Inductor and method of manufacturing the same

Patent metadata

Field	Value
Publication number	US-9431166-B2
Application number	US-201414196786-A
Country	US
Kind code	B2
Filing date	Mar 4, 2014
Priority date	Mar 6, 2013
Publication date	Aug 30, 2016
Grant date	Aug 30, 2016

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.

First claim

The invention claimed is:

1. An inductor, comprising:
a magnetic core;
a winding formed around the magnetic core;
a first resin provided between turns of the winding;
a second resin covering the winding and the first resin; and
a conductive plate provided on one surface of the second resin,
wherein the second resin has higher filler content than the first resin, and the conductive plate is attached to the second resin with a conductive material having lower rigidity than the conductive plate interposed therebetween.

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 , wherein a gap is formed in the magnetic core, and
a capacitor is provided in the gap.

7. The inductor according to claim 6 , wherein the gap is formed in an end part in a direction perpendicular to a direction of winding of the winding.

8. The inductor according to claim 6 , wherein a rectifier is provided in the gap.

9. The inductor according to claim 1 , 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.

10. An inductor, comprising:
a magnetic core;
a winding formed around the magnetic core;
a first resin provided between turns of the winding;
a second resin covering the winding and the first resin; and
a tubular bobbin, wherein:
the second resin has higher filler content than the first resin,
the magnetic core is inserted into a hold of the bobbin,
the winding is wound around the bobbin, and
a conductive material having lower rigidity than the bobbin and the magnetic core is provided between the bobbin and the magnetic core.

11. The inductor according to claim 10 , wherein recesses and projections are formed on an outer periphery of the bobbin, and the winding is disposed in the recesses.

Assignees

• Toshiba Kk

Inventors

• Shijo Tetsu
• Okamoto Tetsushi
• Sakai Masahiro
• Hiroshima Satoshi
• Obayashi Shuichi
• Yamada Akiko

Classifications

• H01F41/127

  Encapsulating or impregnating (encapsulating coil and core H01F41/005) · CPC title

• H01F27/022 Primary

  Encapsulation · CPC title

• H01F41/005

  Impregnating or encapsulating (insulating of windings H01F41/12) · CPC title

• H01F27/34 Primary

  Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields · CPC title

• Y10T29/49071

  by winding or coiling · CPC title