Abstract:
The technology of this invention is to combine the advantage of cold and hot forming magnetic component. Use the advantage of hot forming technology which is 3D complex forming, and use hot-forming magnetic powder to form magnetic component body. Single or multiple rod spaces including T shape, “I” shape or rod shape are previously reserved, and advantage of cold forming technology is used to produce core rod in the highest density of magnetic line, in order to provide the source of high induction magnetic line. Next, assemble single or multiple core rods with body, in order to obtain assembling magnetic component of final desiring magnetic induction.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Technical Field 
         [0002]    The invention relates to an assembling magnetic component which combines the advantage of cold and hot forming magnetic component, and assembles cold forming high-density core rod in hot forming magnetic component body, in order to obtain the final high magnetic induction. 
         [0003]    2. Description of Related Art 
         [0004]    Concerning the magnetic inductor component which is used in market condition, the basic structure is the current-carrying coil which is set at the periphery of the core rod, and magnetic shield material is packaged at the periphery of core rod and current-carrying coil. A general production method is divided into cold and hot forming method. A cold forming method is to form a core rod and magnetic shield material by cold forming method first, and then assemble with current-carrying coil to form a cold forming magnetic component. A hot forming method is to form core rod and magnetic shield material by hot forming method, and then assemble with current-carrying coil to form a hot forming magnetic component. 
         [0005]    As we know, obvious property differences exist in the magnetic component produced by hot and cold forming technology. Hot forming technology is to inject softened/liquefied powder into mold for hot forming, and the advantages are being consistent with complex design shape requirement, high mechanical strength, and low magnetic line loss. Besides, cold forming technology is to force the powder to cold form by pressing, and the advantages are high magnetic material weight rate and lower production cost. Therefore, when producing magnetic component with single hot forming or cold forming method, reverse disadvantages other than the advantage exist. 
         [0006]    According to the disadvantage of traditional hot forming or cold forming magnetic component, hot/cold forming and assembling magnetic component is investigated and developed in this study. It combines the advantage of cold and hot forming magnetic component, and obtains the assembling magnetic component with final desiring magnetic induction. 
       BRIEF SUMMARY OF THE INVENTION 
       [0007]    Before describing the technology content of this invention, please allow us to define or explain the material or technology applied in this invention as follow:
   Core rod: The magnetic inductive material surrounded by coil in general magnetic component, which can be single individual or with components according to requirements, and there are different shape variations, such as T type and rod type.   Magnetic powder: As for magnetic powder mentioned in this invention, the possible material includes Iron, Iron-Silicon (Fe—Si), Ferrite, Sendust or other magnetic material, such as Hi-Flux, MPP (Molypermalloy Powder) and Amorphous, or aforementioned composite material.   Hot-forming magnetic powder: The hot-forming magnetic powder mentioned in this invention is the aforementioned magnetic powder with heated liquid plastic material, such as PC, PS, PE, Nylon, and PP. Please refer to the content of U.S. patent pending application Ser. No. 12/559,580 for technical detail.   Coil: Coil mentioned in this invention is copper wire with insulation surface, which becomes coils in singles or multiple turns, in order to carry current and generate an external magnetic field.   Assembly: Assembly mentioned in this invention is to reserve holes, tenon, and location design for assembly of each component previously, and combine by mechanical or manual means. Common glue sold in market condition can be used for adhesion between each component, such as epoxy resin, silica gel, and instant glue.   Hot forming technology: Mainly heat heat-forming magnetic powder to soften and melt during heat and pressure process. Powder flows to mold and forms, which can form 3D complex forms, such as corner, hollow, and small size. The product doesn&#39;t require annealing and the size is precise, but the disadvantage is high production cost.   Cold forming technology: Press the powder to form. Mechanical pressure is mainly used to form, and then the product is completed by annealing and sintering. The advantage is low production cost, but the disadvantages are the product requires annealing, size varies more, and 3D complex forming cannot be performed.   
 
         [0015]    The differences between the technology characteristics of this invention and technology of general cold or hot forming assembling magnetic component are listed and analyzed as follow: 
         [0000]    
       
         
               
               
               
               
             
           
               
                   
               
             
             
               
                 Name 
                 (This invention) 
                 Traditional cold 
                 Traditional hot 
               
               
                   
                 Hot/cold forming 
                 forming 
                 forming 
               
               
                   
                 assembling 
                 assembling 
                 assembling 
               
               
                   
                 magnetic 
                 magnetic 
                 magnetic 
               
               
                   
                 component 
                 component 
                 component 
               
               
                 Illustration 
                 After the hot forming of 
                 Each component 
                 Each component 
               
               
                   
                 coil and hot-forming 
                 is formed by cold 
                 is formed by hot 
               
               
                   
                 magnetic powder, 
                 forming method, 
                 forming method, 
               
               
                   
                 cold-forming 
                 and then coil is 
                 and then coil is 
               
               
                   
                 production magnetic 
                 assembled to 
                 assembled to 
               
               
                   
                 core is assembled and 
                 form a magnetic 
                 form a magnetic 
               
               
                   
                 combined to form a 
                 component. 
                 component. 
               
               
                   
                 magnetic component. 
               
               
                 Multiple 
                 Yes 
                 Yes 
                 Yes 
               
               
                 material 
               
               
                 assembling 
               
               
                 Magnetic 
                 High 
                 High 
                 Lowest 
               
               
                 material 
               
               
                 weight rate 
               
               
                 Forming 
                 Low 
                 High 
                 Lowest 
               
               
                 pressure 
               
               
                 Assembling gap 
                 Low 
                 Highest 
                 Low 
               
               
                 Loss of gap 
                 Low 
                 Highest 
                 Low 
               
               
                 magnetic 
               
               
                 line 
               
               
                 Saturation gap design* 
                 Yes 
                 Yes 
                 Yes 
               
               
                 External 
                 High 
                 Low 
                 High 
               
               
                 strength 
               
               
                 Production 
                 Medium 
                 Low 
                 High 
               
               
                 cost 
               
               
                 Reference 
                 The content of this 
                 http://www.magict 
               
               
                   
                 invention 
                 ec.com.tw/product 
               
               
                   
                   
                 s.html APL series 
               
               
                   
                   
                 induction, Magic 
               
               
                   
                   
                 Technology 
               
               
                   
               
               
                 *General magnetic component generates air gap in magnetic field line, which delays magnetic saturation. 
               
             
          
         
       
     
         [0016]    From the above comparative analysis, this invention combines hot forming technology of which the advantages are complicated design, high mechanical strength and low magnetic line loss with cold forming technology of which the advantages are high magnetic material weight rate and lower production cost, and creates several assembling form of body and core rod, which can be applied to new magnetic component development, in order to obtain assembling magnetic component of final desiring magnetic induction. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0017]    As demonstrated from  FIG. 1 to 6  of this invention, hot/cold forming assembling magnetic component in this invention is mainly composed of four parts, including rod shape core rod  1 , current-carrying coil  2 , a pair of lead pads  3  and hot forming body  4 . 
         [0018]    The rod shape core rod  1  is composed of magnetic powder, which is generated and formed by cold forming technology, and mainly provides the induction magnetic line source of magnetic component. It is loaded in rod space  41  of hot forming body  4 . There are also variations in rod shape core rod  1 , such as rod shape core rod including single body  1 , T shape core rod  1 A, and rod shape core rod  1  and T shape core rod  1 A which are composed of multiple core rod components. 
         [0019]    As for current-carrying coil  2 , the coil is generated by insulated copper wire with functions of current carrying and external magnetic field generation. 
         [0020]    A pair of lead pads  3  are mainly generated by conductive copper pads. One end of each lead pad connects to one end electricity of current-carrying coil  2 , and another end extends out of hot forming body  4  as current input and out put electrodes. 
         [0021]    Hot forming body  4  is composed of hot-forming magnetic powder and generated by hot forming technology. Magnetic powder coats current-carrying coil  2  and part of lead pad  3 , and rod space  41  for rod shape core rod  1  loading is reserved. Rod space  41  can also be T shape rod space  41 A. 
         [0022]    As demonstrated in  FIGS. 3 and 6 , rod shape core rod  1  or T shape core rod  1 A is added with glue and loaded in rod space  41  or T shape rod space  41 A of hot forming body  4  in this invention, in order to assemble hot/cold forming assembling magnetic component of this invention. 
         [0023]    After current passes through two ends of lead pad  3 , external magnetic field will be generated in current-carrying coil  2 , and then a magnetic field M will be generated in core rod  1  (as demonstrated in the dotted line region of the figure), in order to become the electromagnetic component with energy storage function. 
         [0024]    Rod shape core rod  1  of this invention can be divided into independent single body or combination of multiple components: 
         [0000]    A. Independent single body: The material is totally the same, which is generated by single magnetic powder through cold forming technology, as demonstrated in  FIGS. 2 and 4 . The main application shapes in this invention are rod shape core rod  1  and T shape core rod  1 A. The advantages are simple production, and rapid mass production. Besides, the above two single bodies can combine with other or the same single body.
 
B. Multiple components: Final T shape core rod  1 A is assembled by using multiple components. The same or different magnetic powder can be used in each component, which is generated by cold forming technology. The advantage is to combine different magnetic powders according to magnetic component requirement, as demonstrated from  FIG. 7 to 9 , which include
       1. Combine disk shape core rod  11  with rod shape core rod to form T shape core rod  1 A.   2. Combine groove disk shape core rod  13  of groove  131  with rod shape core rod  12  to form T shape core rod  1 A.   3. Combine perforated disk shape core rod  14  of hole  141  with rod shape core rod  12  to form T shape core rod  1 A. As for rod shape core rod  12 , the length can be adjusted to be out of the surface of perforated disk shape core rod  14  according to requirements.       
 
         [0028]    Hot forming body  4  of this invention includes:
   A. As demonstrated in  FIG. 10 , hot forming body  4  formed by hot-forming magnetic powder through hot forming forms bowl structure which coats exterior and bottom of current-carrying coil  2  and interior of current-carrying coil, top, and coil center are exposed to form T shape rod space  41 A right above the center of current-carrying coil  2 .   B. As demonstrated in  FIG. 11 , hot forming body  4  formed by hot-forming magnetic powder changes into bowl structure to coat the external side and bottom of current-carrying coil  2 , and interior of current-carrying coil and top of the coil are exposed. Besides, the side right below the center of current-carrying coil is not coated, and T shape rod space is formed  41 A.   C. As demonstrated in  FIG. 12 , hot forming body  4  formed by hot-forming magnetic powder changes into bowl structure to coat the external side and bottom of current-carrying coil  2 , and interior of current-carrying coil  2  is exposed. Besides, the side right above the center of current-carrying coil  2  and the side right below the center of coil are not coated, and rod shape rod space is formed  41 .   D. As demonstrated in  FIG. 13 , hot forming body  4  formed by hot-forming magnetic powder changes into bowl structure to coat the external side of current-carrying coil  2  only. Interior, top, and bottom of current-carrying coil  2  are exposed to form “I” shape rod space which is composed of two T shape rod spaces.   E. As demonstrated in  FIG. 14 , hot forming body  4  formed by hot-forming magnetic powder changes into derivative shape, the difference in shape with hot forming body  4  in  FIG. 10  is hot-forming magnetic powder coated in current-carrying coil  2 .   F. As demonstrated in  FIG. 15 , hot forming body  4  formed by hot-forming magnetic powder changes into another derivative shape. The difference in shape with hot forming body  4  in  FIG. 11  is hot-forming magnetic powder coated in current-carrying coil  2 .   
 
         [0035]    To sum up, aforementioned rod shape core rod  1 , the following are the combination variation of T shape core rod  1 A and hot forming body  4 :
   A. As demonstrated from  FIG. 16 to 19 , there is T shape rod space  41 A in the hot forming body  4  in this group product, which combines T shape core rod  1 A.   B. As demonstrated from  FIG. 20 to 21 , there are combinations with different rod  1  and T shape core rods  1 A in hot forming body  4  of this group product.   C. As demonstrated from  FIG. 22 to 25 , there are combinations with different rod shape core rod  1  and T shape core rod  1 A single bodies and T shape core rod  1 A combination in hot forming body  4  of this group product, and an air gap A is formed between two core rods.   
 
         [0039]    The above description is the magnetic component of hot forming body  4  which combines with single rod space or different core rods in the invention. As demonstrated in  FIG. 26 , during the implementation of hot forming body  4  in this invention, multiple rod shape rod spaces  41  or T shape rod spaces can be generated in single integrated hot forming body  4 A, which performs the same or different rod space designs. Each rod space can also be combined with core rod and works with current-carrying coil and a pair of lead pads to produce integrated hot/cold forming assembling magnetic component. Hence, this invention includes multiple different core rod combination ways. 
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       [0040]      FIG. 1  is the magnetic component three-dimensional figure of rod shape core rod combination in this invention. 
         [0041]      FIG. 2  is the magnetic component decomposition three-dimensional figure of rod shape core rod combination in this invention. 
         [0042]      FIG. 3  is the magnetic component cross section view of rod shape core rod combination in this invention. 
         [0043]      FIG. 4  is the magnetic component three-dimensional figure of T shape core rod combination in this invention. 
         [0044]      FIG. 5  is the magnetic component decomposition three-dimensional figure of T shape core rod combination in this invention. 
         [0045]      FIG. 6  is the magnetic component cross section view of T shape core rod combination in this invention. 
         [0046]      FIGS. 7 to 9  are the decomposition three-dimensional figures of different T shape core rods which are composed of multiple components in this invention. 
         [0047]      FIGS. 10 to 15  is the cross section view of every kind of hot forming body in this invention. 
         [0048]      FIGS. 16 to 25  is the cross section view of every product which is combined in this invention. 
         [0049]      FIG. 26  is the three-dimensional figure of hot forming body with multiple rod and T shape rod spaces in this invention, and magnetic component combined with multiple rod and T shape core rods. 
       DESCRIPTION OF PARTS 
       [0000]    
       
         Rod shape core rod  1   
         T shape core rod  1 A 
         Disk shape core rod  11   
         Rod shape core rod  12   
         Groove disk shape core rod  13   
         Groove  131   
         Perforated disk shape core rod  14   
         Hole  141   
         Current-carrying coil  2   
         Lead pad  3   
         Hot forming body  4   
         Integrated hot forming body  4 A 
         Rod shape rod space  41   
         T shape rod space  41 A 
         Air gap A 
         Magnetic field M