The present invention relates to a magnetic component and a manufacturing method thereof, and more particularly to a magnetic component and a manufacturing method thereof without the wire winding frame.
With the requirements of high-frequency and high-power intensity in a magnetic component, there is a need to downsize the magnetic component. Basically, the magnetic component is composed of three portions including a magnetic core, a conductive body and a wire winding frame. The magnetic core and the conductive body have electrically characteristics while the magnetic component is activated, and the wire winding frame has the functions of sustentation and insulation. Due to the miniaturization trend of the magnetic component, the removal of the wire winding frame from magnetic component is one way to downsize the magnetic component. However, after the wire winding frame is removed from magnetic component, the problems of how to perform the process of wire winding frame and how to insulate the conductive body from the magnetic core are induced. Moreover, while the wire winding frame is removed from magnetic component, the conductive body directly faces against the magnetic core. However, when the voltage between the conductive body and the magnetic core is gradually increased, the conductive body applies the larger spark current to the magnetic core, which the power supply with the magnetic component damages the machine equipped with the power supply.
Currently, some drawbacks exist in the conventional solution to the above-mentioned spark problem. For example, two cases of the spark problem are described below.
In another case,
Consequently, there is a need to develop a proper method to solve the aforementioned spark problem of the conductive body and magnetic core therebetween without the wire winding frame.
One objective of the present invention is to provide a magnetic component and a manufacturing method thereof for simplifying the manufacturing process of the magnetic component and forming a better insulation between the magnetic and conductive body of the magnetic component.
According to the above objective, the present invention sets forth a manufacturing method of the magnetic component, the method including the steps of:
(1) coating an insulation material on a surface of a magnetic core to form an insulation magnetic core thereon;
(2) bending a conducting material into a predetermined shape to form a preformed conductive body; and
(3) assembling the preformed conductive body with the insulation magnetic core to form the magnetic component.
In one embodiment, a surface region of the preformed conductive body may be wrapped around three insulation strip layers.
In one embodiment, a surface region of the preformed conductive body may be covered with a casing unit.
In one embodiment, a surface region of the preformed conductive body may be attached by an adhesive tape.
In one embodiment, a surface region of the preformed conductive body may be coated by the insulation material.
In one embodiment, the magnetic core may include a lead angle portion.
In one embodiment, the magnetic core may be coated with the insulation material in either a uniform thickness or a non-uniform thickness.
In one embodiment, the magnetic core may be either wholly or partly coated with the insulation material.
In one embodiment, the magnetic core may be assembled with the preformed conductive body to form a magnetic unit with a specific shape.
In one embodiment, the magnetic core comprises at least two portions.
A magnetic component includes:
In one embodiment, the magnetic core comprises a lead angle portion.
In one embodiment, the magnetic core may be coated with the insulation material in either a uniform thickness or a non-uniform thickness.
In one embodiment, the magnetic core may be either wholly or partly coated with the insulation material.
In one embodiment, the magnetic core may be assembled with the preformed conductive body to form a magnetic unit with a specific shape.
In one embodiment, the magnetic core comprises at least two portions.
In one embodiment, the insulation material may be selected one group consisting of epoxy resin, magnesium oxide, aluminum oxide, quartz powder and the combinations.
A transformer apparatus includes:
The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
The embodiments of the magnetic component and the manufacturing method thereof are further described below.
In step S400, an insulation material may be coated on a surface of the first portion 301 and the second portion 302 of a magnetic core for generating an insulating coating layer 303 (shown in
In step S401, a conducting material is bent to be a predetermined shape so as to form a preformed conductive body 304. For example, the conducting material may be copper for the person skilled in the art. Person skilled in the art bends conducting material to be a predetermined shape so as to form a preformed conductive body 304. In one embodiment, the copper wire may be wrapped around a copper wire winding set. In another embodiment, person skilled in the art bends conducting material to be a default shape which may be dependent on the user design requirement.
In step S402, the preformed conductive body 304 may be assembled with the insulation magnetic core 307 to form the magnetic component 305. Based on the insulation magnetic core 307 including the first portion 301 and the second portion 302 and the preformed conductive body 304, the insulation magnetic core 307 including the first portion 301 and the second portion 302 may be assembled with the preformed conductive body 304 to form the magnetic component 305 wherein an insulation material may be coated on a surface of the first portion 301 and the second portion 302 of the magnetic core. For example, if the preformed conductive body 304 may be a copper wire winding set and the central column 308 of the first portion 301 and the second portion 302 of the magnetic core may be a cylinder, the magnetic component 305 may be formed when the preformed conductive body 304 may be disposed on the surface of the central column 308 of the first portion 301 and/or the second portion 302 of the magnetic core.
In one embodiment, the surface of the preformed conductive body 304 may be covered with the insulation material. In another embodiment, an insulation layer may be adhered to the surface of the preformed conductive body 304 so that the preformed conductive body 304 having the insulation layer cooperates with the insulation magnetic core 307 to facilitate the insulation effect between the preformed conductive body 304 and the insulation magnetic core 307.
Based on the aforementioned descriptions, since the steps S400 and S401 may be performed independently, the steps S400 and S401 may be either simultaneously or sequentially performed according to the user design requirement.
In the present invention, the shape of the magnetic core may not by limited to form either regular or irregular shape. For example, the core shape of “EE” can be core shapes of “EI” and “UU” so that the magnetic core may be assembled with the preformed conductive body 304 to form the magnetic component having arbitrary shapes of magnetic cores.
In one embodiment, the magnetic core includes at least two portions and the insulating coating layer may be covered on the surface of the magnetic core to form the insulation magnetic core 307. The insulation magnetic core 307 and the preformed conductive body 304 form the magnetic component. In the magnetic component of the present invention, the wire winding frame may be omitted advantageously, and the spark effect between the conductive body and the magnetic core and the damage of the power supply are thus avoided. In one embodiment, the magnetic component may be either inductive component or transformer.
In one embodiment, when the edge of the magnetic core forms a sharp profile, the magnetic core includes a lead angle portion for preventing the sharp edge of the magnetic core from the integrity and completeness of the insulating coating layer 303 before coating the insulating coating layer 303. In
According to the above-mentioned descriptions, the contact region between the magnetic core and the conductive body includes the insulating coating layer to improve the spark effect between the conductive body and the magnetic core.
The magnetic component and a manufacturing method of the present invention simplify the manufacturing process of the magnetic component for advantageously shrinking the volume of the magnetic component. Further, the magnetic component and a manufacturing method form a better insulation between the magnetic and conductive body of the magnetic component to improve the spark effect between the conductive body and the magnetic core due to the insulating coating layer on the surface of the magnetic core.
As is understood by a person skilled in the art, the foregoing preferred embodiments of the present invention are illustrative rather than limiting of the present invention. It is intended that they cover various modifications and similar arrangements be included within the spirit and scope of the appended claims, the scope of which should be accorded the broadest interpretation so as to encompass all such modifications and similar structure.
Number | Date | Country | Kind |
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201110455600.3 | Dec 2011 | CN | national |