INDUCTOR AND CORE THEREOF

• US 20090102589A1
• Filed: 05/05/2008
• Published: 04/23/2009
• Est. Priority Date: 10/19/2007
• Status: Abandoned Application

• Current Assignee: Delta Electronics Incorporated
• Original Assignee: Delta Electronics Incorporated
• Inventors: YUAN, Zong-Ting, SHING, Tai-Kang, LEE, Cheng-Chang, CHANG, Heng-Chung, CHEN, Huang-Kun
• Application Number:
  US12/115,092
• Publication Number:
  US 20090102589A1
• Time in Patent Office: Days
• US Class Current: 336/83
• CPC Class Codes: H01F 17/045 with core of cylindric geometry and coil wound along its longitudinal axis, i.e. rod or drum core
• CPC Class Codes: H01F 2017/046 helical coil made of flat wire, e.g. with smaller extension of wire cross section in the direction of the longitudinal axis
• CPC Class Codes: H01F 2017/048 with encapsulating core, e.g. made of resin and magnetic powder
• CPC Class Codes: H01F 27/255 made from particles H01F27/26 takes precedence

Abstract

An inductor includes a coil and a core. The core covers the coil and includes a plurality of magnetic particles. Each of the magnetic particles includes a nucleus and a first shell enveloping the nucleus. The nucleus and the first shell are formed by different materials with different specific gravities. When the nucleus includes a polymer material, the first shell includes the first magnetic material. When the nucleus includes the first magnetic material, the first shell includes the polymer material.

Claims

1. A core comprising:

a plurality of magnetic particles, wherein each of the magnetic particles comprises a nucleus and a first shell enveloping the nucleus, and the nucleus and the first shell comprise different materials.

2. The core as claimed in claim 1, wherein when the first shell comprises a first magnetic material, the nucleus comprises a polymer material;

or when the nucleus comprises the first magnetic material, and the first shell comprises the polymer material.

3. The core as claimed in claim 2, wherein the first magnetic material comprises iron (Fe), silicon (Si), cobalt (Co), nickel (Ni), aluminum (Al), molybdenum (Mo), manganese (Mn) or chromium (Cr).

4. The core as claimed in claim 2, wherein the polymer material comprises polyvinyl chloride (PVC) or polyimide (PI).

5. The core as claimed in claim 2, wherein a thickness of the first shell is thinner than a skin depth of the first magnetic material.

6. The core as claimed in claim 2, wherein the first shell comprises an amorphous structure or a microcrystalline structure.

7. The core as claimed in claim 2, wherein each of the magnetic particles further comprises a second shell enveloping the first shell.

8. The core as claimed in claim 7, wherein the second shell comprises a second magnetic material, and the second magnetic material comprises iron (Fe), silicon (Si), cobalt (Co), nickel (Ni), aluminum (Al), molybdenum (Mo), manganese (Mn) or chromium (Cr).

9. The core as claimed in claim 8, wherein the first or second shell is formed by a chemical plating method.

10. The core as claimed in claim 8, further comprising an insulating layer between the first shell and the second shell, and the insulating layer comprises oxide, metal oxide, silicon dioxide or a combination thereof.

11. The core as claimed in claim 1, wherein an outer surface of each of the magnetic particles is covered by an outer shell, and the outer shell comprises an insulating material or epoxy resin.

12. The core as claimed in claim 1, further comprising resin mixed with the magnetic particles.

13. The core as claimed in claim 1, wherein the first shell has a specific gravity different from that of the nucleus.

14. An inductor, comprising:

a coil; and

a core covering the coil and comprising a plurality of magnetic particles, wherein each of the magnetic particles comprises a nucleus and a first shell around the nucleus, and the nucleus and the first shell comprise different materials.

15. The inductor as claimed in claim 14, wherein the inductor is a choke inductor applicable for a switching power supply.

16. The inductor as claimed in claim 14, wherein the coil comprises a circular-shaped, square-shaped or flat-shaped wire with a plurality of windings.

17. The core as claimed in claim 14, wherein when the first shell comprises a first magnetic material, the nucleus comprises a polymer material;

or when the nucleus comprises the first magnetic material, and the first shell comprises the polymer material.

18. The core as claimed in claim 17, wherein the first magnetic material comprises iron (Fe), silicon (Si), cobalt (Co), nickel (Ni), aluminum (Al), molybdenum (Mo), manganese (Mn) or chromium (Cr), and the polymer material comprises polyvinyl chloride (PVC) or polyimide (PI).

19. The core as claimed in claim 17, wherein the first shell comprises an amorphous structure or a microcrystalline structure.

20. The core as claimed in claim 17, wherein each of the magnetic particles further comprises a second shell enveloping the first shell, and the second shell comprises a second magnetic material, and the second magnetic material comprises iron (Fe), silicon (Si), cobalt (Co), nickel (Ni), aluminum (Al), molybdenum (Mo), manganese (Mn) or chromium (Cr).

21. The core as claimed in claim 14, wherein the first shell has a specific gravity different from that of the nucleus.

22. The core as claimed in claim 20, further comprising an insulating layer between the first shell and the second shell, and the insulating layer comprises oxide, metal oxide, silicon dioxide or a combination thereof.

23. The core as claimed in claim 14, wherein an outer surface of each of the magnetic particles is covered by an outer shell, and the outer shell comprises an insulating material or epoxy resin.