Nonlinear inductor and manufacturing method thereof, nonlinear inductor array

Abstract

The application provides a nonlinear inductor, a manufacturing method thereof and a nonlinear inductor array. The nonlinear inductor comprises two magnetic core assemblies, a conductor and a magnetic plastic sealing layer. The magnetic core assembly comprises a magnetic core, the magnetic core comprises a blade and a column arranged on the blade, two columns of the two magnetic core assemblies are oppositely arranged, and the two columns have non-uniform air gaps therebetween and / or the magnetic core assemblies are made of different materials. The conductor is arranged on the two columns, the two magnetic core assemblies and the conductor are located in the magnetic plastic sealing layer, an electrode part of the conductor is exposed outside the magnetic plastic sealing layer, the magnetic core assemblies and the magnetic plastic sealing layer are made of different materials, and thus the nonlinear inductor has a stepped saturation characteristic.

Description

Technical Field

[0001] This invention relates to inductors, and more particularly to a nonlinear inductor, its manufacturing method, and a nonlinear inductor array. Background Technology

[0002] In switching power converters, to improve circuit stability under light load conditions, the power inductor needs to have a sufficiently large inductance to allow the circuit to operate in continuous or critical mode when the light load current is small. Simultaneously, under heavy load current conditions, a sharp drop in inductance must be avoided. To meet this requirement, a nonlinear inductor is used. This inductor needs to have a large inductance under light load conditions, and the inductance decreases as the current increases. With a given inductor volume, the required inductance can be met across the entire load range from light to heavy load.

[0003] With existing nonlinear inductors, given a certain inductance volume, a larger inductance value requires more coil turns, resulting in a smaller wire diameter, higher resistance, lower temperature rise current, and lower saturation current. While an inductor with a low saturation current can achieve a high inductance value under light loads, its inductance will decrease or even fail under heavy loads with large currents. Furthermore, a low temperature rise current prevents the inductor from operating under high currents.

[0004] The above background information is provided only to aid in understanding the inventive concept and technical solution of this invention. It does not necessarily belong to the prior art of this patent application. In the absence of clear evidence that the above information was disclosed before the filing date of this patent application, the above background information should not be used to evaluate the novelty and inventiveness of this application. Summary of the Invention

[0005] The main objective of this invention is to overcome the deficiencies of the aforementioned background technology and provide a nonlinear inductor and its manufacturing method, as well as a nonlinear inductor array, which optimizes saturation characteristics and initial inductance.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] A nonlinear inductor includes two magnetic core assemblies, a conductor, and a magnetic encapsulation layer. Each magnetic core assembly includes a magnetic core, which includes blades and a central post disposed on the blades. The two central posts of the two magnetic core assemblies are disposed opposite each other, with a non-uniform air gap between them, and / or the magnetic core assemblies are made of different materials. The conductor is disposed on the two central posts. Both the two magnetic core assemblies and the conductor are located within the magnetic encapsulation layer, with the electrode portion of the conductor exposed outside the magnetic encapsulation layer. The magnetic core assemblies and the magnetic encapsulation layer are made of different materials, thereby giving the nonlinear inductor a stepped saturation characteristic.

[0008] Preferably, the magnetic core assembly further includes a boss disposed on the central column, and steps are provided between the blade and the central column, as well as between the boss and the central column.

[0009] Preferably, the magnetic core assembly further includes a magnetic rod, the magnetic core having a groove, the magnetic rod being fixed within the groove, and the magnetic rod being made of a different material than the magnetic core.

[0010] Preferably, the magnetic core assembly further includes a T-shaped magnetic sheet, the magnetic core has a T-shaped groove, the shape of the T-shaped groove matches the T-shaped groove, the T-shaped groove passes through the central column and the blade, the T-shaped magnetic sheet is fixed in the T-shaped groove, and the T-shaped magnetic sheet is made of a different material than the magnetic core.

[0011] Preferably, the conductor is a hollow coil, which includes a coil body and electrode portions respectively disposed at both ends of the coil body, and the coil body is fixed on the central column of the two magnetic cores.

[0012] Preferably, the conductor is a metal terminal, comprising a base, two bent portions connected to the base, two electrode portions respectively connected to the two bent portions, and two widened portions connected to the base; each of the two bent portions extends downward from opposite sides of the base; each of the two electrode portions is correspondingly disposed at one end of the two bent portions away from the base; each of the two widened portions extends outward from the other opposite sides of the base and is flush with the base; a terminal hole is also provided in the central region of the base; the top of the blade has a blade groove for matching the widened portions, and the bottom of the blade has an electrode groove for placing the electrode portions.

[0013] Preferably, the widened portion is further provided with a first locking portion on both sides, and the blade groove is provided with a second locking portion on both sides to cooperate with the first locking portion. One of the first locking portion and the second locking portion is a slot and the other is a protrusion. The metal terminal and the magnetic core are fixed by the cooperation of the first locking portion and the second locking portion.

[0014] Preferably, the metal terminal is integrally formed from a copper plate through stamping, electroplating, cutting, and bending.

[0015] A method for manufacturing a nonlinear inductor includes the following steps: S1, assembling two magnetic core assemblies and a conductor to form an assembly; S2, using a molding process to cover the assembly with a magnetic material, exposing the electrode portion of the conductor; S3, under a preset molding pressure and a preset baking temperature, curing the magnetic material to form a magnetic encapsulation layer, thereby covering the two magnetic core assemblies and the portion of the conductor other than the electrode portion in the magnetic encapsulation layer, while the electrode portion of the conductor is exposed outside the magnetic encapsulation layer.

[0016] A nonlinear inductor array, composed of the aforementioned nonlinear inductors.

[0017] The present invention has the following beneficial effects:

[0018] The nonlinear inductor provided by this invention employs a core assembly with a central column having a non-uniform air gap and / or a core assembly made of different materials, thereby giving the nonlinear inductor a stepped saturation characteristic (or multi-segment saturation characteristic). For a core assembly with a central column having a non-uniform air gap, the stepped saturation characteristic means that as the current increases, areas with smaller air gaps saturate first. After reaching a certain inductance, as the current continues to increase, areas with larger air gaps gradually begin to reach saturation, forming a stepped saturation characteristic. For a core assembly made of different materials, the stepped saturation characteristic means that, based on the difference in saturation magnetic induction intensity of different materials, as the current increases, materials with smaller saturation magnetic induction intensity saturate first, and then materials with larger saturation magnetic induction intensity gradually reach saturation as the current increases, thus forming a stepped saturation characteristic where one material saturates first and then the other materials gradually saturate. The advantage of this invention is that, while maintaining the same inductance as conventional components, the component retains a certain amount of inductance under high current, meaning the invention optimizes saturation characteristics. Furthermore, while maintaining the same inductance as conventional components under high current, the initial inductance of this invention is higher to a certain extent, indicating optimized initial inductance. Therefore, compared to existing nonlinear inductors of the same volume, the nonlinear inductor of this invention has a higher initial inductance, lower resistance, larger saturation current, and larger temperature rise current, while being smaller in size than existing nonlinear inductors with equivalent inductance characteristics. Attached Figure Description

[0019] Figure 1a This is a schematic diagram of the structure of the magnetic core assembly 120 in Embodiment 1 of the present invention;

[0020] Figure 1b This is a schematic diagram of the structure of the hollow coil 110 in Embodiment 1 of the present invention;

[0021] Figure 1cThis is a schematic diagram of the assembly process of the nonlinear inductor 100 in Embodiment 1 of the present invention;

[0022] Figure 1d This is a schematic diagram comparing the saturation characteristic curve of the nonlinear inductor 100 in Embodiment 1 of the present invention with the saturation characteristic curves of a uniform air gap inductor and an alloy inductor.

[0023] Figure 1e This is a schematic diagram comparing another saturation characteristic curve of the nonlinear inductor 100 in Embodiment 1 of the present invention with the saturation characteristic curves of the uniform air gap inductor and the alloy inductor.

[0024] Figures 2a-2b This is a schematic diagram of the structure of the magnetic core 220 in Embodiment 2 of the present invention;

[0025] Figure 2c This is a schematic diagram of the structure of the magnetic rod 230 in Embodiment 2 of the present invention;

[0026] Figure 2d This is a schematic diagram of the structure of terminal 210 in Embodiment 2 of the present invention;

[0027] Figure 2e This is a schematic diagram of the assembly process of the nonlinear inductor 200 in Embodiment 2 of the present invention;

[0028] Figure 2f This is a schematic diagram of the nonlinear inductor 200 from another perspective in Embodiment 2 of the present invention;

[0029] Figures 3a-3b This is a schematic diagram of the structure of the magnetic core 320 in Embodiment 3 of the present invention;

[0030] Figure 3c This is a schematic diagram of the structure of the T-shaped magnetic sheet 330 in Embodiment 3 of the present invention;

[0031] Figure 3d This is a schematic diagram of the process of assembling the T-shaped magnetic sheet 330 and the magnetic core 320 into a magnetic core assembly 350 in Embodiment 3 of the present invention;

[0032] Figure 3e This is a schematic diagram of the structure of terminal 310 in Embodiment 3 of the present invention;

[0033] Figure 3f This is a schematic diagram of the assembly process of the nonlinear inductor 300 in Embodiment 3 of the present invention;

[0034] Figure 3g This is a schematic diagram of the nonlinear inductor 300 from another perspective in Embodiment 3 of the present invention;

[0035] Figure 4a This is a schematic diagram of the structure of terminal 410 in Embodiment 4 of the present invention;

[0036] Figures 4b-4c This is a schematic diagram of the structure of the magnetic core assembly 420 in Embodiment 4 of the present invention;

[0037] Figure 4d This is a schematic diagram of the assembly process of the nonlinear inductor bus 400 in Embodiment 4 of the present invention;

[0038] Figure 4e This is a schematic diagram of the nonlinear inductor array 400 from another perspective in Embodiment 4 of the present invention;

[0039] Figures 5a-5b This is a schematic diagram of the structure of the magnetic core 510 in Embodiment 5 of the present invention;

[0040] Figure 5c This is a schematic diagram of the structure of the T-shaped magnetic sheet 520 in Embodiment 5 of the present invention;

[0041] Figure 5d This is an assembly flowchart of the T-shaped magnetic sheet 520 and magnetic core 510 in Embodiment 5 of the present invention;

[0042] Figure 5e This is a schematic diagram of the assembly process of the nonlinear inductor array 500 in Embodiment 5 of the present invention. Detailed Implementation

[0043] The embodiments of the present invention will be described in detail below. It should be emphasized that the following description is merely exemplary and not intended to limit the scope and application of the present invention.

[0044] It should be noted that when a component is referred to as "fixed to" or "set on" another component, it can be directly on or indirectly on that other component. When a component is referred to as "connected to" another component, it can be directly connected to or indirectly connected to that other component. Furthermore, a connection can be used for fixing, coupling, or communication.

[0045] It should be understood that the terms "length", "width", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the embodiments of the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention.

[0046] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of embodiments of the present invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0047] This invention provides a nonlinear inductor comprising two magnetic core assemblies, a conductor, and a magnetic encapsulation layer. Each magnetic core assembly includes a magnetic core, which comprises blades and a central post disposed on the blades. The two central posts of the two magnetic core assemblies are disposed opposite each other, with a non-uniform air gap between them, and / or the magnetic core assemblies are made of different materials. The conductor is disposed on the two central posts. Both the two magnetic core assemblies and the conductor are located within the magnetic encapsulation layer, with the electrode portion of the conductor exposed outside the magnetic encapsulation layer. The magnetic core assemblies and the magnetic encapsulation layer are made of different materials, thereby giving the nonlinear inductor a stepped saturation characteristic. "A non-uniform air gap between the two central posts and / or the magnetic core assemblies are made of different materials" means that when there is a non-uniform air gap between the two central posts, the magnetic core assemblies can be made of one material or different materials; when the magnetic core assemblies are made of different materials, there can be a non-uniform air gap, a uniform air gap, or no air gap between the two central posts. This invention also provides a method for manufacturing a nonlinear inductor, comprising the following steps:

[0048] S1. Assemble two magnetic core assemblies and one conductor to form an assembly;

[0049] S2. The assembly is coated with magnetic material using a molding process, exposing the electrode portion of the conductor;

[0050] S3. Under a preset molding pressure and a preset baking temperature, the magnetic material is cured to form a magnetic encapsulation layer, thereby covering the two magnetic core assemblies and the conductor except for the electrode portion in the magnetic encapsulation layer, while the electrode portion of the conductor is exposed outside the magnetic encapsulation layer.

[0051] In a preferred example, the molding pressure is 0 to 100 MPa.

[0052] This invention also provides a nonlinear inductor array, which is composed of the aforementioned nonlinear inductors.

[0053] The present invention will be described in detail below through some embodiments.

[0054] Example 1

[0055] like Figures 1a-1eAs shown, the nonlinear inductor includes two magnetic core assemblies 120, a conductor, and a magnetic encapsulation layer 130.

[0056] like Figure 1a The diagram shows a schematic of the magnetic core assembly 120. The magnetic core assembly 120 includes a magnetic core and a boss 122. The magnetic core includes blades 123 and a central post 121. The central post 121 is disposed on the blades 123, and the boss 122 is disposed on the central post 121. Steps are provided between the blades 123 and the central post 121, and between the boss 122 and the central post 121. That is, the size of the blades 123 is larger than the size of the central post 121, and the size of the central post 121 is larger than the size of the boss 122. In this example, it is preferred that the central post 121 is disposed in the central region of the blades 123, and the boss 122 is disposed in the central region of the central post 121. In this example, there is one boss 122, but the invention is not limited to this. In other variations, the number of bosses 122 can be set to more than one according to actual needs. In this example, the magnetic core assembly is integrally formed from the same material, for example, by sintering ferrite, but the material is not limited to ferrite.

[0057] like Figure 1b As shown, the conductor is a hollow coil, which includes a coil body 113 and electrode portions 112 respectively disposed at both ends of the coil body 113. In this example, the hollow coil 110 is made by winding enameled copper flat wire on a jig with a central column size that is equivalent to that of the magnetic core to be matched (of course, enameled copper flat wire can also be directly wound on the central column of the magnetic core). The hollow coil 110 has only one layer, with the coils on both sides tightly attached and a gap 111 left in the middle for the plastic sealant to be injected into the air gap of the central column of the magnetic core during subsequent plastic sealing.

[0058] like Figure 1cThe diagram shows the assembly process of the nonlinear inductor 100. After the central pillars of the two magnetic core assemblies 120 are positioned opposite each other (i.e., face-to-face), the conductor is assembled onto the central pillar 121 of the magnetic core assembly 120. For example, epoxy resin can be used to fix the relative positions of the hollow coil 110 and the magnetic core assembly 120, forming an assembly 140. The mating gap between the hollow coil 110 and the central pillar 121 is 20–150 μm to facilitate automated assembly. Then, the assembly 140 is transferred to an injection mold and subjected to compression molding (in this example, injection molding) to remove the conductor. The electrode portion 112 of the hollow coil 110 is encased in a magnetic material (i.e., except for the electrode portion 112 of the hollow coil 110, the magnetic material powder fills all gaps in the assembly and covers the outer surface of the assembly). In this example, the magnetic powder contained in the magnetic material is passivated and insulated FeSiCr metal soft magnetic powder, the molding pressure is 30 MPa, and the permeability μi is 20-35. After demolding, a molded semi-finished product is obtained. Then, the molded semi-finished product is baked at 100°C or above for 4 hours to solidify the organic components of the magnetic material and form a magnetic encapsulation layer 130 covering the assembly. Since the inductor in this example uses hollow coil leads as the electrode portion 112, the electrode portion 112 also needs to undergo a deenamel coating process, followed by electrode metallization, to finally obtain a nonlinear inductor 100.

[0059] This example yields a single-phase stepped saturated molded inductor. The dual-core assembly is used in conjunction, with a non-uniform air gap formed between the central pillars. When the two core assemblies 120 are used together, the initial inductance and initial saturation characteristics of the nonlinear inductor can be controlled by adjusting the height of the bosses 122 and / or the spacing between the two bosses 122; the inductance after initial saturation and the secondary saturation characteristics can be controlled by adjusting the spacing between the central pillars 121 of the two cores.

[0060] This example utilizes the uneven distribution of the air gap between the two magnetic core assemblies to control the initial inductance and the inductance after applying a saturation current. For example... Figure 1d The figure shows a comparison of the saturation characteristic curves of a nonlinear inductor 100 (still having a stepped air gap) with a portion of the core's central column without an air gap, and the saturation characteristic curves of a uniform air gap inductor (e.g., an assembled inductor with a uniform air gap) and an alloy inductor (e.g., a toroidal inductor, an NR inductor, etc.). Figure 1e The figure shows a comparison of the saturation characteristic curves of a nonlinear inductor 100 (with a stepped air gap) with the saturation characteristic curves of a uniformly air-gap inductor (e.g., an assembled inductor with a uniform air gap) and an alloy inductor (e.g., a toroidal inductor, an NR inductor, etc.) when the central column of the magnetic core has all the air gaps open. Figure 1dIn this example, because the magnetic saturation induction intensity (Bs) of the core assembly material (ferrite) is smaller than that of the magnetic encapsulation layer material, the ferrite core assembly saturates preferentially as the current increases, while the magnetic encapsulation layer located in the air gap begins to exhibit soft saturation characteristics as the current continues to increase. Figure 1e In the process, the magnetic encapsulation layer located in the smaller air gap initially exhibits soft saturation characteristics, while the magnetic encapsulation layer located in the larger air gap begins to exhibit soft saturation characteristics as the current increases. Regardless of... Figure 1d and Figure 1e Compared with inductors with uniform air gaps, it has better saturation characteristics under high current.

[0061] Example 2

[0062] like Figures 2a-2f As shown, the nonlinear inductor includes two magnetic core assemblies, a conductor, and a magnetic encapsulation layer 240, wherein the magnetic core assemblies include a magnetic core 220 and a magnetic rod 230.

[0063] like Figures 2a-2b The diagram shows a schematic of the magnetic core 220. The magnetic core 220 includes blades 223, a central post 221, and a groove 222. The central post 221 is disposed on the blades 223. The groove is provided to fix the magnetic rod. The depth of the groove is not limited. In this example, the groove 222 penetrates the surface of the central post away from the blade but does not penetrate the blade itself. However, this is not a limitation; in other examples, the groove 222 may penetrate the blade. Figure 2c The diagram shows the structure of the magnetic rod 230. When it mates with the magnetic core 220, one end of the magnetic rod 230 is fixed in the groove 222 (for example, the magnetic rod 230 and the groove 222 are fixedly assembled with epoxy resin). The magnetic rod 230 and the magnetic core 220 are made of different materials. For example, the magnetic core 220 is integrally formed and can be sintered from ferrite, but the material is not limited to ferrite. The material of the magnetic rod 230 can be iron-nickel or nanocrystalline material, but it is not limited to these, as long as the materials of the magnetic rod 230 and the magnetic core 220 are different. In this example, the groove 222 is located in the central region of the central column 221, but the invention is not limited to this. Depending on the actual needs, the position of the groove can be in other positions of the central column 221. Similarly, in this example, there is one groove 222, but the invention is not limited to this. In other variations, the number of grooves 222 can be set to more than one according to actual needs. Correspondingly, each groove needs to mate with one magnetic rod. In this example, the magnetic rod is cube-shaped, matching the shape of the groove. However, the invention is not limited to this; in other variations, the magnetic rod can be other shapes, or it may not need to match the shape of the groove as long as it can be fixed in the groove. In this example, see [reference needed]. Figure 2a and 2bThe top of the blade 223 also has a blade groove 224 for matching the two widened portions 213 of the terminal 210, and the bottom of the blade also has an electrode groove 225 for placing the two electrode portions 211 of the terminal 210.

[0064] like Figure 2d The diagram shows a schematic of the terminal 210. The terminal 210 includes a base 214, two bent portions 215 connected to the base 214, two electrode portions 211 connected to the two bent portions 215 respectively, and two widened portions 213 connected to the base 214. Each of the two bent portions 215 extends downwards from opposite sides of the base 214. Each of the two electrode portions 211 is correspondingly disposed at one end of each bent portion 215 away from the base 214. Each of the two widened portions 213 extends outwards from the other opposite sides of the base 214 and is flush with the base 214. A terminal hole 212 is also provided in the central region of the base 214. The terminal hole 212 corresponds to the air gap between the central pillars of the two magnetic cores, ensuring that the molding compound can fill the air gap between the central pillars of the two magnetic cores during molding. The widened portions 213 can compensate for the reduction in terminal cross-sectional area and increase in resistance caused by the terminal hole 212. The terminals are integrally formed from copper plates through stamping, electroplating, cutting, and bending.

[0065] like Figure 2e The diagram shows the assembly process of the nonlinear inductor 200. A magnetic rod 223 is assembled into the groove 222 of the magnetic core 220 (for example, the magnetic core 220 and the magnetic rod 230 can be fixed using epoxy resin). The central pillars of the two magnetic cores 220 are positioned opposite each other, and the terminal 210 is assembled onto the central pillar 221 of the magnetic core 220 to form an assembly 250. The assembly 250 is then transferred to an injection mold, and an injection molding process is used to encapsulate the assembly 250, except for the electrode portion 211 of the terminal 210, within a magnetic material. In this example, the magnetic powder contained in the magnetic material is passivated and insulated FeSiCr soft magnetic powder, the molding pressure is 30 MPa, and the permeability μi is 20–35. After demolding, a molded semi-finished product is obtained. This semi-finished product is then baked at 100°C or higher for 4 hours to solidify the organic components of the magnetic material, forming a magnetic encapsulation layer 240 covering the assembly, ultimately resulting in the nonlinear inductor 200. like Figure 2f The diagram shown is a structural schematic of the nonlinear inductor 200 from another perspective, showing that the electrode portion 211 is located outside the magnetic encapsulation layer 240, while the other portions are encapsulated within the magnetic encapsulation layer 240.

[0066] This example yields a single-phase stepped saturated molded inductor. Compared to Example 1, since the hollow coil 110 is replaced by terminal 210, the processes of removing the enameling film and metallizing the electrodes can be eliminated. In Example 1, the entire core assembly is made of ferrite material, resulting in poor initial saturation characteristics. In Example 2, a magnetic rod made of iron-nickel or nanocrystalline material is used in conjunction with the core to form the core assembly, which can improve the initial saturation characteristics. The initial inductance and initial saturation characteristics of the inductor can be adjusted by adjusting the cross-sectional area of ​​the magnetic rod 230; the initial saturation inductance and secondary saturation characteristics of the inductor can also be adjusted by adjusting the air gap between the columns of the two cores 220.

[0067] In Example 2, by adding a magnetic rod made of a different material than the magnetic core to the central column of the magnetic core, a stepped saturation characteristic is formed (one material reaches saturation first, and then another material reaches saturation; in this example, the magnetic core encapsulation layer between the magnetic cores saturates first, and then the magnetic rod saturates). This improves the saturation characteristic of the inductance itself while increasing the initial inductance.

[0068] Example 3

[0069] In Embodiment 2, the assembly between the magnetic core 220 and the magnetic rod 230 is used to fix the relative position of the terminal 210 with the magnetic core 220 and the magnetic rod 230, which is difficult to implement in automated assembly. Embodiment 3 replaces the magnetic rod 230 with a T-shaped magnetic sheet 330. After assembling the T-shaped magnetic sheet 330 with the magnetic core 320 to form a magnetic core assembly 350, the magnetic core assembly 350 is then assembled with the terminal. This makes automated assembly much easier to achieve. Figures 3a-3g As shown, the nonlinear inductor includes two magnetic core assemblies 350, a conductor, and a magnetic encapsulation layer 340, wherein the magnetic core assembly 350 includes a magnetic core 320 and a T-shaped magnetic sheet 330.

[0070] like Figures 3a-3b The diagram shows the structure of the magnetic core 320. The magnetic core 320 includes blades 323, a central post 322, and a T-shaped groove 321. The central post 322 is disposed on the blades 323, and the T-shaped groove 322 passes through the central post 322 and the blades 323. Figure 3c The diagram shown is a structural schematic of the T-shaped magnetic sheet 330. Figure 3dThe diagram shows a flow chart of the assembly of the T-shaped magnetic sheet 330 and the magnetic core 320 into a magnetic core assembly 350. When the T-shaped magnetic sheet 330 and the magnetic core 320 are engaged, the T-shaped magnetic sheet 330 is fixed in the T-shaped groove 321 (for example, the T-shaped magnetic sheet 330 and the T-shaped groove 321 can be fixedly assembled using epoxy resin). In this example, the magnetic post 331 of the T-shaped magnetic sheet 330 protrudes from the central post 322, but this is not the only example. In other examples, the magnetic post 331 of the T-shaped magnetic sheet 330 can also be flush with or lower than the plane of the central post. The T-shaped magnetic sheet 330 and the magnetic core 320 are made of different materials. For example, the magnetic core 320 is integrally formed and can be sintered from ferrite, but the material is not limited to ferrite. The material of the T-shaped magnetic sheet 330 can be iron-nickel or nanocrystalline material, but this is not the only requirement, as long as the materials of the T-shaped magnetic sheet 330 and the magnetic core 320 are different. In this example, the T-shaped groove 321 is located in the central area of ​​the central post 322. However, the invention is not limited to this. Depending on actual needs, the position of the T-shaped groove 321 can be in other positions of the central post 322. Similarly, in this example, the number of T-shaped grooves 321 is one. However, the invention is not limited to this. In other variations, the number of T-shaped grooves 321 can be set to more than one depending on actual needs. Correspondingly, each T-shaped groove 321 needs to be matched with a T-shaped magnet. Preferably, in this example, see [reference needed]. Figure 3a and Figure 3b The top of the blade 323 also has a blade groove 324 for mates with the two widened portions 313 of the terminal 310, and the bottom of the blade also has an electrode groove 326 for placing the two electrode portions 311 of the terminal 310. Of course, in other examples, blade grooves and electrode grooves of different shapes can be used, or blade grooves and / or electrode grooves can be omitted, depending on the structure of the conductor.

[0071] like Figure 3fThe diagram shows a schematic of the terminal 310. The terminal 310 includes a base 316, two bent portions 315 connected to the base 316, two electrode portions 311 connected to the two bent portions 315 respectively, and two widened portions 313 connected to the base 316. Each of the two bent portions 315 extends downwards from opposite sides of the base 316. Each of the two electrode portions 311 is correspondingly disposed at one end of each bent portion 315 away from the base 316. Each of the two widened portions 313 extends outwards from the other opposite sides of the base 316 and is flush with the base 316. A terminal hole 312 is also provided in the central region of the base 316. The terminal hole 312 corresponds to the air gap between the central pillars of the two magnetic cores, ensuring that the molding compound can fill the air gap between the central pillars of the two magnetic cores during molding. The widened portions 313 can compensate for the reduction in terminal cross-sectional area and increase in resistance caused by the terminal hole 312. The terminal is integrally formed from a copper plate through stamping, electroplating, cutting, and bending. Compared with the terminal 210 in Embodiment 2, the two widened portions 313 of the terminal 310 in this example are provided with first locking portions on both sides. In this example, the first locking portions are locking grooves 314, and there are a total of 4, but this is not a limitation. Correspondingly, second locking portions that cooperate with the first locking portions are provided on both sides of the blade groove 324 at the top of the blade 323. In this example, the second locking portions are protrusions 325.

[0072] like Figure 3f The diagram shows the assembly process of the nonlinear inductor 300. The T-shaped magnetic sheet 330 is assembled into the T-shaped groove 321 of the magnetic core 320. The central posts of the two magnetic cores 320 are positioned opposite each other. The terminal 310 is assembled onto the central post 322 of the magnetic core 320, forming an assembly 350 (in this example, the terminal 310 and the magnetic core 320 are fixed by the engaging of the slot 314 and the protrusion 325). Then, the assembly 350 is transferred to an injection mold, and the assembly 350, except for the electrode portion of the terminal 310, is molded using an injection molding process. 311 is encapsulated within a magnetic material. In this example, the magnetic powder contained in the magnetic material is passivated and insulated FeSiCr soft magnetic powder. The molding pressure is 30 MPa, and the permeability μi is 20–35. After demolding, a molded semi-finished product is obtained. This semi-finished product is then baked at 100°C or higher for 4 hours to solidify the organic components of the magnetic material, forming a magnetic encapsulation layer 340 of the encapsulated assembly. Finally, a nonlinear inductor 300 is obtained. In this example, a single-phase stepped saturated molded inductor is obtained. For example... Figure 3g The diagram shown is a structural schematic of the nonlinear inductor 300 from another perspective, showing that the electrode portion 311 is located outside the magnetic encapsulation layer 340, while the other portions are encapsulated within the magnetic encapsulation layer 340.

[0073] In the above embodiments 1-3, the two magnetic core assemblies in each embodiment have the same size and structure, but are not limited thereto. In other examples, the nonlinear inductor 3 can also use magnetic core assemblies with different structures and / or sizes. For example, after a magnetic core assembly in embodiment 2 is combined with a magnetic core assembly in embodiment 1 or embodiment 3, it is then combined with a terminal or hollow coil to form a nonlinear inductor, which also has stepped saturation characteristics.

[0074] As variations of the above embodiments 1-3, in other examples, the magnetic core assembly 120 of embodiment 1 can be combined with the terminal 210 in embodiment 2 or the terminal 310 in embodiment 3 to form a nonlinear inductor; the hollow coil 110 of embodiment 1 can be combined with the magnetic core 220 and magnetic rod 230 of embodiment 2 to form a magnetic core assembly, or combined with the magnetic core assembly 350 of embodiment 3 to form a nonlinear inductor; similarly, the terminal 210 of embodiment 2 can be combined with the magnetic core assembly 350 of embodiment 3 to form a nonlinear inductor; the magnetic core assembly formed by the magnetic core 220 and magnetic rod 230 of embodiment 2 can also be combined with the terminal 310 of embodiment 3 to form a nonlinear inductor.

[0075] Example 4

[0076] Example 4 is a nonlinear inductor array, which is a multiphase stepped saturated molded inductor. For example... Figures 4a-4e As shown, the nonlinear inductor includes three terminals 410, two magnetic core assemblies 420, and a magnetic encapsulation layer 430.

[0077] like Figure 4a The diagram shows a schematic of terminal 410. The structure of terminal 410 is similar to that of terminal 310; therefore, the structure of terminal 410 is briefly described as follows: Terminal 410 is integrally formed from a copper plate through stamping, electroplating, cutting, and bending. Terminal 410 includes an electrode portion 411, a terminal hole 412, and a widened portion 413. During molding, the terminal hole 412 ensures that the molding compound can fill the air gap between the central pillars of the two magnetic core assemblies 420. The widened portion 413 compensates for the reduced cross-sectional area and increased resistance caused by the terminal hole 412. The widened portion 413 has slots 414 on both sides for fixing the terminal 410 to the magnetic core assembly 420 during assembly.

[0078] like Figure 4b and 4cThe diagram shows a schematic of the core assembly 420. The core assembly 420 uses a ferrite sintered core. In this example, the core assembly 420 consists of three core assembly units. The structure of each core assembly unit is similar to that in Example 1. When assembled into a nonlinear inductor array, each core assembly unit is equipped with a terminal or a hollow coil. In this example, the core assembly 420 has three central pillars 426 and three bosses 421. The top of the blade 422 is provided with a blade groove 423 for matching the widened portions 413 on both sides of the top of the terminal. The blade groove 423 is provided with protrusions 424 on both sides for fixing the position when assembled with the terminal 410. The bottom of the blade 422 is provided with an electrode groove 425 for placing the electrode portion 411 of the terminal.

[0079] like Figure 4d The diagram shows the assembly process of the nonlinear inductor array 400. Three terminals 410 and two magnetic core assemblies 420 are fixed together using a snap-fit ​​method to form an assembly 440. Using injection molding, the assembly 440, except for the electrode portion 411 of the terminals 410, is encapsulated within a magnetic encapsulation layer 430. After demolding and baking, the nonlinear inductor array 400 is finally obtained. Figure 4e The diagram shown is a structural schematic of the nonlinear inductor array 400 from another perspective, showing that the electrode portion 411 is located outside the magnetic encapsulation layer 430, while the other portions are encapsulated within the magnetic encapsulation layer 430.

[0080] Example 5

[0081] Example 5 is a nonlinear inductor array, which is a multiphase stepped saturated molded inductor. For example... Figures 5a-5e As shown, the nonlinear inductor array includes two magnetic core assemblies 540, three terminals 410 as in Embodiment 4, and a magnetic encapsulation layer 530. The magnetic core assembly 540 includes a magnetic core 510 and a T-shaped magnetic sheet 520.

[0082] like Figures 5a-5b The diagram shows the structure of the magnetic core 510. The magnetic core 510 is made of ferrite sintering and is similar to the magnetic core 320 in Example 3. The magnetic core 510 has multi-phase T-shaped grooves 511, which penetrate the central pillars 512 (there are at least two central pillars 512, three in this example). Figure 5c The diagram shows the structure of the T-shaped magnetic sheet 520. The T-shaped magnetic sheet 520 is composed of three T-shaped magnetic sheet units. The structure of each T-shaped magnetic sheet unit is the same as that of the T-shaped magnetic sheet 330 in Embodiment 3. The T-shaped magnetic sheet 520 is inserted into and fixed in the multi-phase T-shaped groove 511, and the magnetic post 521 protrudes from the central post 512. The number of central posts 512 is the same as the number of magnetic posts 521. In this example, as shown... Figure 5dThe diagram shows the assembly process of the T-shaped magnetic sheet 520 and the magnetic core 510. The T-shaped magnetic sheet 520 and the magnetic core 510 can be assembled together using epoxy adhesive to form a magnetic core assembly 540. (See reference...) Figure 5a The top of the blade 513 of the magnetic core 510 is provided with a blade groove 514 for matching the widened portions 413 on both sides of the top of the terminal. The blade groove 514 is provided with protrusions 515 on both sides for fixing the position when the magnetic core assembly 540 and the terminal 410 are assembled. The bottom of the blade 513 is provided with an electrode groove 516 for placing the electrode portion 411 of the terminal.

[0083] like Figure 5e The diagram shows the assembly process of the nonlinear inductor 500. The T-shaped magnetic sheet 520 and the magnetic core 510 are assembled with epoxy resin to form a magnetic core assembly 540. Then, the two magnetic core assemblies 540 and the three terminals 410 are fixed together by snap-fit ​​to form an assembly 550. The assembly 550, except for the electrode part 411 of the terminal 410, is encapsulated in a magnetic molding layer 530 by injection molding. After demolding and baking, the nonlinear inductor 500 is finally obtained. The electrode part 411 is located outside the magnetic molding layer 530, while the other parts are encapsulated in the magnetic molding layer 530.

[0084] The background section of this invention may include background information about the problems or environment in which the invention is being developed, and is not necessarily a description of prior art. Therefore, the content included in the background section does not constitute an admission of prior art by the applicant.

[0085] The above description provides a further detailed explanation of the present invention in conjunction with specific / preferred embodiments, and it should not be construed that the specific implementation of the present invention is limited to these descriptions. For those skilled in the art, various substitutions or modifications can be made to these described embodiments without departing from the concept of the present invention, and all such substitutions or modifications should be considered within the scope of protection of the present invention. In the description of this specification, the reference to terms such as "an embodiment," "some embodiments," "preferred embodiment," "example," "specific example," or "some examples," etc., indicates that the specific features, structures, materials, or characteristics described in connection with that embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described can be combined in any suitable manner in one or more embodiments or examples. Without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification and the features of different embodiments or examples. Although the embodiments of the present invention and their advantages have been described in detail, it should be understood that various changes, substitutions, and modifications can be made herein without departing from the scope of protection of the patent application.

Claims

1. A non-linear inductor, characterized by, The nonlinear inductor comprises two magnetic core assemblies, a conductor and a magnetic plastic sealing layer, the magnetic core assembly comprises a magnetic core, the magnetic core comprises a blade and a column arranged on the blade, the two columns of the two magnetic core assemblies are oppositely arranged, the two columns have a non-uniform air gap, the conductor is arranged on the two columns, the two magnetic core assemblies and the conductor are located in the magnetic plastic sealing layer, an electrode part of the conductor is exposed outside the magnetic plastic sealing layer, the magnetic core assembly and the magnetic plastic sealing layer are made of different materials, and thus the nonlinear inductor has a stepped saturation characteristic. The stepped saturation characteristic of the magnetic core assembly with the column having the non-uniform air gap refers to that, as the current increases, the place with the small air gap is saturated preferentially, and after a certain inductance is reached, as the current continues to increase, the place with the large air gap gradually reaches a saturation state, thereby forming the stepped saturation characteristic. The magnetic core assembly further comprises a magnetic rod, the magnetic core has a groove, and the magnetic rod is fixed in the groove. Alternatively, the magnetic core assembly further comprises a T-shaped magnetic sheet, the magnetic core has a T-shaped groove, the shape of the T-shaped groove matches that of the T-shaped groove, the T-shaped groove penetrates the column and the blade, and the T-shaped magnetic sheet is fixed in the T-shaped groove.

2. The non-linear inductor of claim 1, wherein, The conductor is a hollow coil, which comprises a coil body and electrode parts arranged at two ends of the coil body respectively, and the coil body is fixed on the columns of the two magnetic cores.

3. The non-linear inductor of claim 1, wherein: The conductor is a metal terminal, which comprises a base, two bent parts connected with the base, two electrode parts connected with the two bent parts respectively, and two widened parts connected with the base; the two bent parts each extend downward from opposite sides of the base; the two electrode parts are each arranged at an end of the two bent parts away from the base; and the two widened parts each extend outward from the other two opposite sides of the base and are flush with the base. A terminal hole is further arranged in a middle region of the base. A blade groove is arranged at a top of the blade for matching the widened part, and an electrode groove is arranged at a bottom of the blade for placing the electrode part.

4. The nonlinear inductor as described in claim 3, characterized in that, First clamping parts are further arranged at two sides of the widened part, second clamping parts matched with the first clamping parts are arranged at two sides of the blade groove, one of the first clamping parts and the second clamping parts is a clamping groove, and the other is a convex point, and the metal terminal and the magnetic core are fixed through the matched clamping of the first clamping parts and the second clamping parts.

5. The nonlinear inductor as described in claim 3, characterized in that, The metal terminal is integrally formed by punching, electroplating, cutting and bending of red copper plate.

6. A method of manufacturing a non-linear inductor as claimed in any one of claims 1 to 5, characterized in that, The method comprises the following steps: S1, assembling two magnetic core assemblies and a conductor to form an assembly; S2, covering the assembly with a magnetic material by using a mold pressing forming process, and exposing an electrode part of the conductor; S3, curing the magnetic material under a preset forming pressure and a preset baking temperature to form a magnetic plastic sealing layer, so as to cover the two magnetic core assemblies and the part of the conductor except the electrode part in the magnetic plastic sealing layer, and expose the electrode part of the conductor outside the magnetic plastic sealing layer.

7. A non-linear inductive array characterized by, The non-linear inductor is formed by the combination of any one of claims 1-5.

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