INDUCTOR AND METHOD OF MANUFACTURING THE SAME

• US 20140253275A1
• Filed: 03/04/2014
• Published: 09/11/2014
• Est. Priority Date: 03/06/2013
• Status: Active Grant

• Current Assignee: Kabushiki Kaisha Toshiba (Toshiba Corporation)
• Original Assignee: Kabushiki Kaisha Toshiba (Toshiba Corporation)
• Inventors: Shijo, Tetsu, Okamoto, Tetsushi, Obayashi, Shuichi, Yamada, Akiko, Sakai, Masahiro, Hiroshima, Satoshi
• Granted Patent: US 9,431,166 B2
• Time in Patent Office: Days
• US Class Current: 336/105
• CPC Class Codes: H01F 27/022 Encapsulation
• CPC Class Codes: H01F 27/22 Cooling by heat conduction through solid or powdered fillings
• CPC Class Codes: H01F 27/327 Encapsulating or impregnating encapsulating coil and core H01F27/022
• CPC Class Codes: H01F 27/34 Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
• CPC Class Codes: H01F 38/14 Inductive couplings for wireless supply or distribution of electric power using inductive coupling H02J50/10
• CPC Class Codes: H01F 41/005 Impregnating or encapsulating insulating of windings H01F41/12
• CPC Class Codes: H01F 41/06 Coil winding
• CPC Class Codes: H01F 41/127 Encapsulating or impregnating encapsulating coil and core H01F41/005
• CPC Class Codes: Y10T 29/49071 by winding or coiling

Abstract

According to an embodiment, there is an inductor, including: a magnetic core; a winding formed around the magnetic core; a first resin provided between turns of the winding; and a second resin covering the winding and the first resin, wherein the second resin has higher filler content than the first resin.

Claims

1. An inductor;

comprising;

a magnetic core;

a winding formed around the magnetic core;

a first resin provided between turns of the winding; and

a second resin covering the winding and the first resin,

wherein the second resin has higher filler content than the first resin.

2. The inductor according to claim 1, wherein the winding is formed by a stranded wire of a plurality of conductive strands, and

the first resin fills an interior of the winding.

3. The inductor according to claim 1, wherein the winding is covered with an insulating material having a surface with a hole or a mesh of insulating material.

4. The inductor according to claim 1, wherein both end parts of the magnetic core in a direction perpendicular to a direction of winding of the winding have an exposed surface.

5. The inductor according to claim 1, wherein a part of the magnetic core within a predetermined distance from the winding is covered with the second resin, parts of the magnetic core beyond the predetermined distance are covered with a third resin, and

the third resin has lower filler content than the second resin.

6. The inductor according to claim 1, further comprising:

a conductive plate provided on one surface of the second resin.

7. The inductor according to claim 6, wherein the conductive plate is attached to the second resin with a conductive material having lower rigidity than the conductive plate interposed therebetween.

8. The inductor according to claim 1, wherein a gap is formed in the magnetic core, and

a capacitor is provided in the gap.

9. The inductor according to claim 8, wherein the gap is formed in an end part in a direction perpendicular to a direction of winding of the winding.

10. The inductor according to claim 8, wherein a rectifier is provided in the gap.

11. The inductor according to claim 6, wherein the magnetic core has:

a first core around which the winding is wound; and

a second core provided on an end part of the first core in a direction perpendicular to a direction of winding of the winding, and

the second core is disposed on the opposite side of the first core to the conductive plate.

12. The inductor according to claim 1, further comprising:

a tubular bobbin,

wherein the magnetic core is inserted into a hold of the bobbin, and

the winding is wound around the bobbin.

13. The inductor according to claim 12, wherein a conductive material having lower rigidity than the bobbin and the magnetic core is provided between the bobbin and the magnetic core.

14. The inductor according to claim 12, wherein recesses and projections are formed on an outer periphery of the bobbin, and the winding is disposed in the recesses.

15. A method of manufacturing an inductor, comprising:

winding a winding around a tubular bobbin;

impregnating the winding with a first resin;

inserting a magnetic core into a hole of the bobbin;

housing the bobbin, the winding and the magnetic core in a mold such that one end of the magnetic core in a length direction is located at the bottom; and

pouring a second resin, a third resin having higher filler content than the first resin and the second resin and the second resin into the mold in this order and curing each resin.

16. The method of manufacturing an inductor according to claim 15, wherein a conductive plate is housed in the mold before the resins are poured into the mold.