising a magnetic material, the body being formed around the coil, and the plurality of first leads being disposed on an outer side of the body.

Description

Technical Field

[0001] This invention relates to an inductor, and more particularly to a choke coil construction. Prior Technology

[0002] A choke is an inductor, typically consisting of a coil wound around a magnetic core, that suppresses changes in alternating current (ripple current).

[0003] For example, Republic of China Patent No. I789230 describes an "inductor with a high current coil and low DC resistance," which includes a coil formed of a conductor and having a meandering shape. The coil may have an "S" shape. The coil has two leads extending from opposite ends of the coil. An inductor body surrounds the coil and the leads. The leads may be wound around the body to create contact points on the outside of the inductor.

[0004] However, referring to Figure 27 of patent I789230, the exposed leads on both sides of the main body account for about 20% of the overall coil, but cannot provide inductance, resulting in low utilization. If the leads on both sides are adjusted into the main body, it will affect the "S"-shaped coil, reducing inductance and current withstand capability.

[0005] Therefore, how to eliminate the above-mentioned deficiencies is the technical difficulty that the inventors of this case want to solve. Summary of the Invention

[0006] In view of the conventional application, the present invention aims to solve and improve the problems and deficiencies existing in the conventional application.

[0007] To achieve the above objectives, the present invention provides a choke coil structure comprising: a coil defining a first axis and a second axis perpendicular to each other; the coil including a plurality of first leads along the first axis, a plurality of second leads along the second axis, a plurality of third leads along the first axis, a plurality of fourth leads along the second axis, a plurality of fifth leads along the first axis, a plurality of sixth leads along the second axis, and a seventh lead along the first axis; the first leads connecting to the second leads, the second leads connecting to the third leads, the third leads connecting to the fourth leads, the fourth leads connecting to the fifth leads, the fifth leads connecting to the sixth leads, and the sixth leads connecting to the seventh lead; and a body comprising a magnetic material, the body being formed around the coil, and the plurality of first leads being disposed on an outer side of the body.

[0008] The length of the plurality of first leads is less than the length of the plurality of third leads.

[0009] Among them, the plurality of first leads are arranged with their extension direction facing outward or inward.

[0010] The length of the plurality of second leads is greater than the length of the plurality of fourth leads.

[0011] The magnetic material is at least one of carbonyl iron powder (CIP), alloy iron powder, amorphous powder, nanocrystalline, or sintered magnetic material, or a combination thereof.

[0012] The inductance can be adjusted by changing the length of the fourth lead. Furthermore, the first, second, third, fourth, and fifth leads surround multiple regions, and the magnetic flux can be adjusted by adjusting the area of ​​each region, thereby adjusting the inductance and current withstand capability. Simple Explanation of the Diagram

[0013] [Figure 1] is a schematic diagram of the choke coil structure of the present invention. [Figure 2] is a cross-sectional view of the first embodiment of the choke coil structure of the present invention. [Figure 3] is a cross-sectional view of the second embodiment of the choke coil structure of the present invention. [Figure 4] is a cross-sectional view of the third embodiment of the choke coil structure of the present invention. [Figure 5] is a graph showing the relationship between the length of the fourth lead and the inductance in this invention. [Figure 6] is a cross-sectional view of the fourth embodiment of the choke coil structure of the present invention. [Figure 7] is a cross-sectional view of the fifth embodiment of the choke coil structure of the present invention. [Figure 8] is a cross-sectional view of the sixth embodiment of the choke coil structure of the present invention. [Figure 9] is a graph showing the relationship between the area ratio and the inductance in this invention. [Figure 10] is a first comparative diagram of the choke coil structure of the present invention and a conventional inductor. [Figure 11] is a second comparative diagram of the choke coil structure of the present invention and a conventional inductor. [Figure 12] is a third comparative diagram of the choke coil structure of the present invention and the inductor of the prior art. [Figure 13] is an extended schematic diagram of the choke coil structure of the present invention. [Figure 14] is a schematic diagram of the first lead in the present invention with different orientations. Implementation

[0014] To facilitate a concise understanding for your examiner of the other features, advantages, and effects of this invention, the invention is described in detail below with reference to the accompanying drawings:

[0015] Please refer to Figures 1 and 2. The present invention provides a choke coil structure, which includes:

[0016] A coil 1 defines a first axis X and a second axis Y that are perpendicular to each other. The coil 1 includes a plurality of first leads 11 for the first axis X, a plurality of second leads 12 for the second axis Y, a plurality of third leads 13 for the first axis X, a plurality of fourth leads 14 for the second axis Y, a plurality of fifth leads 15 for the first axis X, a plurality of sixth leads 16 for the second axis Y, and a seventh lead 17 for the first axis X. The first leads 11 are connected to the second leads 12, the second leads 12 are connected to the third leads 13, the third leads 13 are connected to the fourth leads 14, the fourth leads 14 are connected to the fifth leads 15, the fifth leads 15 are connected to the sixth leads 16, and the sixth leads 16 are connected to the seventh leads 17.

[0017] A main body 2, comprising a magnetic material, is formed around the coil 1, and a plurality of first leads 11 are provided on an outer side 21 of the main body 2. The magnetic material can be carbonyl iron powder (CIP), alloy iron powder, amorphous powder, nanocrystalline material, or sintered magnetic material. Carbonyl iron powder is a high-purity iron powder; during low-temperature curing, it can act as a filler to improve the mechanical properties and wear resistance of the material. Alloy iron powder refers to a powdered material composed of iron and other alloying elements (such as carbon, nickel, chromium, copper, etc.), such as Fe-Si-Cr alloy or Fe-Si alloy. Fe-Si-Cr alloy refers to an alloy of iron (Fe), silicon (Si), and chromium (Cr), which can enhance the strength and corrosion resistance of the material. Fe-Si alloy refers to an alloy of iron (Fe) and silicon (Si), which can improve the magnetic properties and electrical conductivity of the material. Amorphous powder refers to powder materials with irregularly arranged atoms within them. Amorphous powders typically possess good strength, toughness, and corrosion resistance. An example of an amorphous powder is the Fe-Si-Cr-BC alloy. The Fe-Si-Cr-BC alloy is an alloy of iron (Fe), silicon (Si), chromium (Cr), boron (B), and carbon (C), which can form an amorphous structure during rapid cooling. Sintered magnetic materials include, for example, Fe-Si-Al alloys, Fe-Si-Mo alloys, Fe-Ni alloys, Fe-Si alloys, or Mn-Zn alloys. Sintering is a process of heating powder materials to near their melting point to promote interparticle bonding and form a dense solid material. For instance, Fe-Si-Al alloys can be sintered in powder form to create high-performance magnetic materials.

[0018] In Figure 2, the length H1 of the plurality of first leads 11 is less than the length H3 of the plurality of third leads 13. The plurality of first leads 11 serve as pins. The length H2 of the plurality of second leads 12 is greater than the length H41 of the plurality of fourth leads 14.

[0019] Magnetic flux: The number of magnetic field lines passing perpendicularly to a given area. In Figure 2, the first lead 11, the second lead 12, the third lead 13, the fourth lead 14, the fifth lead 15, and the sixth lead 16 enclose three regions A1, A2, and A3. In Figure 3, the first lead 11, the second lead 12, the third lead 13, the fourth lead 14, the fifth lead 15, and the sixth lead 16 enclose three regions B1, B2, and B3. In Figure 4, the first lead 11, the second lead 12, the third lead 13, the fourth lead 14, the fifth lead 15, and the sixth lead 16 enclose three regions C1, C2, and C3. Because in Figures 2, 3, and 4, the lengths H1 of the first lead 11, H2 of the second lead 12, H4 of the fourth lead 14, and H6 of the sixth lead 16 are all the same, but the lengths H31, H32, and H33 of the third lead 13 are different, and the lengths H51, H52, and H53 of the fifth lead 15 are also different, the magnetic flux can be adjusted by adjusting the area of ​​each region A1, A2, A3, B1, B2, B3, C1, C2, and C3, thereby adjusting the inductance and current withstand capability. Please refer to Figure 5. The horizontal axis represents the length of the third lead 13 and the fifth lead 15, in millimeters (mm). The vertical axis represents the inductance, in Nyhrenels (nH). The label A100 on curve L1 represents the inductance of the choke structure in Figure 2, the label A200 on curve L1 represents the inductance of the choke structure in Figure 3, and the label A300 on curve L1 represents the inductance of the choke structure in Figure 4. That is to say, when the length H31 of the third lead 13 and the length H51 of the fifth lead 15 are adjusted to 2mm, the overall inductance is approximately 108nH; when the length H32 of the third lead 13 and the length H52 of the fifth lead 15 are adjusted to 4mm, the overall inductance is approximately 112nH; when the length H33 of the third lead 13 and the length H53 of the fifth lead 15 are adjusted to 8mm, the overall inductance is approximately 124nH.

[0020] In Figure 6, the first lead 11, the second lead 12, the third lead 13, the fourth lead 14, the fifth lead 15, and the sixth lead 16 surround three regions D1, D2, and D3. In Figure 7, the first lead 11, the second lead 12, the third lead 13, the fourth lead 14, the fifth lead 15, and the sixth lead 16 surround three regions E1, E2, and E3. In Figure 8, the first lead 11, the second lead 12, the third lead 13, the fourth lead 14, the fifth lead 15, and the sixth lead 16 surround three regions F1, F2, and F3. Because in Figures 6, 7, and 8, the lengths H1 of the first lead 11, H2 of the second lead 12, H3 of the third lead 13, H5 of the fifth lead 15, and H6 of the sixth lead 16 are the same, but the lengths H41, H42, and H43 of the fourth lead 14 are different, the magnetic flux can be adjusted by adjusting the areas of each region D1, D2, D3, E1, E2, E3, F1, F2, and F3, thereby adjusting the inductance. Please refer to Figures 6, 7, 8, and 9. The horizontal axis represents the area ratio, and the vertical axis represents the inductance, with the unit being Nyhrenheit (nH). Curve L2 shows the relationship between the area ratio and the inductance when the length H3 of the third lead 13 is 2mm and the length H5 of the fifth lead 15 is 2mm, and the lengths H41, H42, and H43 of the fourth lead 14 are adjusted. Curve L3 shows the relationship between the area ratio and the inductance when the length H3 of the third lead 13 is 2mm and the length H5 of the fifth lead 15 is 8mm, and the lengths H41, H42, and H43 of the fourth lead 14 are adjusted. As can be seen from Figure 9, when the area ratio is 0.275, the inductance value is 124nH, which is the optimal solution.

[0021] Furthermore, the choke structure of this invention can be compared with conventional inductors. Please refer to Figure 10, where the horizontal axis represents frequency in Hertz (Hz) and the vertical axis represents AC impedance in milliohms (mΩ). Curve S1 represents a conventional inductor, and curve M1 represents the choke structure of this invention. As shown in Figure 10, at the same frequency (i.e., the same DC impedance), the choke structure of this invention has a lower AC impedance compared to conventional inductors. Please refer to Figure 11, where the horizontal axis represents permeability and the vertical axis represents inductance in Nyhrenels (nH). Curve S2 represents a conventional inductor, and curve M2 represents the choke structure of this invention. As shown in Figure 11, at the same permeability, the choke structure of this invention increases the inductance by 16% to 20% compared to conventional inductors. Please refer to Figure 12. The horizontal axis represents the DC bias voltage in volts (V), and the vertical axis represents the inductance in Nyhrenels (nH). Curve S3 represents the inductor of the prior art, and curve M3 represents the choke structure of this invention. As can be seen from Figure 12, under similar DC impedance, the choke structure of this invention provides higher inductance and current withstand capability.

[0022] Please refer to Figure 13, the choke structure of this case can be further expanded.

[0023] Please refer to Figures 1 and 14 at the same time. The first lead 11 in Figure 1 and the first lead 11a in Figure 14 are arranged with their extension direction facing outward or inward, which can be adjusted according to actual needs.

[0024] The inductance can be adjusted by changing the lengths H31, H32, and H33 of the third lead 13 and the lengths H51, H52, and H53 of the fifth lead 15. Furthermore, the first lead 11, the second lead 12, the third lead 13, the fourth lead 14, the fifth lead 15, and the sixth lead 16 surround a plurality of regions, and the magnetic flux can be adjusted by adjusting the area of ​​each region, thereby adjusting the inductance.

[0025] The above discussion is merely a preferred embodiment of the present invention and is not intended to limit the scope of the present invention. Therefore, any equivalent modifications, combinations, substitutions, or modifications made without departing from the spirit and scope of the present invention should be covered within the scope of the patent application of the present invention.

[0026] 1: Coil 11: First Lead 11a: First lead 12: Second lead 13: Third lead 14: Fourth lead 15: Fifth Lead 16: Sixth lead 17: Seventh Lead 2: Main Body 21: Outer side X: First axis Y: Second axis H1: Length H2: Length H3: Length H4: Length H41: Length H42: Length H43: Length H5: Length H51: Length H52: Length H53: Length A1: Area A2: Area A3: Area B1: Area B2: Area B3: Area C1: Area C2: Area C3: Area D1: Area D2: Area D3:Area E1: Area E2: Area E3: Area F1: Area F2: Area F3: Area L1: Curve L2: Curve L3: Curve S1: Curve S2: Curve S3: Curve M1: Curve M2: Curve M3: Curve

Claims

1. A choke coil configuration comprising: a coil defining a first axis and a second axis perpendicular to each other, the coil including a plurality of first leads along the first axis, a plurality of second leads along the second axis, a plurality of third leads along the first axis, a plurality of fourth leads along the second axis, a plurality of fifth leads along the first axis, a plurality of sixth leads along the second axis, and a seventh lead along the first axis, the first leads connecting to the second leads, the second leads connecting to the third leads, the third leads connecting to the fourth leads, the fourth leads connecting to the fifth leads, the fifth leads connecting to the sixth leads, and the sixth leads connecting to the seventh lead; and a body comprising a magnetic material, the body being formed around the coil, and the plurality of first leads being disposed on an outer side of the body.

2. The choke construction as described in claim 1, wherein the length of the plurality of first leads is less than the length of the plurality of third leads.

3. The choke structure as described in claim 1, wherein the plurality of first leads are arranged with their extension direction facing outward or inward.

4. The choke construction as described in claim 1, wherein the length of the plurality of second leads is greater than the length of the plurality of fourth leads.

5. The choke structure as described in claim 1, wherein the magnetic material is at least one of or a combination of carbonyl iron powder (CIP), alloy iron powder, amorphous powder, nanocrystalline material, or sintered magnetic material.

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