High Current Amorphous Powder Core Inductor

• US 20100085139A1
• Filed: 10/08/2008
• Published: 04/08/2010
• Est. Priority Date: 10/08/2008
• Status: Active Grant

• Current Assignee: Cooper Technologies Company (Eaton Corporation PLC.)
• Original Assignee: Cooper Technologies Company (Eaton Corporation PLC.)
• Inventors: Bogert, Robert James, Yan, Yipeng
• Granted Patent: US 8,310,332 B2
• Time in Patent Office: Days
• US Class Current: 336/221
• CPC Class Codes: H01F 1/15358 Making agglomerates therefrom, e.g. by pressing
• CPC Class Codes: H01F 17/04 with magnetic core
• 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
• CPC Class Codes: H01F 27/2847 Sheets; Strips H01F27/2866 takes precedence
• CPC Class Codes: H01F 41/0226 from amorphous ribbons
• CPC Class Codes: H01F 41/0246 Manufacturing of magnetic circuits by moulding or by pressing powder magnetic cores made by moulding or by pressing powder H01F27/255; soft magnetic particles H01F1/20, H01F1/36
• CPC Class Codes: Y10T 29/49073 by assembling coil and core

Abstract

A magnetic component and a method of manufacturing the same. The method comprises the steps of providing at least one shaped-core fabricated from an amorphous powder material, coupling at least a portion of at least one winding to the at least one shaped-core, and pressing the at least one shaped-core with at least a portion of the at least one winding. The magnetic component comprises at least one shaped-core fabricated from an amorphous powder material and at least a portion of at least one winding coupled to the at least one shaped-core, wherein the at least one shaped-core is pressed to at least a portion of the at least one winding. The winding may be preformed, semi-preformed, or non-preformed and may include, but is not limited to, a clip or a coil. The amorphous powder material may be an iron-based or cobalt-based amorphous powder material or a nanoamorphous powder material.

Claims

1. A magnetic component, comprising:

at least one shaped-core fabricated from an amorphous powder material; and

at least one winding, wherein at least a portion of the at least one winding is coupled to the at least one shaped-core, and

wherein the at least one shaped-core is pressed to at least a portion of the at least one winding.

2. The magnetic component of claim 1, wherein the at least one winding comprises one of a preformed coil, a semi-preformed coil, a non-preformed coil, a preformed clip, a semi-preformed clip, a non-preformed clip, and a stamped conductive foil.

3. The magnetic component of claim 1, wherein the amorphous powder material is an iron-based amorphous powder material.

4. The magnetic component of claim 1, wherein the amorphous powder material is a nanoamorphous powder material.

5. The magnetic component of claim 1, wherein the at least one shaped-core comprises a first shaped-core and a second shaped-core, wherein the at least one winding is coupled between the first shaped-core and the second shaped-core.

6. The magnetic component of claim 5, wherein the first shaped core is an ER shaped-core and the second shaped-core is an I core.

7. The magnetic component of claim 5, wherein the first shaped core is a U shaped-core and the second shaped-core is an I core.

8. The magnetic component of claim 7, wherein the I core provides for mistake proofing.

9. The magnetic component of claim 7, wherein the U shaped-core is symmetrical.

10. The magnetic component of claim 7, wherein the U shaped-core is asymmetrical.

11. The magnetic component of claim 1, wherein the amorphous powder material is coupled around the at least one winding and pressed together to form the magnetic component, wherein the magnetic component comprises at least one shaped-core.

12. The magnetic component of claim 11, wherein the at least one shaped-core is at least one U core.

13. The magnetic component of claim 11, wherein the at least one shaped-core is a bead core and the at least one winding is a winding.

14. The magnetic component of claim 13, wherein the winding is a clip.

15. The magnetic component of claim 11, wherein the at least one shaped-core is a plurality of shaped-cores and the at least one winding is a plurality of windings.

16. The magnetic component of claim 15, wherein the plurality of shaped-cores is a plurality of U cores and the plurality of windings is a plurality of clips, wherein each of the plurality of clips correspond to each of the plurality of U cores.

17. The magnetic component of claim 15, wherein the plurality of windings are connected in series.

18. The magnetic component of claim 15, wherein the plurality of windings are connected in parallel.

19. The magnetic component of claim 15, wherein the plurality of windings are connected to accommodate multi-phase current.

20. A magnetic component, comprising:

a first shaped-core fabricated from an amorphous powder material;

a second shaped-core fabricated from an amorphous powder material;

a clip, wherein at least a portion of the clip is coupled between the first shaped-core and the second shaped core, and

wherein the first shaped-core, the second shaped-core, and the winding are pressed together.

21. The magnetic component of claim 20, wherein the amorphous powder material is an iron-based amorphous powder material.

22. The magnetic component of claim 20, wherein the amorphous powder material is a nanoamorphous powder material.

23. A method of forming a magnetic component, comprising:

providing at least one shaped-core fabricated from an amorphous powder material;

coupling at least a portion of at least one winding to the at least one shaped-core; and

pressing the at least one shaped-core with at least a portion of the at least one winding.

24. The method of claim 23, wherein the at least one shaped-core comprises a first shaped-core and a second shaped-core, wherein the at least one winding is coupled between the first shaped-core and the second shaped-core.

25. The method of claim 23, wherein the amorphous powder material is coupled around the at least one winding and pressed together to form the magnetic component, wherein the magnetic component comprises at least one shaped-core.

26. The magnetic component of claim 23, wherein the at least one shaped-core is a plurality of shaped-cores and the at least one winding is a plurality of windings.