High current inductor and the manufacturing method

• US 7,281,315 B2
• Filed: 10/20/2005
• Issued: 10/16/2007
• Est. Priority Date: 07/02/2004
• Status: Active Grant

• Current Assignee: Chang Mao Cheng
• Original Assignee: Chang Mao Cheng
• Inventors: Cheng, Chang Mao
• Primary Examiner(s): Nguyen; Tuyen T.
• Application Number:
  US11/253,674
• Publication Number:
  US 20060038652A1
• Time in Patent Office: 726 Days
• Field of Search: 336/65, 336/83, 336/200, 336/233, 296/021, 29605-608, 252/62.51 R, 252 6253- 54
• US Class Current: 29/602.1
• 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
• CPC Class Codes: H01F 27/292 Surface mounted devices
• CPC Class Codes: H01F 41/005 Impregnating or encapsulating insulating of windings H01F41/12
• 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: H01F 41/10 Connecting leads to windings making electric connections in general H01R43/00
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor

Abstract

An inductor with the characteristic of resisting high current comprising a conductor coil and a magnet envelope, the magnet envelope tightly wraps the periphery of the conductor coil and forms the main body of the inductor, and the two extending parts of the conductor coil extend to outside of the main body of the inductor, forming terminal electrode. As of the manufacturing method, it includes the part of toroid coil and the extending parts composing the conductor coil. After the toroid coil part is winded into rings, the unwinded wire ends form the extending parts. Through magnet envelope die-casting and wrapping the molded magnet core of the conductor coil to form the main body of the inductor, and the extending parts of the conductor coil extend to outside of the main body to form the terminal electrode.

Claims

1. A way to manufacture inductor, which mainly include the following steps:

a) Fully and evenly stir the three types of magnet powder and insulation material and dilution, and put them into a furnace for roasting, so that the insulation material can be setting and form a layer of insulation film on the surface of the magnet powder;

b) After adding Epoxy and silicone into the materials after insulation treatment, fully stir it into paste, then make use of granule-making machine to make granules, after that, put the materials after granule-making operation into furnace, after completion of roasting, put the lubricant (Zinc Stearate) into the material and blend evenly, then the complete molding material is formed;

c) Fill the complete molding material into two permanent moulds to make the first and second magnet envelope precast density ranging form 2.5 g/cm³ to 4.0 g/cm³;

d) Then put the precast first magnet envelope, conductor coil and the second magnet envelope into another permanent mould for die-casting operation, and make the density of the magnet envelope reach 5.5 g/cm³ to 4.0 g/cm³, and cover the periphery of the toroid coil of the conductor coil in a wholly closed way, then form an inductor after die-casting; and

e) Put the inductor after die-casting into a tunnel firing furnace for annealing, and make those materials added into the magnet envelope of the inductor namely epoxy, silicone and lubricant (Zinc Stearate) etc. reach the status of hot fusion and thermosetting, so that make an electrical inductor.

2. The way to make inductor according to claim 1, wherein the firing condition of the furnace under which the magnet powder, insulation material and dilution are roasted:

annealing temperature;

60°

C.-180°

C., roast time;

30 minutes-180 minutes.

3. The way to make inductor according to claim 1, wherein the firing condition of the furnace under which the materials after granule-making:

annealing temperature;

100°

C., annealing time;

45 minutes.

4. The way to make inductor according to claim 1, wherein the firing condition of the tunnel firing furnace:

roast temperature;

120°

C.-200°

C., annealing time;

60 minutes.