WO2015008969A1 - Inductor having self-focusing structure, method for manufacturing same, and hybrid inductor comprising same - Google Patents

Abstract

The present invention relates to an inductor having a self-focusing structure, a method for manufacturing the same, and a hybrid inductor comprising the same and, more particularly, to an inductor, a method for manufacturing the same, and a hybrid inductor comprising the same, the inductor comprising: a core assembly comprising a core having a core body of a predetermined length and a coil wound around the core body; and a focusing cover containing a permeable substance, the focusing cover being formed such that, after the core assembly is inserted therein, the focusing cover surrounds at least a part of the coil at the outer periphery of the core assembly, thereby limiting external diffusion of lines of magnetic force generated by a current flow through the coil and focusing the lines of magnetic force. The present invention is advantageous in that, by focusing lines of magnetic force through the focusing cover, the efficiency of a choke transformer or another type of transformer is improved further; an air gap can be formed through a gap flange; and the simple structure reduces manufacturing costs.

Description

Inductor having a magnetic focusing structure, a method of manufacturing the same and a hybrid inductor including the same

The present invention relates to an inductor having a self-focusing structure, a method of manufacturing the same, and a hybrid inductor including the same. More specifically, the inductor is applied to various power supply devices such as ballasts of discharge lamps to focus magnetic force lines. Disclosed are an inductor having a focusing cover for increasing efficiency as an air gap and also easily adjusting inductance through a gap flange which functions as an air gap or as a winding guide, and furthermore, a method of manufacturing the same. A hybrid inductor including an inductor such as a transformer and an inductor for controlling a trigger of a switching device is disclosed.

Generally, a choke transformer is applied to the power supply for the purpose of controlling the output voltage to be constant. For example, a discharge lamp such as a fluorescent lamp requires a high voltage for driving (starting and maintaining lighting) and has a stabilizer because the discharge is stable only when the supplied voltage is constant. Is used.

1 is a cross-sectional view showing an example of an inductor that can function as a general choke transformer.

As shown in FIG. 1, an inductor for a choke transformer may include cores 11a, 11b, 12a, and 12b made of ferrite, bobbins 40, and bobbins 40 in which the cores are inserted. It is configured to include a coil (50) and the like wound in the). FIG. 1A illustrates an embodiment in which E-E type cores 11a and 12a are applied, and FIG. 1B illustrates an embodiment in which E-I type cores 11b and 12b are applied.

When the voltage is regulated by the choke transformer (when current flows in the coil), the choke transformer generates magnetic force as shown in FIG. 2, and the magnetic force lines generated by the choke transformer must be focused so as not to spread widely outside the coil 50. The function as an inductor is improved.

However, typical inductors for choke transformers are structurally limited in limiting the diffusion of magnetic field lines out of the coil 50. In particular, the choke transformer inductor having a T-shaped core or an I-shaped core shown in FIG. 2 has a simpler structure than the inductor for a choke transformer having an EE-type core or an EI-type core. Although there is an advantage that it can be, since there is no structure for magnetic field line focusing around the coil, the efficiency is lower than the inductor for the choke transformer having an EE type core or EI type core and is used only in part.

Furthermore, the inductor accumulates energy in the form of a magnetic field in the core. When the inductor exceeds the amount of energy that the inductor can store, saturation occurs and the inductor does not accumulate energy and the winding is shorted.

Therefore, in order to give the inductor greater magnetic field strength, an air gap is used. Referring to the air gap concept diagram of the inductor shown in FIG. 3, in contrast to the case where the air gap is not applied, The larger the size of the air gap, the greater the inductor's ability to accumulate more energy in the air gap, thereby increasing the magnetic field strength of the inductor.

To this end, portions of the EE cores 11a and 12a shown in FIG. 1A are in contact with each other, and portions of the EI cores 11b and 12b shown in FIG. 1B are in contact with each other. Air gaps are formed, allowing larger currents to flow through the same core without reaching saturation.

When air is used to form such an air gap in the inductor, there is a problem in that the inductor is not easily assembled due to the formation of the air gap and the air gap is not formed to the correct thickness. In addition, it is also difficult to precisely adjust the thickness of the pores, and there is a problem that the manufacturing process of the inductor is complicated.

Furthermore, in the case of applying a T-shaped core or an I-shaped core unlike an E-E-type core or an E-I-type core, there is a problem in that it is not easy to apply an air gap due to the shape limitation of the core.

The present invention is to solve the problems of the prior art as described above, it is possible to effectively focus the magnetic force lines generated during voltage regulation, and the structure of the inductor and such an inductor that can be used as a structurally simple choke transformer, etc. It is to provide a manufacturing method that can be easily produced.

Furthermore, when air is used to form an air gap in the inductor, the inductor is not easily assembled due to the formation of the air gap, and the air gap is not formed with the correct thickness. It is to solve the problem that the thickness of the air gap is not easy to adjust and the manufacturing process of the inductor is complicated. Especially, in the case of applying a T-shaped core or an I-shaped core, unlike the EE-type core and the EI-type core, the shape of the core is limited. Due to this problem, it is not easy to apply an air gap, and in the case of a straight core or a T-shaped core, it is intended to solve the problem that the coiled coil is easily detached.

Furthermore, an object of the present invention is to provide a hybrid inductor including an inductor for a choke transformer and a switching trigger.

In addition, in the manufacturing process of a conventional transformer or choke transformer or the like to remove the dangerous press process to provide a manufacturing method that can be more simply and easily manufacture an inductor such as a transformer or a choke transformer.

The problem to be solved by the present invention is not limited to the above problem, and other problems that are not mentioned will be clearly understood by those skilled in the art from the following description.

In accordance with an aspect of the present invention, an inductor includes a core assembly including a core having a core body having a predetermined length and a coil wound around the core body; And a magnetic material line, wherein the core assembly is inserted to surround at least a portion of the coil at an outer side of the core assembly, thereby limiting external diffusion of the magnetic force line generated according to the current flow of the coil. It may be configured to include a focusing cover to focus.

Preferably, the core assembly may include a core having a flange formed of a magnetic material at one or both ends of the longitudinal body of the core body and having a vertical cross section having an I-type or a T-type.

More preferably, the flange may be formed such that the thickness becomes thinner from the center toward the side such that the vertical cross sectional area of the inner circumference on the flange and the horizontal cross sectional area of the core body are the same.

Alternatively, the core assembly may include a core having a vertical flange having an I-type or T-type with a gap flange formed of a non-conductive material at either or both ends of the longitudinal body.

Further, the core assembly may include a core having a vertical cross-section of an I-type having a flange formed of a magnetic material at one of both ends of the core body in the longitudinal direction and a gap flange formed of a non-magnetic material at the other. .

The core assembly may further include a bobbin in which the core body is inserted into a central portion thereof; And it may include a coil wound around the bobbin.

Preferably the core assembly, the insulating layer formed on part or all of the core; And a coil wound around a portion of the core in which the insulating layer is formed.

More preferably, the focusing cover may be formed in a circular or polygonal pipe structure provided with openings formed at both ends thereof to insert the core assembly to surround the outer circumference of the coil.

Here, the focusing cover may be configured by combining a plurality of focusing cover pieces vertically divided in the longitudinal direction.

Further, the focusing cover may be spaced apart at regular intervals along the side circumference to form a plurality of through holes.

Alternatively, the focusing cover may be provided with a plurality of grooves spaced apart at regular intervals in the longitudinal direction from the upper or lower side of the side surface, or alternately spaced at regular intervals in the longitudinal direction alternately with the upper and lower sides of the side surfaces to form a plurality of grooves. It may be.

Further, the focusing cover may have a cup structure in which an opening is formed at one end and a shielding part is formed at the other end, and the core assembly is inserted into the opening to surround the outer circumference of the coil.

Further, the focusing cover may include: an upper focusing cover formed of a cup structure into which an upper end of the core assembly is inserted; And a lower focusing cover formed of a cup structure into which the lower end of the core assembly is inserted.

Preferably, the focusing cover may be formed with a plurality of openings whose sides are opened from the one end to the other end.

In addition, the focusing cover may be formed in a plurality of fan-shaped or cross-shaped shapes in which the shielding part is unfolded from the center to the outside, and the opening part may be formed in correspondence with the shape of the shielding part.

Furthermore, a coupling groove corresponding to an upper end shape of the core assembly may be formed on an inner surface of the shielding part of the focusing cover, and the upper end of the core assembly may be fitted into the coupling groove to be fastened.

The focusing cover of another form is formed in a closed cylindrical structure having a space in which shields are formed at both ends of a circular or polygonal pipe to accommodate the core assembly, and a plurality of focusing cover pieces vertically divided in the longitudinal direction are combined. Can be.

Here, the focusing cover may be formed with a plurality of openings whose side surfaces are open from the upper surface to the lower surface.

In another embodiment, the focusing cover may have a rectangular frame structure having a predetermined thickness, and the core assembly may be inserted into the focusing cover but fitted to the rectangular frame of the focusing cover in a longitudinal direction.

Further, the focusing cover in another form may include a plurality of support members having a surface corresponding to a longitudinal outer surface of the core assembly and spaced apart from each other by a predetermined distance along an outer angle of the core assembly; And a connecting member connecting the supporting members between the supporting members.

Preferably, the support member has a horizontal cross section having three surfaces, one surface corresponding to the outer surface of the core assembly, two surfaces perpendicular to each other, and the four support members are the outer angle of the core assembly. Along each other is spaced apart from each other, the horizontal cross section of the focusing cover may form a square.

More preferably, the end of the flange or gap flange and the focusing cover may be fixed to maintain the separation distance between the core assembly and the focusing cover at a predetermined position on the inside of the focusing cover. One end may be coupled to each other coupled to each other.

Another type of core assembly includes a first core body wound around a first coil; A second core body wound around a second coil; And a gap flange positioned between the first coil and the second coil.

Furthermore, the hybrid inductor according to the present invention comprises a core assembly comprising a core having a core body of a predetermined length and a coil wound around the core body; And a magnetic material line, wherein the core assembly is inserted to surround at least a portion of the coil at an outer side of the core assembly, thereby limiting external diffusion of the magnetic force line generated according to the current flow of the coil. A first inductor including a focusing cover to focus; It may be configured to include a second inductor including a toroidal coil wound in the longitudinal direction to the focusing cover.

Preferably, the first inductor is spaced apart at regular intervals in the longitudinal direction from the upper or lower side of the side surface to form a plurality of grooves, or alternately spaced at regular intervals in the longitudinal direction by alternating the upper and lower sides of the plurality of grooves. And a formed focusing cover, and the toroidal coil of the second inductor may be wound around the groove of the focusing cover.

Furthermore, it includes an insulating layer coated on the surface of the focusing cover, wherein the toroidal coil may be wound on the insulating layer.

Alternatively, the first inductor may include: a plurality of support members having a surface corresponding to a longitudinal outer surface of the core assembly and spaced apart from each other by a predetermined distance along an outer angle of the core assembly; And a focusing cover including a connecting member connecting the supporting members between the supporting members, and the toroidal coil of the second inductor may be wound around the connecting member.

A core assembly comprising a core having a core body of a predetermined length and a coil wound around the core body; And a magnetic material line, wherein the core assembly is inserted to surround at least a portion of the coil at an outer side of the core assembly, thereby limiting external diffusion of the magnetic force line generated according to the current flow of the coil. A first inductor including a focusing cover to focus; A second inductor may include an inductor ring spaced apart from an upper portion of the focusing cover and connected to the focusing cover with a plurality of support legs, and a coil wound in a toroidal shape on the inductor ring.

Furthermore, the inductor manufacturing method according to the present invention, the core body manufacturing step of manufacturing a core body of a round or polygonal cross-section wound a certain number of magnetic steel sheet; A core assembly manufacturing step of manufacturing a core assembly by winding a coil surrounding the core body at a stop portion of the core body; A focusing cover manufacturing step of manufacturing a focusing cover containing a magnetic material and having an opening corresponding to a cross section of the core assembly; And a focusing cover forming step of inserting the core assembly into a focusing cover to surround at least a portion of the coil at an outer side of the core assembly.

Preferably, in the focusing cover manufacturing step, the core assembly may be inserted into a predetermined number of times to form a steel plate having a magnetic property so as to have a through space surrounding the core assembly.

More preferably, the method further includes a flange manufacturing step of manufacturing a flange by winding a predetermined number of magnetic steel sheets to have a through space corresponding to the cross-sectional diameter of the core body, wherein the core assembly manufacturing step includes: an upper end of the core body Or fitting the flange to the core body by fitting the flange to at least one of lower ends; And forming a coil wound around the core body at a stop portion of the core body.

Furthermore, the core body manufacturing step may include: manufacturing a core body having a circular or polygonal cross section wound by winding a steel plate having a magnetic conductivity; And coating the outer surface of the core body with an insulating material or inserting the core body into an insulating member having a through hole corresponding to the diameter of the core body.

According to the inductor having a magnetic focusing structure according to the present invention, by focusing the magnetic force lines by the focusing cover, the efficiency of the inductor applied to the choke transformer or transformer can be further improved, and the coil usage of the core assembly can be relatively reduced. The manufacturing cost can be reduced, and the inductor used in the choke transformer or transformer can be made more compact, thereby reducing the footprint of the installation.

In addition, in the present invention, the inductance of the inductor can be easily adjusted by the reluctance according to the thickness of the gap flange by applying a gap flange, and in particular, it is not easy to apply an air gap in the structure of an I-shaped or T-shaped core. In addition, the gap flange may be applied to a straight or T-shaped core to facilitate winding of the coil and prevent the wound coil from being separated.

Furthermore, the present invention simplifies the manufacturing process and reduces the manufacturing cost by removing the bobbin and replacing the insulating layer, and at the same time, the overall volume and the installation area of the inductor are smaller and the coil usage is reduced compared to the case of using the bobbin. The additional effect of efficient use of resources is also obtained.

And the focusing cover in the present invention by removing a certain portion that is not a full cylindrical or open to ensure the appropriate thickness, through which heat generated in the internal coil can be easily generated in the air can lower the temperature of the coil In addition, it is possible to provide an inductor that effectively focuses magnetic field lines while saving material for manufacturing the focusing cover.

Furthermore, the present invention provides a core through which the magnetic force lines forming closed loops can pass through the same cross-sectional area, and the same overall length as that of a conventional core by applying a core having a flange-adjusted thickness. The structure can increase the number of turns while having the same number of turns, but can reduce the overall length of the core while reducing the overall size while improving the performance of the inductor.

In the hybrid inductor according to the present invention, the first inductor used as a choke transformer or the like and the second inductor used as an oscillator to trigger the switching element are packaged into one to further increase the integration of components while miniaturizing the overall electrical and electronic devices. Can contribute to

In addition, the method of manufacturing an inductor having a self-focusing structure according to the present invention manufactures a core by winding a steel sheet in the form of a roll, thereby making it possible to manufacture the inductor through a simpler and safer process by eliminating the existing dangerous and complicated press working process. The manufacturing cost can be lowered, and in particular, since the thickness of the steel sheet constituting the core and the number of windings in the form of rolls can be selectively controlled, the characteristics of the inductor can be adjusted by adjusting the core itself without depending on the number of turns of the coil.

1 is a cross-sectional view showing an example of an inductor that can function as a general choke transformer,

2 shows an example of a magnetic force generated in an inductor,

3 shows a schematic diagram of an air gap of the inductor shown,

4 shows a perspective view of a first embodiment of an inductor according to the invention,

FIG. 5 is an exploded perspective view of the modified focusing cover of the first embodiment of FIG. 4;

6 shows a sectional view of the first embodiment of FIG. 4,

FIG. 7 shows an example of magnetic field lines generated in the inductor according to the present invention shown in FIG. 6,

8 shows a cross-sectional view of a variant embodiment of the first embodiment of FIG. 4,

9 is a conceptual diagram of a core having the same cross-sectional area in the magnetic force line traveling direction proposed in the present invention,

10 shows a cross-sectional view of the core according to the invention of FIG. 9,

11 shows various examples of the focusing cover of the inductor according to the present invention,

12 shows an embodiment of the fastening structure of the core assembly and the focusing cover in the inductor according to the present invention,

13 shows a perspective view of a second embodiment of an inductor according to the invention,

FIG. 14 shows a sectional view of the second embodiment of FIG. 13;

FIG. 15 shows a sectional view of a modified embodiment of the second embodiment of FIG. 13;

FIG. 16 shows a perspective view of another modified embodiment of the second embodiment of FIG. 13;

17 shows a perspective view of a third embodiment of an inductor according to the invention,

FIG. 18 shows a perspective view of a modified embodiment of the third embodiment of FIG. 17;

19 shows a perspective view of a fourth embodiment of an inductor according to the present invention;

20 shows a perspective view of a modification to the fourth embodiment of FIG. 19,

21 shows a perspective view of a fifth embodiment of an inductor according to the present invention;

FIG. 22 shows a perspective view of a modified embodiment of the fifth embodiment of FIG. 21;

23 shows a perspective view of a sixth embodiment of an inductor according to the present invention;

FIG. 24 shows a sectional view of the sixth embodiment of FIG. 23;

25 shows a perspective view of a seventh embodiment of an inductor according to the present invention;

26 shows a perspective view of an eighth embodiment of an inductor according to the present invention;

27 shows a perspective view of a ninth embodiment of an inductor according to the invention,

28 shows a perspective view of a tenth embodiment of an inductor according to the present invention;

29 shows a perspective view of an eleventh embodiment of an inductor according to the present invention;

30 shows a process embodiment for a method of manufacturing an inductor according to the present invention,

FIG. 31 illustrates various modified embodiments of a process of manufacturing a core assembly in a method of manufacturing an inductor according to the present invention.

32 shows a first embodiment of a hybrid inductor according to the present invention,

33 illustrates magnetic field lines in a hybrid inductor according to the present invention,

34 shows a second embodiment of a hybrid inductor according to the present invention,

35 shows a third embodiment of a hybrid inductor according to the present invention,

36 shows a fourth embodiment of the hybrid inductor according to the present invention.

In order to explain the present invention, the operational advantages of the present invention, and the objects achieved by the practice of the present invention, the following describes exemplary embodiments of the present invention and looks at it with reference.

First, the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention, and singular forms may include plural forms unless the context clearly indicates otherwise. Also in this application, terms such as "comprise" or "have" are intended to indicate that there is a feature, number, step, action, component, part, or combination thereof described on the specification, one or more other It is to be understood that the present invention does not exclude the possibility of adding or presenting features or numbers, steps, operations, components, components, or combinations thereof.

In describing the present invention, when it is determined that the detailed description of the related well-known configuration or function may obscure the gist of the present invention, the detailed description thereof will be omitted.

In the present invention, the first focusing inductor having a magnetic focus structure through the focusing cover, the second through the magnetic field line of the magnetic field of the flange thickness is adjusted so that the same, the third winding guide function or air gap (gap) gap gap applied self-focusing An inductor having a structure, a first coil wound by a fourth gap flange and an inductor wound around a second coil, a manufacturing method of an inductor having a fifth self-focusing structure, and a sixth hybrid inductor are described below. Through the present invention will be described.

First, the inductor having a self-focusing structure through the focusing cover will be described as the first main feature of the present invention.

4 shows a perspective view of a first embodiment of an inductor according to the invention.

In the first embodiment of the inductor having a magnetic focusing structure according to the present invention, the inductor 100 is composed of a core assembly 110 and a focusing cover 160 into which the core assembly 110 is inserted. The focusing cover 160 focuses the magnetic force lines by restricting the diffusion of the magnetic force lines generated by the current flow of the coil of the core assembly to the outside. For this purpose, the focusing cover 160 has a magnetic force line along the surface of the focusing cover 160. It is formed by containing a magnetic material to flow.

In the first embodiment illustrated in FIG. 4, the focusing cover 160 is a cylindrical pipe structure having openings 161 and 162 through which both ends penetrate, and the focusing cover 160 surrounds the coil of the assembly 110. The core assembly 110 is inserted into the openings 161 and 162 of the focusing cover 160. The focusing cover 160 may be formed of a polygonal pipe such as a square in addition to the cylindrical shape.

FIG. 5 is an exploded perspective view of the modified focusing cover of the first embodiment illustrated in FIG. 4, wherein a plurality of pipe focusing covers 160 are vertically divided in the longitudinal direction as illustrated in FIG. 5. The two focusing cover pieces (a, b) may be configured in combination. By combining the plurality of focusing cover pieces ab divided in this way to form the focusing cover 160, it is easy to accommodate the core assembly 110 in the focusing cover 160 regardless of the shape of the core assembly 110. Become.

Referring to the cross-sectional view of the first embodiment shown in FIG. 6 to look at the first embodiment in more detail, the core 120 in the core assembly 110 is located on the upper and lower portions of the core body 121. The core body 121 is inserted into the bobbin 140 to which the coil 150 is wound, as an I type core having flanges 123 and 124, respectively. Here, the core body 121 and the flanges 123 and 124 may be made of various materials through which magnetic force is transmitted, including ferrite, silicon steel, general steel, and the like, and the core assembly 110 may include an I-shaped core. Various types of cores, such as a straight core and a T-shaped core, may be applied.

The focusing cover 160 is a pipe structure provided to surround the bobbin 140 at predetermined intervals, and the coil 150 of the core assembly 110 is positioned inside the focusing cover 160. The focusing cover 160 may contain various magnetic materials through which magnetic force passes, including ferrite, silicon steel, and general steel. For example, when the focusing cover 160 is made of ferrite, the focusing cover 160 may be manufactured by pressing and molding and then sintering. In the case where the focusing cover 160 is made of silicon steel, the drawing cover or the plate may be rounded and then bent. It can be manufactured by the method of joining both bent ends, etc. Furthermore, it can also manufacture by winding several sheets in a circular roll form.

The core assembly 110 and the focusing cover 160 may be coupled using an adhesive, an adhesive tape, a shrinking tube, or the like, or may include a mechanical coupling method such as a press-fitting method for the core assembly 110 and the focusing cover 160. Various methods may be used that can be combined firmly.

Furthermore, in the first embodiment of FIGS. 4 to 6, the flanges 123 and 124 of the core assembly 110 are illustrated as being inserted into the focusing cover 160, but depending on the applied situation or the manufacturing process. One or both of the flanges 123 and 124 of the assembly 110 may be configured to span the focusing cover 160 without being inserted into the focusing cover 160.

In the first embodiment, when a current flows in the coil 150, a magnetic force line is generated in the core assembly 110. In the present invention, the magnetic force lines generated in the core assembly 110 are focused by applying the focusing cover 160. FIG. 7 illustrates an example of magnetic force lines generated in the inductor according to the present invention illustrated in FIG. 6, and as shown in FIG. 7, the coil circumference of the core assembly 110 contains a magnetic material. Since the magnetic field lines directed to the outside flow along the focusing cover 160, the diffusion of the magnetic field lines to the outside of the focusing cover 160 is confined.

Accordingly, in the inductor having the magnetic focusing structure of the first embodiment according to the present invention, the efficiency of the inductor can be improved by focusing a magnetic force line, so that the first embodiment can relatively use the coil 150 of the core assembly 110. In addition, the manufacturing cost can be reduced, and the inductor used in the choke transformer or transformer can be made more compact, thereby reducing the footprint of the installation.

On the other hand, the first embodiment has a simple structure of the core assembly 110 can further reduce the manufacturing cost, and in the case of the choke transformer or transformer is generally installed to adjust the characteristic values such as L value and Q value In order to avoid loss of air gap, it is effective to avoid the area around the winding of the coil. In the case of EE core, the air gap must be formed in the area where both E-type cores meet each other, so it is inevitably corresponding to the loss of magnetic field lines. The coil is wound around the coil, and at this time, the coil located at a portion around the air gap where the two E-type cores meet tends to not function. However, according to the first embodiment of the present invention, since the gap is formed in a portion where the core assembly 110 and the focusing cover 160 are in contact with each other, this loss can be avoided, thereby reducing the number of turns of the coil while having the same effect. The coil consumption can be further reduced and the inductor volume as a whole can be reduced.

FIG. 8 shows a cross-sectional view of a variant embodiment of the first embodiment of FIG. 4, in which FIG. 8 removes the bobbin 140 and the coil 150 from the core body 121 in the configuration shown in FIG. 6. It is directly wound on. In order to remove the bobbin 140 and directly wind the coil 150 to the core body 121, an insulating layer 130 made of an insulating material is coated on the surface of the core body 121. In FIG. 8, the insulating layer 130 is coated on the core body 121 and the flanges 123 and 124 as a whole. However, in some cases, only the surface portion of the core body 121 to which the coil 150 is wound is limited. And may be coated. Furthermore, in addition to the coating method, the insulating layer 130 may be formed in various ways. For example, the core layer 121 may be inserted into a separately manufactured insulating member to form the insulating layer 130.

The insulating layer 130 may be formed by coating with an insulating material such as liquid silicone, urethane, or insulating paint, or may be formed by other methods such as winding an insulating tape or injecting a tube or plastic.

Since the embodiment of FIG. 8 replaces the bobbin 140 with the insulating layer 130 in comparison with the first embodiment of FIG. 6, the manufacturing process can be simplified to reduce the manufacturing cost. Compared to the case of using the A-type inductor, the overall volume and installation area of the inductor can be reduced, and the additional effect of efficient use of resources such as reducing the amount of coil usage can be obtained.

In more detail on the effect of removing the bobbin in the embodiment of Figure 8, in the case of the cores based on the E-type core commonly used in the existing or the embodiment shown in FIG. In order to achieve the proposition, the coil is wound around the insulator bobbin and the coil is wound into the core, which increases the dimensions of the coil winding area by the minimum thickness of the bobbin, thereby increasing the overall coil usage. . In addition, in the transformer, a certain cross-sectional area is required for the core used for stable focusing of the magnetic field lines. Due to the characteristics of the E-shaped coils arranged in a plane, the core length becomes too large when the core is designed to optimize the consumption of the coil. As a result, the cross-sectional area of the general core has a rectangular shape, which leads to a problem in that the length of the coil must be longer.

However, as shown in the present invention, when the coil is removed and the coil is wound directly on the core having a circular cross section, the coil consumption can be reduced by about 30% compared to the conventional E-type core of the same standard. Even so, the coil consumption can be reduced by nearly 20% compared to the existing E type.

More specifically, in the case of the E16 type core, the center cross section has a dimension of 4.0 * 8.2mm, and the bobbin cross section for winding the coil is 5.7 * 9.6mm. If a coil of 0.27mm diameter is wound around 250 turns on such bobbin, the coil bundle size is about 10.2 * 14.3mm and a coil wire of about 9,950mm is required. However, when the bobbin applied in the present invention is removed and the central cross section of the I-type or T-type core in which the coil is directly wound is about 6.5 mm, the coil bundle having an outer diameter of 11 mm is formed when the coil is wound with the same number of turns, thereby forming a coil of about 6,870 mm. Only the wires are needed, which saves about 31% of the coil compared to the use of bobbins on existing E-type cores.

When the bobbin is used for an I-type or T-type core having a circular cross section as in the present invention as described above with reference to FIG. 6, the required bobbin cross section diameter is 8.0 mm, in which case the outer diameter of the coil bundle of the same turn number is 12.5. The required coil wire length is about 8,050mm, which saves about 19% of the coil compared to the existing E-type core, but consumes about 15% more wire than the bobbin is removed.

As such, when the bobbin is not used in the inductor having the self-focusing structure according to the present invention, the required outer diameter of the core can be reduced by about 1.6 mm. Even if an air gap is provided outside the flange, the size is within 14 mm. Since the volume can be limited compared to the existing E16 type core, the volume is reduced by about 30% and the installation area by about 15%, contributing to the miniaturization of the applied product.

In addition, the present invention proposes a new type of core, which looks at the core whose flange thickness is adjusted so that the area through which the lines of magnetic force, the second main feature of the present invention passes, is the same. The core proposed in the present invention is a core through which the magnetic force lines that travel from the core body toward the flange and form a closed loop can pass through the same cross-sectional area, and FIG. 9 illustrates a core having the same cross-sectional area of the magnetic force line traveling direction of the present invention. A conceptual diagram is shown.

9 (a) is an EE type core, which is formed to have the same cross-sectional area of each part on a path along which a magnetic force line generated through a coil wound around the core travels, and has a cross-sectional area A1 of the core center and both cross-sectional areas of the upper part of the core. By forming the sum of B1 and the sum of the cross-sectional areas of both sides of the core side, the closed loops of the magnetic force lines passing through the core all pass through the same cross-sectional area, thereby improving the efficiency of the inductor.

However, in the case of the I-shaped or T-shaped core, the cross-sectional area of the core through which the magnetic force lines travel is partially different. As shown in FIG. 9B, the flange 123 is formed from the cross-sectional area A2 of the core body 121. From the center B2 toward the outer C2, the cross-sectional area becomes larger, i.e., if the arc radius of the point where the line of magnetic force passes is R, the area through which the line of magnetic force passes is calculated as 2πR * (flange thickness), The cross-sectional area through which the magnetic field lines pass is doubled by 2πR * (flange thickness). Therefore, in the case of (b) of FIG. 9, B2 is larger than A2 and C2 is much larger than B2.

In the present invention, in order for the closed loops of the magnetic force lines to pass through the same area, the flanges are formed to be thinner from the center to the side so that the vertical cross sectional area of the inner circumference on the flange and the horizontal cross sectional area of the core body are the same. As shown in FIG. 9C, the thickness becomes thinner toward the outside from the center of the flange 123 ', where the horizontal cross-sectional area A3 of the core body 121' and the inner arc of the flange 123 'are formed. The vertical cross-sectional areas B3, C3, and the like are all formed to be the same, and more preferably, the flange 123 'may be formed to satisfy the following [Equation 1].

[Equation 1]

Where t (r) is the flange thickness, r is the radius of the inner arc of the flange, and S is the horizontal cross-sectional area of the core body.

As described above, the present invention proposes a core through which magnetic force lines forming a closed loop can pass through the same cross-sectional area similarly to the E-E type core by applying a core having a flange thickness adjusted thereto.

Furthermore, the core proposed in the present invention has the same overall length as the conventional core and can increase the number of turns or reduce the overall length of the core while having the same number of turns, thereby reducing the overall size while improving the performance of the inductor. In this regard, it looks at with reference to the cross-sectional view of the core according to the invention shown in FIG.

In FIG. 10 (a), a typical I-type core is shown. Flanges 123 and 124 are formed at upper and lower portions of the core body 121, respectively, so that the entire length of the core 120 is H1 and the coil is wound. The length of the portion is shown in the form of H2, in contrast to Figure 10 (b) and (c) shows a new type of core (120 ', 120 ″) proposed in the present invention.

10 (b) has the same total length H1 as the general I-type core shown in FIG. 10 (a). As described with reference to the embodiment of FIG. 9, the flange 123 of the core 120 'is illustrated. ', 124' is formed to become thinner from the center toward the side, so that the length of the region in which the coil can be wound around the core 120 'is H3, which is relatively higher than that of H2 of FIG. Lengthened Accordingly, the core 120 ′ according to the present invention shown in FIG. 10 (b) may increase the number of turns of the coil while having the same overall length as the core 120 shown in FIG. 10 (a). do.

In FIG. 10C, the length of the region in which the coil can be wound around the core 120 ″ is H2 equal to that of the core 120 in FIG. 9A, but the flange of the core 120 ″ The total length H4 of the core 120 ″ is formed so that the thickness 123 ″ and 124 ″ becomes thinner from the center to the side, so that the total length H4 of the core 120 shown in FIG. It is relatively shorter than H1. Accordingly, when the core 120 ″ as shown in FIG. 10C is applied, the total length of the core can be reduced while having the same number of turns as the core 120 shown in FIG. 10A. The overall size of the inductor can be further reduced.

As described above, the new type of core proposed in the present invention can pass through the same cross-sectional area of magnetic force lines that form a closed loop by traveling from the body of the core toward the flange, thereby improving the performance of the inductor and at the same time as the conventional core. It is possible to increase the number of turns while having the same or decrease the total length of the core while having the same number of turns.

11 shows various examples of the focusing cover of the inductor according to the present invention.

The focusing cover shown in (a) of FIG. 11 illustrates the focusing cover of the cylindrical pipe structure described above, and in the present invention, in addition to the focusing cover of the simple cylindrical pipe structure, a plurality of the focusing cover as shown in FIG. It may be applied to a focusing cover formed with a through hole, and as shown in (c) of FIG. 11, a plurality of grooves may be formed spaced apart at regular intervals along the circumferential direction from the upper and lower portions of the focusing cover. Alternatively, as shown in (d) of FIG. 11, a plurality of grooves may be formed in the longitudinal direction by alternately alternating the upper and lower portions of the focusing cover.

Furthermore, a focusing cover comprising an inner surface corresponding to the longitudinal outer surface of the core assembly to be inserted and a connecting member connecting the support members between the plurality of support members and the support members disposed spaced apart from each other along the outer periphery of the core assembly. Preferably, the support member may be formed such that a horizontal cross section has a plurality of surfaces, and a surface adjacent to the core assembly corresponds to an outer surface of the core assembly, and the plurality of the support members are formed along the outer angle of the core assembly. Spaced apart at regular intervals, the horizontal cross section of the overall focusing cover is formed to form a square. As an embodiment thereof, in FIG. 11E, the support member has three surfaces thereof, one surface corresponding to an outer surface of the core assembly, and an arc, and two surfaces formed at right angles to each other. The focusing cover is spaced apart from each other by a predetermined interval along the outer shell of the core assembly into which the four supporting members are inserted, and is formed such that the outer shell of the cross section forms a quadrangle as a whole.

As described above, the focusing cover of FIGS. 11 (b) to (e) to be applied in the present invention may be made in various forms by removing a predetermined portion rather than a completely cylindrical shape in consideration of an appropriate thickness. As described above, it is preferable to configure the magnetic force lines forming the closed loop to pass through the same cross-sectional area, but due to limitations in the manufacturing process of the focusing cover, it is not easy to manufacture the focusing cover below a certain thickness or to reduce the thickness to a certain size or less. There are various problems such as a sharp increase in manufacturing costs. Due to such problems in the manufacturing process of the focusing cover, the cross-sectional area of the focusing cover is larger than the cross-sectional area of the core through which the magnetic lines of force pass, and as the cross-sectional area of the focusing cover becomes larger than necessary, material loss for manufacturing the focusing cover is increased. Therefore, by considering the proper thickness of the cross-sectional area through which the magnetic force lines pass, by manufacturing a focusing cover that removes a certain portion rather than a cylindrical shape, material loss for manufacturing the focusing cover can be reduced. That is, in the case where it is assumed that the thickness of the focusing cover shown in FIG. 11 (a) is an appropriate thickness in consideration of the cross-sectional area where a substantial magnetic force line passes, the (b) to (b) of FIG. The focusing cover shown in e) may have the same cross-sectional area as that of the focusing cover shown in FIG. 11A while increasing its thickness, thereby substantially reducing overall material loss of the focusing cover.

Furthermore, as a certain portion of the focusing cover is removed, heat generated in the internal coil can be easily generated in the air, thereby lowering the temperature of the coil.

The various types of focusing covers shown in FIG. 11 may be applied not only to the inductor having the bobbin shown in FIG. 6 but also to the inductor having the bobbin shown in FIG. 8 removed, and to various embodiments according to the present invention. Appropriately applicable.

Furthermore, the present invention provides a fastening structure of the core assembly and the focusing cover to more stably fix the core assembly to the focusing cover. FIG. 12 illustrates an embodiment of the fastening structure of the core assembly and the focusing cover in the inductor according to the present invention. Shows.

12 illustrates various structures in which the cores 120a, 120b, and 120c of the core assembly and the focusing covers 160a, 160b, and 160c are coupled to each other. In FIGS. 12A and 12C, an upper flange ( End portions 127a and 127c of the 123a and 123c and end portions 163a and 163c of the focusing covers 160a and 160c correspond to each other to form a joining portion, and when the core assembly is inserted into the focusing cover, the joining portions are joined to each other. The core assembly is fixed to the focusing cover. In addition, in FIG. 12 (b), the core assembly may be fixed to the focusing cover by forming an engaging portion to fasten the end portion 127b of the core 120b of the core assembly to the upper through hole 163b of the focusing cover 160b. have.

The coupling portion or the focusing cover 160b to which the end portions 127a and 127c of the upper flanges 123a and 123c and the end portions 163a, 163b and 163c of the focusing covers 160a and 160c correspond to each other and are fastened. When the core assembly is inserted into the focusing cover through the coupling part where the core 120b and the end portion 127b of the core assembly are fastened to the upper through hole 163b, the core assembly can be easily assembled at the correct position to maintain a predetermined position of the core assembly. In addition, by providing a desired separation distance between the ends of the focusing cover (160a, 160b, 160c) and the lower flange (124a, 124b, 124c) of the core assembly, the adjustment of the space created at the separation distance acting as a kind of air gap It becomes easy.

13 shows a perspective view of a second embodiment of the inductor according to the invention, and FIG. 14 shows a sectional view of the second embodiment of FIG.

13 and 14, the second embodiment shown in FIGS. 13 and 14 has the same configuration and operation as those of the first embodiment described above, and since the main difference is in the focusing cover 260, repeated description thereof will be omitted. And focusing on the focusing cover 260 will be described.

In the inductor 200 of the second embodiment shown in FIGS. 13 and 14, the focusing cover 260 has an opening 262 formed at one end thereof and a shielding part 265 formed at the other end thereof to have a cup structure as a whole. The core assembly 210 is inserted into the opening 262 of the focusing cover 260. When the focusing cover 260 is made of silicon steel or amorphous metal, the focusing cover 260 can be easily manufactured by drawing.

In the second embodiment, the flange 220 is formed only at one end of the core body 221 as the core 220 as the T-shaped core, and the core body 221 is the bobbin 240 having the coil 250 wound thereon. Inserted in the core assembly 210 is configured, which is not limited to this embodiment may be applied to the type I core with a flange formed on both ends of the core body, all the case of applying the type I core The flange may be formed smaller than the diameter of the focusing cover and both may be inserted into the focusing cover, or the upper flange may be formed smaller than the inner diameter of the focusing cover and inserted into the focusing cover, and the lower flange may be formed larger than the inner diameter of the focusing cover. The opening of the focusing cover may be shaped to span the lower flange.

Furthermore, FIG. 15 shows a cross-sectional view of a modified embodiment of the second embodiment of FIG. 14, in which the bobbin 240 of FIG. 14 is removed and the coil 250 is wound directly on the core body 221. In one case, an insulating layer 230 is formed on the core body 221 and the flange 224 to insulate the core 220 and the coil 250. In FIG. 15, an insulating layer 230 is formed on the core body 221 and the flange 224 as a whole, but an insulating layer may be formed only on a portion of the core body according to a region in which the coil 250 is wound.

FIG. 16 also shows a perspective view of another modified embodiment of the second embodiment of FIG. 13, wherein in FIG. 16, an opening 262 is formed at one end and the other end is similar to the second embodiment of FIG. 13. The shielding part 265 is formed to apply the focusing cover 260 having a cup structure as a whole, and the coupling groove corresponding to the upper end shape of the core assembly 210 on the inner surface of the shielding part 265 of the focusing cover 260 ( 266).

As described above, the coupling groove 266 is formed on the inner surface of the shield 265 of the focusing cover 260 so that the upper end of the core assembly 210 is inserted into the coupling assembly when the core assembly 210 is inserted into the focusing cover 260. 266), the core assembly 210 is fixed in the focusing cover 260 to maintain a stable position of the core assembly 210 even when the inductor is shaken or impacted.

17 shows a perspective view of a third embodiment of an inductor according to the present invention.

In FIG. 17A, the focusing cover 260a is a modified form of the cup-shaped focusing cover 260 of FIG. 13, and an opening 267a having an open side surface from an opening of the focusing cover 260a to a shielding part is provided. It is formed, the shield 265a is in the form of a plurality of fan-shaped spread from the center. In FIG. 17A, the shield part 265a is formed by unfolding two sectors from the same center, and may be formed in a plurality of sectors such as three or four from the same center.

The core 220a is a T-shaped core. The flange 224a corresponds to the shield portion 265a of the focusing cover 265a, and has a fan shape. The core body is formed on a circular bobbin 240a on which the coil 250a is wound. 221a is inserted, and the core assembly is inserted into the focusing cover 260a to surround a part of the side of the coil.

 In FIG. 17B, the focusing cover 260b has a cross-shaped shield 265b, and an opening 267b is formed at the side of the focusing cover 265b in correspondence with the cross-shaped end of the shield 265b. have.

In addition, the flange 224b of the core 220b has a cross shape corresponding to the shielding portion 265b of the focusing cover 265b, and the core body 221a is formed on a square bobbin 240b in which the coil 250b is wound. ) Is inserted. In addition, as shown in FIG. 17C, the bobbin 240c may have a circular shape. When the bobbin 240c is circular, the inner shape of the focusing cover 260c may also be formed to correspond to the circular bobbin 240c. desirable.

FIG. 18 illustrates a perspective view of a modified embodiment of the third embodiment of FIG. 17, wherein FIG. 18A illustrates a cup-type focusing cover having a fan-shaped shield as a modified form of FIG. 17A. 265a is applied and the core 220a also corresponds to the shape of the focusing cover 265a, which is the same as that of FIG. 17A, but in FIG. 18A, the bobbin is removed and the core 220a of the core 220a is removed. The coil 250 was wound directly on the core body 221a to construct a core assembly. Since it is preferable to insulate between the core 220a and the coil 250, an insulating layer 230a is formed on a part of the core 220a, and the insulating layer can be inferred through the above-described details, so a detailed description thereof will be omitted. Shall be.

In addition, in FIG. 18B, a cup-shaped focusing cover 265b having a cross-shaped shield is used as a modified form of FIG. 17B. In FIG. 18B, FIG. Unlike b), the bobbin was removed and the coil 250 was wound directly on the core body 221b of the core 220b. An insulating layer 230b was formed to insulate the core 220b from the coil 250. In FIG. 18B, the core body 221b is configured in a quadrangular shape. As an optional matter, the core body 221c may be configured in the form of a circular column as shown in FIG. 18C.

By applying a focusing cover having such an opening, it is possible to provide an inductor that focuses a magnetic field line effectively while saving material for manufacturing the focusing cover.

19 shows a perspective view of a fourth embodiment of an inductor according to the present invention.

In the fourth embodiment of FIG. 19, the focusing covers 260d and 260e are formed in a sealed tubular structure having shielding portions formed at both ends of the circular pipe to accommodate the core assemblies 210d and 210e. Two focusing cover pieces 260d ', 260d', in which the focusing covers 260d, 260e are vertically divided in the longitudinal direction to easily accommodate 210d, 210e inside the condensed tubular focusing covers 260d, 260e. 260e ', 260e' '), and two focusing cover pieces are joined with the core assemblies 210d and 210e interposed therebetween, and the focusing covers 260d and 260e accommodate the core assemblies 210d and 210e therein. Is formed. 19A illustrates a focusing cover 260d for accommodating a core assembly 210d having a bobbin coil wound thereon, and in FIG. 19B, a core assembly in which a coil is wound around a straight core ( A focusing cover 260e that houses 210e is shown. As shown in FIG. 19B, coupling grooves corresponding to ends of the core assembly 210e are formed in the upper and lower surfaces of the focusing cover 260e so that the core assembly 210e is fixed in the focusing cover 260e. As the end of the core assembly 210e is inserted into and coupled to the coupling groove, the core assembly 210e may be stably fixed inside the focusing cover 260e.

Furthermore, although shown as a cylindrical focusing cover in FIG. 19, the shape may be variously modified, and the number of fragmented focusing cover pieces may be composed of three or more focusing cover pieces divided in consideration of the shape of the core assembly. Can be.

FIG. 20 illustrates a perspective view of a modified embodiment of the fourth embodiment of FIG. 19, wherein in FIG. 20, a plurality of openings having side surfaces opened from an upper surface to a lower surface in the focusing cover illustrated in the fourth embodiment of FIG. 19. The case where an addition is formed is shown.

In FIG. 20, the upper and lower surfaces of the two focusing cover pieces 260f ', 260f ", 260g', and 260g" vertically divided in the longitudinal direction are formed to correspond to each other. Is formed in a fan shape, and is formed in a V shape in FIG. 20 (b). The two focusing cover pieces 260f ', 260f', 260g ', and 260g' are combined with the core assemblies 210f and 210g interposed therebetween to form the focusing covers 260f and 260g. That is, in FIG. 20 (a), the upper and lower shields of the focusing cover 260f formed by combining two focusing cover pieces 260f 'and 260f' 'correspond to each other to form a fan shape which is unfolded from the center part. In response to the fan shape of the shield, an opening is formed from an upper surface of the upper shield to a lower surface of the lower shield. In addition, in FIG. 20B, the upper and lower shields of the focusing cover 260g formed by combining two focusing cover pieces 260g 'and 260g' 'correspond to each other to form a cross. Corresponding to the cross shape, an opening is formed from an upper surface of the upper shield to a lower surface of the lower shield.

In FIG. 20A, a core assembly 210f to which a bobbin is applied is used, and in FIG. 20B, a core assembly 210g having a coil wound around a straight core is used. It may be variously modified according to performance or application situation, and the coupling groove for stably fixing the core assembly 210g to the focusing cover 260g as shown in FIG. 20 (b) may also be variously modified according to the situation. Can be.

FIG. 21 is a perspective view of a fifth embodiment of the inductor according to the present invention. In FIGS. 21A and 21B, the focusing covers 360a and 360b have a rectangular frame shape, and the core assembly 310a, An inductor 300a or 300b is formed by inserting 310b into the rectangular frame of the focusing covers 360a and 360b in the longitudinal direction.

In FIGS. 21A and 21B, the straight cores 320a and 320b are applied to the core assemblies 310a and 310b to the bobbins 340a and 340b on which the coils 350a and 350b are wound. 320a and 320b are inserted and configured.

FIG. 22 also shows a perspective view of a modified embodiment of the fifth embodiment of FIG. 21, wherein FIGS. 22A and 22B respectively remove bobbins from FIGS. 21A and 21B, respectively. By applying the core assemblies 310c and 310d, the coils 350c and 350d are wound directly on the cores 320c and 320d. An insulating layer 330c and 330d is formed between the cores 320c and 320d and the coils 350c and 350d. Formed.

21 and 22, the fifth embodiment and the modified embodiment according to the present invention apply a focusing cover having a simpler structure, a flanged core may be applied, and polygonal in addition to a circular column or a square column. The core body may be applied.

Next, an inductor having a self-focusing structure in which a gap flange of an air gap function or a winding guide function, which is a third main feature of the present invention, is applied will be described.

As discussed in the prior art, by forming voids in an inductor such as a choke transformer, more magnetic energy can be accumulated in the inductor so that the inductor can be stably driven without reaching saturation even when a large current flows in the core. The present invention proposes an inductor which functions as a kind of air gap by forming a flange of a core with a non-magnetic material, wherein a flange formed of a non-magnetic material is different from a flange formed as a magnetic material. It functions as an air gap, so it is called a gap flange.

Furthermore, the gap flange in the present invention may also function as a winding guide for facilitating winding of the coil and preventing deviation of the coiled coil, and whether the gap flange functions as a void or as a winding guide is an optional function. Depending on the gap flanges may function only as voids or only as winding guides, or as both voids and winding guides.

FIG. 23 shows a perspective view of a sixth embodiment of an inductor according to the present invention, and FIG. 24 shows a sectional view of the sixth embodiment of FIG.

The fifth embodiment of FIG. 23 is an inductor 400 having a core assembly 410 inserted into a cup focusing cover 460 similar to the second embodiment of FIG. 13, and a gap flange ( The core 420 having the 425 formed thereon is applied.

The I-shaped core 420 of the core assembly 410 is composed of a core body 421 formed of a magnetic material and a lower flange 424 and a gap flange 425 formed of a non-magnetic material. The gap flange 425 itself functions as a kind of air gap by forming with a non-conductive material.

That is, the core 420, the flange 424, and the focusing cover 460 form one magnetic line closed loop, and a gap flange (between the core body 421 and the shield 465 of the focusing cover 460) is formed. 425 is positioned so that the gap flange 425 accumulates magnetic energy as a void.

Furthermore, since the thickness of the gap flange 425 becomes the size of the air gap, the reluctance according to the thickness of the gap flange 425 may be adjusted to adjust the inductance of the inductor 400. .

In FIG. 24, the insulation layer 430 is formed on the core body 421 and the flange 424, and the coil 450 is wound directly on the core 420. However, the configuration is not limited thereto. In addition, various focusing covers according to the present invention described above may be applied.

As such, in the present invention, by forming a gap by applying a gap flange to a core such as an I-shape or a T-shape, the inductance of the inductor 400 can be easily adjusted by adjusting the reluctance according to the thickness of the gap flange. Furthermore, by employing a gap flange in the straight core or the T-shaped core, the coil winding can be facilitated, and at the same time, it can function as a winding guide that prevents the winding of the wound coil.

The inductor to which the gap flange is applied in the present invention may be modified in various ways. Hereinafter, some modified embodiments will be described.

Figure 25 shows a perspective view of a seventh embodiment of an inductor according to the present invention.

In FIG. 25A, the focusing cover 560 includes an upper focusing cover 560a and a lower focusing cover 560b, and each of the upper focusing cover 560a and the lower focusing cover 560b has a cup shape. Openings 562a and 562b are formed at the other end, and shields 565a and 565b are formed at the other end, and upper and lower portions of the core assembly 510 are inserted into the upper focusing cover 560a and the lower focusing cover 560b, respectively. The upper focusing cover 560a and the lower focusing cover 560b are configured to completely surround the core assembly 510.

Here, gap flanges 525 and 527 are formed at both ends of the core of the core assembly 510, so that the gap flanges are formed in the closed magnetic loop of the magnetic lines formed by the core assembly 510, the upper focusing cover 560a, and the lower focusing cover 560b. Air gaps through 525 and 527 are formed. In addition, the core may further facilitate winding of the coil to the core through the gap flanges 525 and 527 as winding guides at both ends, and may prevent the winding of the wound coil.

In FIG. 25 (a), it can be seen that the focusing cover 560 of the sealed tubular structure in which the core assembly 510 is accommodated consists of an upper focusing cover 560a and a lower focusing cover 560b horizontally divided. 25 (b), the focusing cover of the left focusing cover 560a 'and the right focusing cover 560b' in which the focusing cover 560 'of the closed cylindrical structure in which the core assembly 510 is accommodated is vertically divided. It is composed of pieces, and the left focusing cover 560a 'and the right focusing cover 560b' are coupled with the core assembly 510 therebetween to form a focusing cover 560 '.

In the seventh embodiment of FIG. 25, a gap flange is formed at both ends of the core. However, in consideration of the characteristics of the required inductor, only one gap flange may be selectively configured, or a flange of the magnetic material may be selectively formed.

Figure 26 shows a perspective view of an eighth embodiment of an inductor according to the present invention.

Similar to the third embodiment of FIGS. 17 and 18, the eighth embodiment illustrated in FIG. 26 is the focusing covers 660a and 660b to which the shields 665a and 665b having a fan shape or cross shape are applied. In the cores 620a and 620b of the core assembly, gap flanges 625a and 625b are formed on the upper portion, thereby controlling the magnetoresistance through the gap flanges 625a and 625b.

FIG. 27 also shows a perspective view of a ninth embodiment of an inductor according to the present invention, similar to the embodiment of FIG. 20, of two focusing cover pieces 660c ', 660c' 'vertically divided longitudinally. The upper and lower surfaces are formed in a fan shape corresponding to each other, and two focusing cover pieces 660c 'and 660c' 'are coupled with the core assembly 610c interposed therebetween to form a focusing cover 660c, and a core assembly 610c. Gap flanges are applied at both ends of).

28 is a perspective view of a tenth embodiment of the inductor according to the present invention, in which the tenth embodiment shown in FIG. 28 has a rectangular frame structure similar to the fifth embodiment of FIGS. 21 and 22. Focusing cover 760a, 760b, 760c is applied, the core assembly (710a, 69b, 769c) is inserted in the longitudinal direction to the inside of the rectangular frame focusing cover (760a, 760b, 760c) Inductors 700a, 700b, and 700c are constructed. Here, gap flanges 725a, 727a, 725b, 727b, 725c, and 727c are formed at both ends of the cores 720a, 720b, and 720c, and the shapes of the gap flanges 725a, 727a, 725b, 727b, 725c, and 727c are It may be formed in various forms such as a circle, a square. In particular, in FIG. 28C, the core assembly 710c has an elliptical shape in cross section, corresponding to the focus cover shape of the rectangular frame, and thus, the coil region may be utilized by utilizing the inner space of the focus cover more widely. have.

Furthermore, the embodiment of FIGS. 25 to 28 may be configured as a core assembly to which a bobbin is applied, or may be configured as an assembly in which a coil is wound directly on the core by removing the bobbin.

By applying the gap flange to the core assembly and the focusing cover of various forms as described above, it is possible to configure the inductor to control the magnetoresistance through the gap flange or to prevent the coil from being wound as a winding guide.

Furthermore, as a fourth main feature according to the present invention, a gap flange may be used to partition the primary coil and the secondary coil. In this regard, FIG. 29 shows a perspective view of an eleventh embodiment of the inductor according to the present invention. .

In the eleventh embodiment of FIG. 29, the core assembly 810 includes a first coil 850a and a second coil 850b, and the first coil 850a and the second coil 850b are stopped. It is divided and separated by the gap flange 825b. The core assembly 810 including the first coil 850a and the second coil 850b is inserted into the focusing cover 860. In the eleventh embodiment of FIG. 29, gap flanges 825a and 825c are applied to the top and bottom of the core assembly 810, but flanges of a magnetic material may be selectively applied to the top and bottom of the core assembly 810. In addition, in addition to the cylindrical pipe structure, the shape of the focusing cover 860 may be applied to the focusing cover of various types described above.

The present invention provides a simpler and easier method of manufacturing the inductor having the above-described self-focusing structure. Hereinafter, a method of manufacturing the inductor having the self-focusing structure as a fifth main feature of the present invention will be described. .

30 shows a process embodiment for the method of manufacturing the inductor according to the present invention.

In the method of manufacturing an inductor according to the present invention, a core body, a flange, a focusing cover, etc. may be selectively manufactured by winding a steel plate having a magnetic property in a roll shape, as shown in FIG. 30 (a). Winding the steel sheet 901 having a predetermined number of times in a roll form to produce a core body 920a having a drum core shape having a predetermined diameter, and having a conductive property to have a through space corresponding to the cross-sectional diameter of the core body 920a. The steel sheet 905 is rolled up a predetermined number of times to produce the flanges 920b and 920c, and also has a ceramic having a ceramic space so as to have a through space in consideration of the cross-sectional diameters of the core body 920a and the flanges 920b and 920c. 907 is wound around a certain number of times to produce a focusing cover 960. Here, the cross-sectional diameters of the core body 920a and the flanges 920b and 920c may be selected according to the performance of the inductor and the application situation, and may be simply adjusted according to the number of times the steel sheet is wound. In addition, the cross section of the core body 920a is not limited to a circular shape, but may be formed in various polygonal shapes such as quadrangular and pentagonal shapes, and flanges and focusing covers may also be formed in various shapes corresponding to the shape of the core body.

Further, as the core body 920a is manufactured by winding a steel sheet in the form of a roll, a hole may be formed in the center of the core body 920a. The inner empty space of the core body 920a thus formed may be filled with a magnetic material. Infill is preferred. Furthermore, the through space formed in the center of the core body 920a may be used as a wiring passage of a coil wound around the core body.

When the core body 920a, the flanges 920b and 920c and the focusing cover 960 are selectively prepared as described above, the flanges 920b and 118b are respectively formed at the top and bottom of the core body 920a as shown in FIG. The core 920 is manufactured by inserting and inserting the 920c and the coil 950 is wound around the core 920 to manufacture the core assembly 910.

In this case, the process of inserting and inserting the flanges 920b and 920c into the core body 920a is optional. For example, when the flanges 920b and 920c are not applied, the core body 920a may be a straight core or a flange. In the case where the 920b and 920c are inserted into only one portion of the top or bottom of the core body 920a, the 920b and 920c may be a T-shaped core.

When the core assembly 910 is prepared through the above process, as shown in FIG. 30C, the core assembly 910 may be inserted into the focusing cover 960 to manufacture an inductor having a self-focusing structure. .

Furthermore, as shown in FIG. 30 (a), the manufacturing of the core body 920a, the flanges 920b, 920c, or the focusing cover 960 by winding the magnetic steel sheet in the form of a roll is an optional process. It may be manufactured using this magnetic steel sheet.

In the present invention, the core assembly may be manufactured in various shapes and configurations, and FIG. 31 illustrates various modified embodiments of the process of manufacturing the core assembly in the method of manufacturing the inductor according to the present invention.

In FIG. 31 (a), after the core body 920a is inserted into the insulating member 930, a flange 920b is selectively inserted into the top and bottom of the core body 920a to manufacture the core 920 '. The coil 950 was wound around the core 920 'to manufacture the assembly 910'. Here, the insulating member 930 is a kind of insulating layer formed between the core body 920a and the coil 950, and may be made of a plastic injection molding or a tube of insulating material having a through space in which the core body 920a is inserted. In addition, the latching jaws 935 of the flanges 920b and 920c may be formed in the insulating member 930 to more stably fix the flanges 920b and 920c at a predetermined position without flowing down.

In addition, FIG. 31 (b) illustrates a case in which an insulating layer is formed by coating an insulating material. An insulating layer is formed of the insulating film 930a by coating the insulating material around the core body 920a. In addition, the core 920 ″ was manufactured by inserting flanges 920b and 920c selectively on the top and bottom of the core body 920a, and the coil 950 was wound thereon to manufacture the core assembly 910 ″.

The process of forming the insulating layer and the like shown in the embodiment of FIG. 31 is optional and may be applied depending on circumstances. For example, in the case of a low frequency inductor, a coil may be wound directly on the core without applying the insulating layer. Flanges are optional and can be applied depending on the circumstances, taking into account the characteristics of the required inductor.

In the manufacturing method of the inductor having a self-focusing structure according to the present invention as described above, since the core is manufactured by winding the steel sheet in the form of a roll, the inductor can be manufactured through a simpler and safer process by eliminating the existing dangerous and complicated pressing process. The manufacturing cost can be reduced, and in particular, the thickness of the steel sheet constituting the core and the number of windings in the form of rolls can be selectively adjusted, so that the characteristics of the inductor can be adjusted by adjusting the core itself without depending on the number of turns of the coil.

Further, by applying the roll-shaped cylindrical core, it is possible to further reduce the coil consumption compared to the number of turns of the coil than when using the conventional angular E-shaped or T-shaped core.

Furthermore, the present invention discloses a hybrid inductor including an inductor having a self-focusing structure as described above and an inductor for controlling a trigger of a switching element. Hereinafter, a hybrid inductor as a sixth main feature of the present invention will be described. It will be described through the embodiment.

The hybrid inductor according to the present invention is configured to include the inductor having a self-focusing structure according to the present invention described above, with respect to the inductor having a self-focusing structure will be omitted with reference to the above description.

In general, an electronic ballast is provided with a so-called oscillator using a toroidal core to trigger two switching elements, and an inductor using a toroidal core is used for transformers and filters in various electronic devices.

In the present invention, various inductors using such a toroidal core as a transformer or choke transformer and an inductor having a self-focusing structure that can be used as a choke transformer as described above are formed into one package, thereby reducing PCB footprint and components. Discuss how to reduce the number.

32 shows a first embodiment of a hybrid inductor according to the present invention.

The first embodiment of the hybrid inductor of FIG. 32 includes a core assembly 1110 and a focusing cover 1160 constituting an inductor having a self-focusing structure according to the present invention as described above with the first inductor 1100.

In addition, the focusing cover 1160 has a cylindrical pipe structure, and the focusing cover 1160 is used as a sleeve core of the inductor, and the coil 1250 is wound in a toroidal form in the longitudinal direction of the focusing cover 1160 to form a second inductor. 1200).

That is, in the hybrid inductor 1000 according to the present invention, the core assembly 1110 and the focusing cover 1160 constitute the first inductor 1100, and the coil wound around the focusing cover 1160 and the focusing cover 1160. 1250 constitutes the second inductor 1200, and the first inductor 1100 and the second inductor 1200 form the hybrid inductor 1000 in a package form.

In the first embodiment shown in FIG. 32, the bobbin is removed and the core assembly 1110 is wound around the core 1120. The core assembly 1110 may be configured as necessary. have.

FIG. 33 illustrates the direction of the magnetic force lines in the first embodiment of the hybrid inductor of FIG. 32 according to the present invention. Referring to FIGS. 32 and 33, the operation principle of the hybrid inductor according to the present invention will be described. do.

The magnetic field is generated by the current flow of the coil, and the change of the magnetic field applied to the coil produces an induced current in a direction to cancel the change of the magnetic field.

For example, as shown in FIG. 33, the hybrid inductor 1000 of FIG. 32 generates a magnetic field B _P according to the direction of current I _P flowing in the coil of the core assembly 1100 of the first inductor 1100 and the second inductor. The magnetic field B _S is generated along the direction of the current I _S flowing in the coil 1250 of 1200.

Since the magnetic field BP generated by the core assembly 1100 of the first inductor 1100 coincides with the direction of the coil 1250 wound on the second inductor 1200, the change of the magnetic field is changed by the second inductor 1200. It has no effect on the toroidal coil 1250. On the contrary, since the magnetic field B _S generated by the second inductor 1200 also coincides with the direction of the coil 1150 of the core assembly 1110 of the first inductor 1100, the magnetic field B _{S does not} affect the coil 1150 of the core assembly 1110. Does not affect

Accordingly, in the case of the hybrid inductor 1000 having the second inductor 1200 coupled to the first inductor 1100 having the self-focusing structure according to the present invention as shown in FIG. 32 and configured as one package, the core assembly 1110 Since the first inductor 1100 and the second inductor 1200 positioned outside the core assembly 1110 do not affect each other, each of them may be individually operated.

34 shows a second embodiment of a hybrid inductor according to the present invention,

In the second embodiment of the hybrid inductor illustrated in FIG. 34, the configuration of the core assembly 1110a of the first inductor 1100a is the same as the inductor having the self-focusing structure according to the present invention as described above. ) Is provided with a focusing cover formed with a plurality of grooves in the longitudinal direction spaced apart at regular intervals in the upper and lower portions along the side circumference. Here, the focusing cover 1160a is used as a sleeve core of the second inductor 1200a, and the coil 1250a of the second inductor 1200a is wound in a toroidal shape in a portion 1161a where the focusing cover 1160a is formed. do. In this way, by winding the coil in the groove of the focusing cover 1160a, the coil can be prevented from being detached to maintain the position of the coil stably. Production is possible, which prevents waste of materials.

In this case, the coil 1160a is wound to insulate the coil 1250a of the second inductor 1200a from the sleeve core 1160a, and the liquid silicone, urethane, or insulating paint is applied to the focusing cover 1160a used as the sleeve core 1160a. The insulating layer may be coated to form an insulating layer, or the insulating layer may be formed by a plastic case, an insulating tape or a tube, or the like.

Furthermore, in addition to the focusing cover illustrated in FIG. 34, various types of focusing covers described with reference to FIG. 11 may be applied to the sleeve core of the second inductor 1200a.

35 shows a third embodiment of a hybrid inductor according to the present invention.

In FIG. 35, since the core assemblies described above are applicable to the core assembly 1110b of the first inductor 1100b, a description thereof will be omitted.

In FIG. 35, the focusing cover 1160b corresponds to the outer surface of the core assembly 1110b at an outer side of the core assembly 1110b, and has four rounded support members 1163 and support members 1163 spaced at regular intervals from each other. It comprises a connecting member 1164 connecting between the support member 1163 between the cross-sectional view as viewed from the top is a quadrangular as a whole.

Here, the supporting member 1163 and the connecting member 1164 are used as the sleeve core of the second inductor 1200b, and the core 1250b is wound around the connecting member 1164 in a toroidal shape.

Also, in order to insulate the coil 1250b of the second inductor and the connecting member 1164, the coil 1250b of the second inductor is wound to connect the connecting member 1164 used as a sleeve core such as liquid silicone, urethane, or insulating paint. The insulating material may be coated to form an insulating layer, or the insulating layer may be formed by a plastic case, an insulating tape or a tube, or the like.

In FIG. 35, four support members 1163 are positioned at four outer parts of the core assembly 1110b to form a quadrangle as viewed from the top, but the present invention is not limited thereto, and three support members are positioned according to circumstances. A plurality of support members may be positioned to form a polygon such as forming a triangle or five support members to form a pentagon.

In addition, although the core assembly 1110b having the bobbin removed is illustrated in FIG. 35C, a core assembly using a bobbin may be used as necessary.

36 shows a fourth embodiment of the hybrid inductor according to the present invention.

In FIG. 36, the core assembly 1310 positioned inside the focusing cover 1360 may be applied to the core assembly described above. In FIG. 36, the inductor ring 1462 is positioned on the focusing cover 1360. The inductor ring 1462 is connected to the upper end of the focusing cover 1360 by a plurality of support legs 1465 and supported by the focusing cover 1360. In addition, the coil 1450 wound in the inductor ring 1541 and the inductor ring 1462 in the form of a toroidal body constitutes the second inductor 1400.

That is, in the hybrid inductor according to the fourth exemplary embodiment of FIG. 36, the first inductor 1300 is configured by the core assembly 1310 and the focusing cover 1360 at the lower end thereof, and the inductor ring 1451 and the support leg 1465 at the upper end thereof. The sleeve core 1460 and the coil 1450 wound around the inductor ring 1462 constitute the second inductor 1400.

Further, as shown in FIG. 36B, the core 1320 of the first inductor 1300 may include a core body 1321 formed of a magnetic material, a flange 1324 at a lower end, and a top of a top formed of a non-magnetic material. It may be composed of a gap flange 1325.

As shown in FIG. 36, in the hybrid inductor in which the first inductor 1300 and the second inductor 1400 are packaged, integration efficiency of components is achieved by using an upper portion of the first inductor 1300 as a space of the second inductor 1400. Can be further improved.

In the hybrid inductor according to the present invention of FIGS. 32 to 36 described above, a bobbin wound with a coil may be selectively applied, a partial insulation layer may be formed on the core, and the coil may be wound thereon. And a core having a flange whose thickness is adjusted through FIG. 10 may be applied. In addition, the inductance of the inductor may be adjusted by applying a gap flange to the hybrid inductor of FIGS. 32 to 36.

The above description is merely illustrative of the technical idea of the present invention, and those skilled in the art to which the present invention pertains may make various modifications and variations without departing from the essential characteristics of the present invention. Therefore, the embodiments described in the present invention are not intended to limit the technical idea of the present invention but to explain, and the technical idea of the present invention is not limited by these embodiments. The protection scope of the present invention should be interpreted by the following claims, and all technical ideas within the scope equivalent thereto should be construed as being included in the scope of the present invention.

Claims (32)

1. A core assembly comprising a core having a core body of a predetermined length and a coil wound around the core body; And

   It is formed by containing a magnetic material and the core assembly is inserted so as to surround at least a portion of the coil at the outer shell of the core assembly to limit the external diffusion of the magnetic force line generated by the current flow of the coil to focus the magnetic force line Inductor comprising a focusing cover to.
2. The method of claim 1,

   The core assembly,

   An inductor comprising a core having a flange formed of a magnetic material on one or both ends of the longitudinal body of the core body, the core having an I-type or a T-shaped vertical section.
3. The method of claim 2,

   And the flange is formed such that the thickness becomes thinner from the center toward the side such that the vertical cross sectional area of the inner circumference on the flange and the horizontal cross sectional area of the core body are equal to each other.
4. The method of claim 1,

   The core assembly,

   And a core having a vertical flange having an I-type or a T-type, with a gap flange formed of a non-magnetic material at one or both ends of the longitudinal body.
5. The method of claim 1,

   The core assembly,

   An inductor of any one of longitudinal ends of the core body includes a core having a flange formed of a magnetic material and the other having a gap flange formed of a non-magnetic material, wherein the core has a vertical cross section.
6. The method according to any one of claims 2 to 5,

   The core assembly,

   A bobbin in which the core body is inserted into the central portion; And

   And a coil wound around the bobbin.
7. The method according to any one of claims 2 to 5,

   The core assembly,

   An insulating layer formed on a portion or the entirety of the core; And

   And a coil wound around a portion of the core in which the insulating layer is formed.
8. The method according to any one of claims 1 to 5,

   The focusing cover,

   An inductor is formed at both ends thereof to form an opening, and the core assembly is inserted into a circular or polygonal pipe structure provided to surround the outer circumference of the coil.
9. The method of claim 8,

   The focusing cover,

   And a plurality of focusing cover pieces vertically divided in the longitudinal direction.
10. The method of claim 8,

    The focusing cover,

    An inductor characterized in that a plurality of through holes are formed spaced apart at regular intervals along the side circumference.
11. The method of claim 8,

    The focusing cover,

    A plurality of grooves are formed spaced apart at regular intervals in the longitudinal direction from the top or bottom of the side,

    An inductor characterized in that a plurality of grooves are formed by alternately spaced in the longitudinal direction alternately the top and bottom of the side.
12. The method according to any one of claims 1 to 5,

    The focusing cover,

    An inductor is formed at one end and a shielding part is formed at the other end, and the core assembly is formed in a cup structure provided to be inserted into the opening to surround the outer circumference of the coil.
13. The method of claim 12,

    The focusing cover,

    An upper focusing cover formed of a cup structure into which an upper end of the core assembly is inserted; And

    And a lower focusing cover formed of a cup structure into which the lower end of the core assembly is inserted.
14. The method of claim 12,

    The focusing cover,

    Inductor, characterized in that a plurality of openings are formed with the side opening from the one end to the other end.
15. The method of claim 12,

    The focusing cover,

    The shielding portion is formed in a plurality of fan-shaped or cross-shaped spread out from the center,

    And the opening is formed corresponding to the shape of the shield.
16. The method according to any one of claims 12 to 15,

    A coupling groove corresponding to an upper end shape of the core assembly is formed on an inner surface of the shielding part of the focusing cover.

    And an upper end of the core assembly is fitted into the coupling groove and fastened.
17. The method according to any one of claims 1 to 5,

    The focusing cover,

    Shields are formed at both ends of the circular or polygonal pipe to form a closed cylindrical structure having a space for accommodating the core assembly,

    And a plurality of focusing cover pieces vertically divided in the longitudinal direction.
18. The method of claim 17,

    The focusing cover,

    Inductor, characterized in that a plurality of openings are opened from the upper surface to the lower surface.
19. The method according to any one of claims 1 to 5,

    The focusing cover,

    It is formed in a rectangular frame structure having a certain thickness,

    The core assembly is inserted into the focusing cover, characterized in that inserted into the rectangular frame of the focusing cover in the longitudinal direction.
20. The method according to any one of claims 1 to 5,

    The focusing cover,

    A plurality of support members having a surface corresponding to the longitudinal outer surface of the core assembly spaced apart from each other by a predetermined interval along the outer surface of the core assembly; And

    Inductor having a magnetic focus structure, characterized in that it comprises a connecting member for connecting between the supporting member between the supporting member.
21. The method of claim 17,

    The support member has a horizontal cross section has a plurality of surfaces, the surface adjacent to the core assembly is formed to correspond to the outer surface of the core assembly,

    And a plurality of the supporting members spaced apart from each other along the outer periphery of the core assembly so that a horizontal cross-sectional outer periphery of the focusing cover has a quadrangular shape.
22. The method according to any one of claims 2 to 5,

    Corresponding to one end of the flange or gap flange and one end of the focusing cover to fix the core assembly to a predetermined position on the inside of the focusing cover while maintaining a separation distance for a portion between the core assembly and the focusing cover. Inductor characterized in that the coupling portion is formed.
23. The method according to claim 4 or 5,

    The core assembly,

    A first core body wound around the first coil;

    A second core body wound around a second coil; And

    And a gap flange positioned between the first coil and the second coil.
24. A first inductor composed of the inductor of any one of claims 1 to 10 or 20 to 22;

    And a second inductor including a toroidal coil wound longitudinally on the focusing cover.
25. The method of claim 24,

    The first inductor is composed of the inductor of claim 11,

    And a toroidal coil of the second inductor is wound around a groove of the focusing cover.
26. The method of claim 24,

    Insulating layer coated on the surface of the focusing cover,

    And the toroidal coil is wound around an insulating layer.
27. The method of claim 24,

    The first inductor is composed of the inductor of claim 20 or 21,

    And a toroidal coil of the second inductor is wound around the connection member.
28. A first inductor composed of the inductor of any one of claims 1 to 18 or 20 to 22; And

    And a second inductor including an inductor ring spaced apart from an upper portion of the focusing cover and connected to the focusing cover with a plurality of support legs, and a coil wound in a toroidal shape on the inductor ring.
29. A core body manufacturing step of winding a steel plate having magnetic properties to produce a core body having a circular or polygonal cross section;

    A core assembly manufacturing step of manufacturing a core assembly by winding a coil surrounding the core body at a stop portion of the core body;

    A focusing cover manufacturing step of manufacturing a focusing cover containing a magnetic material and having an opening corresponding to a cross section of the core assembly; And

    And forming a focusing cover to insert the core assembly into a focusing cover so as to surround at least a portion of the coil at an outer side of the core assembly.
30. The method of claim 29,

    The focusing cover manufacturing step,

    And winding a predetermined number of times to form a steel plate having a magnetic property such that the core assembly is inserted to have a through space surrounding the core assembly.
31. The method of claim 29 or 30,

    The method further includes a flange manufacturing step of manufacturing a flange by winding a steel plate having a magnetic property to have a through space corresponding to a cross-sectional diameter of the core body a predetermined number of times,

    The core assembly manufacturing step,

    Coupling the flange to the core body by fitting the flange to at least one of the upper and lower ends of the core body; And

    And forming a coil wound around the core body at a stop portion of the core body.
32. The method of claim 29,

    The core body manufacturing step,

    Winding a steel sheet having a magnetic content a predetermined number of times to produce a core body having a circular or polygonal cross section; And

    Coating the outer surface of the core body with an insulating material or inserting the core body into an insulating member having a through hole corresponding to the diameter of the core body.

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