Second-order inductor and production method thereof

Abstract

The invention relates to the technical field of inductors, and particularly discloses a second-order inductor which comprises a square-core device (10), a T-core device (20), a coil (30) and a magnetic device (40), and the coil (30) and the magnetic device (40) are arranged between the square-core device (10) and the T-core device (20). The square-core piece (10), the T-core piece (20), the coil (30) and the magnetic piece (40) are orderly combined together in a nested and superposed manner; according to the invention, the independent magnetic part is innovatively added between the traditional core part and the T-core part, so that the limitation that the traditional integrally-formed inductor is single in inductance value change curve and difficult to customize is broken through. The magnetic piece serves as a magnetic field regulator, and the magnetic field attenuation rate of the inductor in different current intervals can be accurately controlled by selecting materials (such as saturation flux density and magnetic conductivity) of the magnetic piece. Specifically, a predetermined nonlinear attenuation curve in which the inductance value is reduced by about 30% under a small current and is reduced by about 70% under a large current can be reliably realized.

Description

Technical Field

[0001] This invention relates to the field of inductor technology, and more particularly to a second-order inductor and its manufacturing method. Background Technology

[0002] Molded inductors are widely used in power conversion and filtering circuits of various electronic devices due to their small size, high mechanical strength, and good magnetic shielding. Their basic performance characteristics, such as inductance, DC resistance (DCR), and saturation current, are mainly determined by the characteristics of the magnetic powder used and the molding process. Traditional molded inductors typically aim to maintain a relatively stable inductance within the rated current range, or to achieve a sharp drop in inductance when reaching the saturation point. However, with the increasing complexity and sophistication of circuit designs, certain specific applications (such as multi-mode switching power supplies and dynamic load management) place more complex and customized demands on the inductance-current characteristics of inductors. For example, inductors need moderate inductance decay in the low-current operating range to optimize light-load efficiency, while in the high-current range, the inductance needs to decrease rapidly to prevent deep core saturation and suppress current spikes, thereby achieving a better balance between overall energy efficiency and dynamic response.

[0003] Currently, conventional molded inductors use general-purpose soft magnetic composite materials (such as reduced or alloyed iron-silicon magnetic powder), whose magnetization curves and saturation characteristics are relatively fixed, making it difficult to achieve the aforementioned interval-based, predictable inductance variation curves. If the requirements are partially met by simply adjusting the powder ratio or increasing the product volume, it often sacrifices DCR, size, or cost advantages.

[0004] Therefore, the following problems urgently need to be solved in the existing technology: how to accurately and repeatedly manufacture an inductor without sacrificing the original structural advantages (such as high strength and good shielding) and low DCR of the integrally molded inductor, so that its inductance value can exhibit a differentiated and controllable attenuation rate according to different preset current thresholds (such as small current region and large current region). Summary of the Invention

[0005] The technical problem to be solved by the present invention is to overcome the shortcomings of the prior art and provide a second-order inductor. This inductor breaks with the traditional inductor approach by adding a magnetic component. By adjusting the material of the magnetic component, the magnetic field strength and magnetic field attenuation can be changed. Thus, under the premise of the original structural advantages and low DCR, the inductance value can exhibit a differentiated and controllable attenuation rate according to different preset current thresholds.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A second-order inductor includes: a square-core component and a T-core component, a coil and a magnetic component disposed between the square-core component and the T-core component; the square-core component, the T-core component, the coil and the magnetic component are arranged together in an orderly manner by nesting and superimposing.

[0007] Preferably, the T-core component includes a cover plate and a cylinder disposed on the cover plate.

[0008] Preferably, the magnetic component is a magnetic plate.

[0009] Preferably, the magnetic plate is mounted on the bottom of the square core component.

[0010] Preferably, the magnetic component is a magnetic tube.

[0011] Preferably, the magnetic tube is sleeved on the cylinder of the T-core component and inserted into the coil hole to form a whole.

[0012] Preferably, the magnetic component is a magnetic column.

[0013] Preferably, the magnetic post and the cylinder of the T-core are inserted together into the coil hole to form a single unit.

[0014] Compared with the prior art, this application has the following beneficial effects: This invention overcomes the limitations of traditional one-piece inductors, which suffer from a single inductance value variation curve and difficulty in customization, by innovatively adding an independent magnetic component between the traditional square-core and T-core components. This magnetic component acts as a "magnetic field regulator," and its material (such as saturation magnetic flux density and permeability) allows for precise control of the magnetic field decay rate of the inductor across different current ranges. Specifically, it reliably achieves a predetermined nonlinear decay curve with an inductance value decrease of approximately 30% under low current and approximately 70% under high current. This programmable saturation characteristic allows the inductor to perfectly match the stringent requirements of advanced circuits such as multi-mode power supplies and dynamic load management, optimizing efficiency under light loads and preventing deep saturation under heavy loads, thereby improving the overall system energy efficiency and dynamic performance. Attached Figure Description

[0015] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings of the embodiments will be briefly described below. Obviously, the drawings described below only relate to some embodiments of the present invention and are not intended to limit the present invention.

[0016] Figure 1 This is a schematic diagram of the structure of a first embodiment of a second-order inductor according to the present invention; Figure 2 for Figure 1 A schematic diagram of the structure of the T-core component; Figure 3 This is a schematic diagram of the structure of a second embodiment of a second-order inductor according to the present invention; Figure 4 for Figure 3 Schematic diagram of the combined exploded structure of the magnetic tube and coil; Figure 5 This is a schematic diagram of the third embodiment of a second-order inductor described in this invention; Figure 6 for Figure 5 A schematic diagram of the combined explosion structure of the magnetic column and the coil. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0018] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0019] Unless otherwise defined, the technical or scientific terms used in this patent document shall have the ordinary meaning understood by one of ordinary skill in the art to which this invention pertains. The terms "first," "second," and similar terms used in this patent specification and claims do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Similarly, the terms "an," "a," or "the" do not indicate a quantity limitation, but rather indicate the presence of at least one. The terms "comprising" or "including" indicate that the element or object preceding "comprising" encompasses the element or object listed following "comprising" or its equivalents, and do not exclude other elements or objects. Terms such as "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer" are used only to indicate relative positional relationships. When the absolute position of the described object changes, the relative positional relationship may also change accordingly. These terms are only for the convenience of describing the invention and for 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, and therefore should not be construed as a limitation of the invention.

[0020] The following detailed description of some embodiments of the present invention is provided in conjunction with the accompanying drawings. Unless otherwise specified, features in the following embodiments can be combined with each other.

[0021] like Figures 1 to 6 As shown, a second-order inductor includes: a square-core component 10 and a T-core component 20, a coil 30 and a magnetic component 40 disposed between the square-core component 10 and the T-core component 20; the square-core component 10, the T-core component 20, the coil 30 and the magnetic component 40 are arranged together in an orderly manner by nesting and stacking; the T-core component 20 includes a cover plate 21 and a cylinder 22 disposed on the cover plate 21.

[0022] Example 1: like Figure 1 and Figure 2 As shown, when magnetic component 40 is a magnetic plate.

[0023] A second-order inductor includes: a square core 10, a magnetic plate mounted on the bottom of the square core 10, a coil 30 disposed on the magnetic plate, and a T-core 20 inserted into the coil 30.

[0024] During installation, the magnetic plate is first installed on the bottom inner side of the square core 10. Then, the coil 30 is peeled off and folded into the square core 10. At this time, the coil 30 is pressed on the magnetic plate. Next, the T-core 20 is inserted into the hole of the coil 30. Then, the coil 30 is folded twice. Finally, temperature and pressure are applied by the mold and machine to form the assembled product into one piece.

[0025] Example 2: like Figure 3 and Figure 4 As shown, when magnetic component 40 is a magnetic tube.

[0026] A second-order inductor includes: a square core 10, a coil 30 installed in the square core 10, a magnetic tube inserted into a hole in the coil 30, and a T-core 20 inserted into the magnetic tube.

[0027] During installation, the coil 30 is peeled and folded once, and then the coil 30 is inserted into the square core part 10. Next, the magnetic tube is inserted into the hole of the coil 30. Then, the T-core part 20 is inserted into the magnetic tube through the cylinder 22. The coil 30 is then folded twice. Finally, temperature and pressure are applied through the mold and machine to form the assembled product into one piece.

[0028] Example 3: like Figure 5 and Figure 6 As shown, when magnetic component 40 is a magnetic column.

[0029] A second-order inductor includes: a square core 10, a coil 30 installed in the square core 10, and a magnetic post and a T-core 20 inserted sequentially into the hole of the coil 30.

[0030] During installation, the coil 30 is peeled and folded once, then the coil 30 is inserted into the square core 10. Next, the magnetic column is inserted into the hole of the coil 30. Then, the T-core 20 is inserted into the hole of the coil 30 through the cylinder 22. The coil 30 is then folded twice. Finally, temperature and pressure are applied by the mold and machine to form the assembled product into one piece.

[0031] All three embodiments described above can effectively achieve the predetermined nonlinear decay curves, with the inductance value decreasing by approximately 30% under low current and approximately 70% under high current.

[0032] The following is a comparison table of actual tests for the three embodiments: plan L(0A) L(2A) L(15A) DCR Temperature rise control group 3.30 3.05 1.62 16.8 38.3 Example 2 3.32 3.10 1.28 9.95 28.6 Example 3 3.33 3.13 1.29 9.92 28.4 Example 1 3.35 3.14 1.27 9.96 28.5 The foregoing has shown and described the basic principles, main features, and advantages of the present invention. It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A second order inductor characterized by, It comprises: a square-core piece (10) and a T-core piece (20), a coil (30) and a magnetic piece (40) arranged between the square-core piece (10) and the T-core piece (20); the square-core piece (10), the T-core piece (20), the coil (30) and the magnetic piece (40) are orderly combined together by means of sleeve embedding and stacking.

2. A second order inductor as claimed in claim 1, characterized in that The T-core piece (20) comprises a cover plate (21) and a cylinder (22) arranged on the cover plate (21).

3. A second order inductor as claimed in claim 1, characterized in that The magnetic piece (40) is a magnetic plate.

4. A second order inductor as claimed in claim 3, characterized in that The magnetic plate is installed at the bottom of the square-core piece (10).

5. A second order inductor as claimed in claim 2, characterized in that The magnetic piece (40) is a magnetic tube.

6. A second order inductor as claimed in claim 5, characterized in that The magnetic tube is sleeved on the cylinder (22) of the T-core piece (20) and inserted into the hole of the coil (30) to form an integrated body.

7. A second order inductor as claimed in claim 2, characterized in that The magnetic piece (40) is a magnetic column.

8. A second order inductor according to claim 7, wherein, The magnetic column is inserted into the hole of the coil (30) together with the cylinder (22) of the T-core piece (20) to form an integrated body.

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