Iron core material parallel connection structure and manufacturing method thereof

Abstract

An iron core material parallel connection structure comprises a first iron core body ring, a second iron core body ring, a third iron core body ring and a fourth iron core body ring, and the second iron core body is combined in the continuous accommodating groove. According to the invention, the second iron core body which is not easy to process is wound in the continuous accommodating groove on the outer side surface of the first iron core body ring, and the second iron core body does not protrude out of the continuous accommodating groove, so that the iron core body has the characteristics of various different working wavebands while being easy to process and produce and increasing the overall energy efficiency of the iron core body. The invention further provides a manufacturing method of the iron core material parallel structure.

Description

Technical Field

[0001] This invention relates to a parallel structure of iron core materials and its manufacturing method, particularly a parallel structure of iron core materials and its manufacturing method that combines high magnetic flux and easy processing by winding a relatively fragile, difficult-to-process but high magnetic flux iron core material into a continuous receiving groove on the outer side of an iron core ring. Background Technology

[0002] Due to the rapid development of electronic product manufacturing technology in recent years, electronic products are constantly shrinking, and correspondingly, various electronic components must also become smaller. Among them, the performance of inductors and transformers, which are indispensable in electronic circuits, is largely determined by their iron core. The higher the magnetic flux of the iron core, the smaller the size of the inductor and transformer can be, while also reducing the number of coils used in the design. This allows for the use of thicker copper wire to wind fewer coils at the same cost, thereby increasing the current and power that the component can withstand.

[0003] Amorphous iron cores are available on the market. These are typically produced by rapidly cooling liquid metal by passing it through a high-speed rotating, low-temperature roller, resulting in an amorphous state. Because these amorphous iron cores lack a long-range ordered structure (crystalline structure), they are easier to magnetize and demagnetize than conventional magnetic materials, resulting in very high magnetic flux and low loss. Due to the limitations of the manufacturing method, amorphous iron cores are usually long, thin strips that need to be wound into the desired shape, such as various rings. However, amorphous iron cores are brittle materials with low toughness, requiring careful handling of pressure during processing to prevent breakage. Furthermore, the edges of the amorphous iron core strip are quite sharp. If a winding machine is used to directly wind enameled wire onto the amorphous iron core, the edges of the strip can damage the enamel film on the wire surface, posing a risk of short circuits.

[0004] Therefore, when using amorphous iron cores, it is usually necessary to add an external plastic shell to prevent the enameled wire from directly contacting the amorphous iron core during winding, or to wind the coil separately and then assemble the coil onto the amorphous iron core. These methods either increase the overall size of the component, thus reducing the energy efficiency-to-volume ratio (energy efficiency / volume ratio, as the plastic shell does not possess the characteristics of an iron core, only increasing volume), or they increase costs and losses. There is still room for improvement.

[0005] Furthermore, when multiple iron cores are required in the same component, the existing technology involves placing two iron cores side by side. For example, in Taiwan Patent Publication No. M553047, the secondary iron core is located on both sides of the main iron core, which means that the completed component must occupy a large area of ​​the circuit board.

[0006] In view of this, the inventor has devoted himself to research and development, hoping to provide a parallel structure of iron core material that can protect amorphous iron core, facilitate processing, and reduce the circuit board area occupied by inductors, as well as its manufacturing method. This is the inventive motivation for the present invention. Summary of the Invention

[0007] The main objective of this invention is to provide a parallel structure for a core material and its manufacturing method. An amorphous material, which is difficult to wind, is wound onto the outer surface of a conventional core ring. A continuous receiving groove is first machined on the outer surface of the core ring, and then the amorphous strip is wound into the continuous receiving groove, thus protecting the amorphous strip. This method enhances the magnetic flux of the conventional core material, reduces the production cost of high-flux components, and allows the core to accommodate characteristics across different operating frequency bands.

[0008] The parallel structure of the iron core material of the present invention includes a first iron core ring with a through hole in the center and a continuous receiving groove on its outer surface; and a second iron core body, which is coupled into the continuous receiving groove. The continuous receiving groove can be cut on the outer surface of the first iron core ring using common machining tools, such as machining tools used to cut I-shaped ferrite.

[0009] Please note that "iron core" in this article is a common part name for inductor components and is not limited to iron-containing materials.

[0010] In one embodiment, the first core ring is a ferrite, such as manganese-zinc ferrite or nickel-zinc ferrite, and the second core is an amorphous core strip or a nanocrystalline core strip.

[0011] The first iron core ring can be a circular ring or a square ring, and can be varied into various polygonal rings depending on the required shape. The second iron core is wound within a continuous receiving groove, and can be wound into a single-turn ring or a multi-turn spiral. The depth of the continuous receiving groove can be matched with the number of turns of the second iron core to be wound, so that the second iron core is approximately flush with the outer surface of the first iron core ring when wound. If necessary, an insulating protective varnish layer can be further provided on the outer side of the first iron core ring and the second iron core.

[0012] The manufacturing method of the parallel structure of iron core material of the present invention includes: preparing a first iron core ring; machining a continuous receiving groove on the outer side of the first iron core ring; and attaching a second iron core in the continuous receiving groove.

[0013] In one embodiment, the first iron core ring is a ferrite, and the second iron core is an amorphous iron core strip or a nanocrystalline iron core strip. The present invention can fabricate ferrite using existing techniques, and process it into a ring shape and cut continuous receiving grooves before sintering. After sintering the ferrite, the amorphous iron core strip or nanocrystalline iron core strip is wound around the continuous receiving grooves, making the amorphous iron core strip or nanocrystalline iron core strip ring-shaped or spiral-shaped.

[0014] The first core ring can be a circular ring or a square ring. Alternatively, an insulating protective varnish layer can be applied to the outside of both the first core ring and the second core.

[0015] The beneficial effects of this invention are as follows: This invention involves winding an amorphous iron core strip within a continuous accommodating groove carved into the ferrite core. The advantages are twofold: firstly, it avoids the non-magnetic outer shell reducing the energy efficiency-volume ratio of the amorphous iron core strip; secondly, it increases the magnetic flux of the original ferrite core; and thirdly, it allows the invention to simultaneously possess the inductive characteristics of two materials, effectively achieving the effect of two inductors in parallel within a single element. If applied to inductor components, it can simultaneously filter two frequency bands. Furthermore, the amorphous iron core strip in this invention does not protrude beyond the ferrite core, minimizing the risk of contact with it during processing. This facilitates post-processing without damage to the amorphous iron core strip. For example, this invention allows a winding machine to directly wind the coil quickly without worrying about damaging the amorphous iron core strip or enameled wire.

[0016] To further understand the features, characteristics, and technical content of this invention, please refer to the following detailed description of this invention. Attached Figure Description

[0017] Figure 1 This is a perspective view of embodiment (1) of the present invention; Figure 2 This is a longitudinal section view of the first figure; Figure 3 This is a perspective view of the first iron core ring of Embodiment (I) of the present invention; Figure 4 A schematic diagram of an inductor fabricated according to Embodiment (I) of the present invention; Figure 5 This is a perspective view of embodiment (II) of the present invention; Figure 6 This is a longitudinal section view of Figure 5; Figure 7 This is a perspective view of the first iron core ring of Embodiment (III) of the present invention; Figure 8 This is a flowchart illustrating the manufacturing method of the parallel structure of the iron core material according to the present invention.

[0018] Explanation of reference numerals in the attached figures 1. First iron core ring; 11. Through hole; 12. Continuous receiving tank; 2. Second iron core; A. Coil; B. Insulating protective varnish layer. Detailed Implementation

[0019] Please see Figures 1 to 3 The accompanying drawings, which disclose the embodiments of the present invention, illustrate an embodiment (I) of a parallel structure of iron core material of the present invention, which includes a first iron core ring 1 with a through hole 11 in the center and a continuous receiving groove 12 on the outer side; and a second iron core 2, which is connected in the continuous receiving groove 12. In Example (I), the first iron core ring 1 is a circular ring, but a square ring or any polygonal ring can also be used depending on the required shape. The second iron core 2 is wound within the continuous receiving groove 12, and can be wound into a single-turn ring or a multi-turn spiral. In Example (I), the second iron core 2 is wound into a spiral shape. The depth of the continuous receiving groove 12 is matched with the number of turns to be wound on the second iron core 2, so that when the second iron core 2 is wound, it is approximately flush with the outer surface of the first iron core ring 1. The continuous receiving groove 12 can be cut out from the outer surface of the first iron core ring 1 using common machining tools, such as machining tools used to cut I-shaped ferrite. The interior of the continuous receiving groove 12 forms a continuous space (flat and without protrusions), which facilitates the winding of the second iron core 2 into a uniform spiral shape and reduces the stress on the second iron core 2. The second iron core 2 can be bonded to the continuous receiving groove 12 using adhesive as needed, or an electrically insulating adhesive can be used to make the first iron core ring 1 and the second iron core 2 electrically insulated from each other.

[0020] In Example (I), the first core ring 1 is a ferrite, such as manganese-zinc ferrite or nickel-zinc ferrite, and the second core 2 is an amorphous iron core strip or a nanocrystalline iron core strip. Example (I) uses ferrite as the carrier for the amorphous iron core strip. This has the advantage of avoiding the significant reduction in the energy efficiency-volume ratio of the amorphous iron core strip due to the non-magnetic outer shell, while increasing the magnetic flux of the original ferrite structure. It also allows Example (I) to simultaneously possess the inductive characteristics of two materials, effectively achieving the effect of two inductors in parallel within a single element. If applied to inductor elements, this can provide filtering for two frequency bands simultaneously. Furthermore, the amorphous iron core strip in Example (I) does not protrude beyond the ferrite core, making it less likely to be touched during processing, facilitating post-processing without concerns about damaging the amorphous iron core strip.

[0021] This invention allows the winding machine to directly wind coil A, quickly and without worrying about damaging the enameled wire during winding or causing short circuits, nor about the thin amorphous iron core strip being damaged by the force applied by the winding machine. Figure 4 As can be seen, in Embodiment (I) of the present invention, two coils A can be wound on the coils to be used as common-mode filter inductors. In Embodiment (I) of the present invention, a thin strip of amorphous iron core with high magnetic flux is used as the second iron core 2 and wound in the continuous receiving groove 12 of the first iron core ring 1. This can increase the magnetic flux in the same volume, so that the number of coils A used in the finished inductor can be reduced, saving the length of copper wire used to wind the coils A and the cost. Alternatively, at the same cost, thicker copper wire can be used to wind the coils A to increase the current and power that the inductor can withstand.

[0022] exist Figure 5 and Figure 6 As can be seen in embodiment (II), if necessary, an insulating protective varnish layer B can be further provided on the outside of the first iron core ring 1 and the second iron core 2, for example by spraying or impregnating the coating.

[0023] exist Figure 7 In embodiment (iii) of the present invention, the first iron core ring 1 is a ring structure with approximately rounded corners, and the second iron core 2 is also wound in the continuous receiving groove 12 on the outer side of the first iron core ring 1 (please note). Figure 7 The second iron core 2 is not shown in the figure. The corners of the continuous receiving groove 12 are rounded to avoid excessive bending of the second iron core 2 at each corner. The present invention does not limit the shape of the first iron core ring 1 to a ring structure of any kind, and can be circular or any polygonal ring.

[0024] and Figure 8 As can be seen, the manufacturing method of the parallel structure of the iron core material of the present invention includes: preparing a first iron core ring 1 (S1); processing a continuous receiving groove 12 on the outer side of the first iron core ring 1 (S2); and combining a second iron core 2 in the continuous receiving groove 12 (S3), and further adding a step: disposing an insulating protective varnish layer B on the outer side of the first iron core ring 1 and the second iron core 2 (S4).

[0025] In this embodiment, the first iron core ring 1 is a ferrite, and the second iron core 2 is an amorphous iron core strip or a nanocrystalline iron core strip. The present invention can use existing methods to fabricate the ferrite, and before sintering, it is processed into a ring shape and a continuous receiving groove 12 is cut. After sintering the ferrite, the amorphous iron core strip or nanocrystalline iron core strip is wound around the continuous receiving groove 12, making the amorphous iron core strip or nanocrystalline iron core strip annular or spiral. The second iron core 2 can be bonded to the continuous receiving groove 12 using adhesive as needed, or an electrically insulating adhesive can be used to make the first iron core ring 1 and the second iron core 2 electrically insulated. The first iron core ring 1 can be a circular ring, a square ring, or an arbitrary polygonal ring.

[0026] However, the above description is only a preferred embodiment of the present invention and should not be used to limit the scope of the present invention. All changes and modifications that can be obviously made by those skilled in the art should be considered as not departing from the essence of the present invention.

Claims

1. A parallel structure of iron core material, characterized in that, include: A first iron core ring has a through hole in the center and a continuous receiving groove on its outer side. and A second iron core body is incorporated into the continuous receiving groove.

2. The parallel structure of the iron core material as described in claim 1, characterized in that, The first iron core ring is a ferrite, and the second iron core is an amorphous iron core strip or a nanocrystalline iron core strip.

3. The parallel structure of the iron core material as described in claim 2, characterized in that, The second iron core is wound within the continuous receiving groove in a ring or spiral shape.

4. The parallel structure of the iron core material as described in claim 1, characterized in that, The first iron core ring is either a circular ring or a square ring.

5. The parallel structure of the iron core material as described in claim 1, characterized in that, It also includes an insulating protective varnish layer disposed on the outside of the first iron core ring and the second iron core.

6. A method for manufacturing a parallel structure of iron core material, characterized in that, include: Prepare a first iron core ring; A continuous receiving groove is machined on the outer surface of the first iron core ring; and A second iron core is attached within the continuous receiving groove.

7. The manufacturing method of the parallel structure of the iron core material as described in claim 6, characterized in that, The first iron core ring is a ferrite, and the second iron core is an amorphous iron core strip or a nanocrystalline iron core strip.

8. The manufacturing method of the parallel structure of the iron core material as described in claim 7, characterized in that, The second iron core is wound within the continuous receiving groove in a ring or spiral shape.

9. The manufacturing method of the parallel structure of the iron core material as described in claim 6, characterized in that, The first iron core ring is either a circular ring or a square ring.

10. The manufacturing method of the parallel structure of the iron core material as described in claim 6, characterized in that, It also includes providing an insulating protective varnish layer on the outside of the first iron core ring and the second iron core.

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