阅读说明：本技术 功率因数校正线圈装置及其制造方法 (Power factor correction coil device and manufacturing method thereof ) 是由 尹晃锡 于 2019-12-27 设计创作，主要内容包括：本发明涉及功率因数校正线圈装置及其制造方法,包括：注塑骨架(100),包括线圈(120、130)；端子部(160),设置在上述注塑骨架(100)的一侧,利用上述线圈(120、130)的端部形成；以及芯部(210、220),与上述注塑骨架(100)相结合。本发明以卷绕镶嵌注塑一体型制造,具有如下优点,即,提高绝缘性,通过将线圈的端部用作端子部来防止因焊接引起的接触不良问题,利用磁芯的滑动结合结构提高结构稳定性。(The invention relates to a power factor correction coil device and a manufacturing method thereof, comprising the following steps: an injection molded armature (100) comprising a coil (120, 130); a terminal part (160) which is provided on one side of the injection-molded bobbin (100) and is formed by using the end parts of the coils (120, 130); and a core (210, 220) combined with the injection molding frame (100). The present invention is integrally manufactured by winding, insert molding, and has advantages of improving insulation, preventing poor contact caused by welding by using an end portion of a coil as a terminal portion, and improving structural stability by a sliding coupling structure of a magnetic core.)

1. A power factor correction coil device is characterized in that,

the method comprises the following steps:

injection molding of the framework; and

a core part combined with the injection molding framework,

the injection molding framework comprises:

a basic skeleton;

a coil wound around the basic bobbin; and

and an injection-molded part that is coupled to the basic bobbin and the coil and is injection-molded, thereby surrounding the coil wound around the basic bobbin such that an end of the coil is drawn out to the outside.

2. The pfc coil apparatus of claim 1, wherein a plurality of lead-out grooves are formed in the basic bobbin, and an end portion of the coil is led out to an upper portion of the basic bobbin through the lead-out grooves.

3. The pfc coil apparatus of claim 2, wherein the basic bobbin includes a fixing portion at a front end of one of two side walls forming the lead-out groove, and an end portion of the coil is hung on the fixing portion and fixed in position.

4. The pfc coil apparatus of claim 3, wherein the lead-out groove has a curved shape.

5. The pfc coil assembly of claim 1 wherein the injection molded bobbin comprises:

a terminal guide groove configured with an end of the coil and guiding the end downward; and

and a tail part for covering the terminal guiding groove.

6. The pfc coil apparatus of claim 1, wherein in a part of the end of the coil, the outer skin is removed and lead is coated.

7. The pfc coil apparatus of claim 1, wherein the core comprises a magnetic core in a band shape having an inner circumferential surface corresponding to an outer circumferential surface of the injection-molded bobbin.

8. The pfc coil apparatus of claim 7, wherein the injection-molded bobbin includes a flange formed to protrude toward an outer circumferential surface of one side, and the magnetic core is in contact with the flange.

9. The PFC coil device of claim 7,

the injection molding frame comprises a core combining hole which is formed by penetrating along the vertical direction,

the core portion includes a center core, and the center core is inserted into the core coupling hole.

10. The pfc coil apparatus of claim 9, wherein gaps are formed between the upper and lower portions of the central core and the magnetic core.

11. The pfc coil assembly of claim 1 wherein the injection molded bobbin includes dummy terminal portions that are not connected to the coil.

12. A method of manufacturing a power factor correction coil device, comprising:

a step of forming a basic skeleton having a core coupling hole and a winding portion by primary injection molding;

winding a coil around the basic bobbin;

forming an injection-molded bobbin by second injection-molding the base bobbin and the coil to form an injection-molded portion, thereby surrounding the coil wound around the base bobbin and drawing an end of the coil to the outside;

lowering an end of the coil downward through a terminal guide groove formed in the injection-molded bobbin; and

and combining the core part with the injection molding framework.

13. The power factor correction coil apparatus manufacturing method according to claim 12,

further comprising a step of forming an end portion of the coil as a terminal portion,

the step of forming the end portion of the coil as a terminal portion includes:

and a step of manufacturing a terminal pin by immersing a part of the end of the coil in a lead solution and removing the outer skin.

14. The method for manufacturing a pfc coil assembly of claim 12, further comprising the step of forming a tail portion for covering the terminal guide groove.

15. The method of manufacturing a pfc coil apparatus of claim 12, wherein the step of combining the core with the injection molded bobbin comprises:

and inserting a central core into the core combining hole to enable the magnetic core to be combined with the side surface of the injection molding framework in a sliding mode.

16. The method for manufacturing a pfc coil apparatus of claim 12, wherein the step of combining the core with the injection molded bobbin further comprises:

and attaching a dummy terminal portion to the injection molding frame.

Technical Field

The present invention relates to a power factor correction coil device and a method of manufacturing the same, and more particularly, to a winding insert-injection-molded integrated power factor correction coil device in which a base bobbin (base bobbin) around which a coil is insert-molded is used to integrate the coil and the base bobbin, and a method of manufacturing the same.

Background

Power Factor Correction (PFC) has a function of improving power efficiency by correcting a power factor of an input power and supplying a stable power. If the waveform of the current input to the power supply is a pulse rather than a sine wave, the power factor is lowered, and when the power factor is lowered, the power quality is lowered and the energy cost is increased as the power loss is increased.

The phase lag of the current with respect to the phase lag of the voltage is a cause of the power factor reduction, and if the load and the power factor compensation circuit are connected in parallel so that the phases of the voltage and the current become as uniform as possible, the power factor can be improved and the energy efficiency can be improved.

However, since the conventional power factor correction adopts a method of assembling the magnetic cores separated from each other by using an epoxy resin or an adhesive tape, there are various problems such as a complicated manufacturing process, low reliability in an environment resistant to moisture, etc., a contact failure due to welding of terminal portions, a heat generation problem during driving, and a large volume.

Disclosure of Invention

Technical problem

An object of the present invention is to provide a power factor correction coil device and a method of manufacturing the same, in which a winding insert-injection-integrated type in which a coil and a basic bobbin are integrated is manufactured by insert-injection-molding the basic bobbin around which the coil is wound, thereby improving insulation, and preventing a contact failure problem due to welding and improving structural stability by using an end portion of the coil as a terminal portion.

Technical scheme

According to the features of the present invention for achieving the above object, the present invention comprises: injection molding of the framework; and a core portion combined with the injection molding skeleton, the injection molding skeleton including: a basic skeleton; a coil wound around the basic bobbin; and an injection part coupled to the basic bobbin and the coil and injection-molded, thereby surrounding the coil wound around the basic bobbin such that an end of the coil is drawn out to the outside.

A plurality of lead-out grooves are formed in the basic bobbin, and an end portion of the coil is led out to an upper portion of the basic bobbin through the lead-out grooves.

The basic frame includes a fixing part at the front end of one of the two side walls forming the leading-out slot, and the end of the coil is hung on the fixing part and fixed.

The lead-out groove is bent.

The injection molding framework comprises: a terminal guide groove configured with an end of the coil and guiding the end downward; and a tail portion for covering the terminal guide groove.

In a part of the end of the coil, the outer skin is removed and lead is applied.

The core portion includes a magnetic core having a band shape with an inner peripheral surface corresponding to an outer peripheral surface of the injection-molded bobbin.

The injection molding framework comprises a flange formed by protruding towards the outer peripheral surface of one side, and the magnetic core is contacted with the flange.

The injection molding frame includes a core coupling hole formed to penetrate in a vertical direction, and the core portion includes a center core inserted into the core coupling hole.

Gaps are formed between the upper and lower portions of the center core and the magnetic core.

The injection molding framework comprises a dummy terminal part which is not connected with the coil.

The manufacturing method of the power factor correction coil device comprises the following steps: a step of forming a basic skeleton having a core coupling hole and a winding portion by primary injection molding; winding a coil around the basic bobbin; forming an injection-molded bobbin by second injection-molding the base bobbin and the coil to form an injection-molded portion, thereby surrounding the coil wound around the base bobbin and drawing an end of the coil to the outside; lowering an end of the coil downward through a terminal guide groove formed in the injection-molded bobbin; and combining the core part with the injection molding framework.

The present invention further includes a step of forming an end portion of the coil as a terminal portion, the step of forming the end portion of the coil as the terminal portion includes: and a step of manufacturing a terminal pin by immersing a part of the end of the coil in a lead solution and removing the outer skin.

The invention also includes a step of forming a tail portion for covering the terminal guiding groove.

The step of combining the core with the injection molded skeleton comprises: and inserting a central core into the core combining hole to enable the magnetic core to be combined with the side surface of the injection molding framework in a sliding mode.

After the step of combining the core part with the injection molding framework, the method further comprises the following steps: and attaching a dummy terminal portion to the injection molding frame.

ADVANTAGEOUS EFFECTS OF INVENTION

Since the injection-molded bobbin of the present invention has a structure in which the coil is surrounded by two times of injection molding, stable winding can be maintained and insulation of the coil can be enhanced, so that the thickness around the coil can be designed to be thin.

Therefore, the present invention can reduce an area and improve performance of the power factor correction coil device by reinforcing insulation, can increase moisture resistance by complete sealing of the coil, and can improve reliability of a product, compared to a conventional power factor correction coil device.

Further, in the present invention, the terminal pin is manufactured by immersing the end portion of the coil in a lead solution and used as the terminal portion, and therefore, the problem of poor contact due to soldering can be prevented.

Further, the core of the present invention is formed in an integrated shape and is coupled to the injection-molded bobbin in a sliding manner, so that the assembly of the core is easy and the manufacturing process is simplified, and the core has uniform quality characteristics without variation in assembly.

Drawings

Fig. 1 is a perspective view showing a power factor correction coil device according to an embodiment of the present invention.

Fig. 2 is a perspective view showing a power factor correction coil device according to an embodiment of the present invention.

Fig. 3 is an exploded perspective view showing a power factor correction coil device according to an embodiment of the present invention.

Fig. 4 is a perspective view showing a basic skeleton of the embodiment of the present invention.

Fig. 5 is a top view showing a basic skeleton of the embodiment of the present invention.

Fig. 6 is a perspective view showing an injection-molded bobbin of an embodiment of the present invention.

Fig. 7 is a perspective view showing a portion of fig. 3 cut in a B-B direction.

Fig. 8 is a view showing a section a-a of fig. 1.

Fig. 9 is a diagram for explaining a manufacturing process of the power factor correction coil device according to the embodiment of the present invention.

Fig. 10 is a perspective view showing an injection-molded bobbin according to another embodiment of the present invention.

Fig. 11 is a sectional view showing a state in which a magnetic core according to another embodiment of the present invention is coupled to an injection-molded bobbin in the up-down direction.

Detailed Description

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.

As shown in fig. 1 and 2, the power factor correction coil device 10 according to the embodiment of the present invention includes an injection mold frame 100, a terminal portion 160, and a core portion 200.

The injection molded armature 100 includes coils 120, 130. The injection-molded bobbin 100 tightly winds the coils 120, 130 and is insulated from the outside by a physical method.

The terminal portion 160 is disposed at a lower end of one side of the injection mold frame 100. The terminal portion 160 is formed by the end portions of the coils 120 and 130.

In the injection mold frame 100, a dummy terminal portion 170 for keeping balance with the terminal portion 160 is provided at the other side lower end opposite to the position where the terminal portion 160 is provided. The dummy terminal portion 170 may be fixed to the injection mold frame 100 by insert bonding, adhesion, or the like. The dummy terminal portions 170 improve the board (board) coupling degree of the terminal portions 160 by being balanced with the terminal portions 160.

Terminal unit 160 is connected to a power supply, and dummy terminal unit 170 is not connected to the power supply.

In the embodiment, the terminal portion 160 is connected to the coils 120 and 130, and the dummy terminal portion 170 is not connected to the coils 120 and 130.

The core 200 is combined with the injection molded frame 100. The core 200 combined with the injection-molded bobbin 100 forms a booster circuit by being electromagnetically combined with the coils 120, 130, thereby functioning to convert an input voltage into a higher voltage to improve a power factor.

The coils 120, 130 are wound only once. The coils 120 and 130 include a main coil 120 and an auxiliary coil 130 (see fig. 8). The main coil 120 forms a step-up (or step-down) circuit by electromagnetically combining with the core 200, and the auxiliary coil 130 can prevent the deterioration of the power quality by complementing the magnetic force in a state of a large load. The number of times the main coil 120 is wound may be determined in proportion to the input voltage. Preferably, in terms of efficiency, although the coil should include the main coil 120 and the auxiliary coil 130, only the main coil 120 may be included.

The core 200 is made of a ferromagnetic substance that can obtain a strong magnetic flux. As the ferromagnetic material forming the core portion 200, a ferrite core having a small loss at a high frequency, for example, a manganese-zinc (Mn — Zn) ferrite core, may be used.

The terminal pin 120b formed with the end of the main coil 120 and the terminal pin 130b formed with the end of the auxiliary coil 130 form a terminal portion 160 for connecting a power supply by protruding downward from one side lower end of the injection-molded bobbin 100. In the embodiment, the terminal portion 160 is a 4-pin terminal. The terminal portion 160 may be a 2-pin terminal or a 6-pin terminal depending on the number of coils wound according to the capacity, the use, and the like of the power factor correction coil device 10.

As shown in fig. 3, the power factor correction coil device 10 may be formed by combining a center core 210 and a magnetic core 220 with an injection-molded bobbin 100. The injection mold frame 100 has a core coupling hole 112 formed substantially at the center thereof so as to penetrate in the vertical direction, and the center core 210 is coupled to the core coupling hole 112 so as to be inserted thereinto. The magnetic core 220 is combined with the injection-molded bobbin 100 in a sliding manner at a side of the injection-molded bobbin 100. The magnetic core 220 has a band shape having an inner circumferential surface corresponding to an outer circumferential surface of the injection-molded bobbin 100. In the embodiment, the core 220 has a shape of a "square" having a through hole 221 at the center corresponding to the outer circumferential surface of the injection mold frame 100.

The center core 210 is inserted into the core coupling hole 112 of the injection-molded bobbin 100, and if the magnetic core 220 is coupled to the injection-molded bobbin 100 in a sliding manner at a side surface of the injection-molded bobbin 100, the center core 210 and the magnetic core 220 may face each other in the vertical direction to form a magnetic circuit.

The core 220 has an integral shape without being separated vertically, and can completely realize a self-shielding structure. Further, since the magnetic core 220 is coupled to the injection-molded bobbin 100 in a sliding manner at the side surface of the injection-molded bobbin 100, the assembly is very uniform without variation, and thus the efficiency can be improved.

The core bonding hole 112 and the central core 210 have a cylindrical shape with an edge rounded. The central core 210 is formed in a shape corresponding to the cross-section of the core coupling hole 112. The edge shape of the arc-processed center core 210 has a shape such that the magnetic flux distribution becomes uniform, thereby reducing the magnetic flux loss and improving the efficiency.

The height of the central core 210 is relatively low compared to the height of the core bonding hole 112. This forms a predetermined GAP (GAP) between the upper and lower portions of the center core 210 facing the magnetic core 220. The gap can be used to adjust the inductance value.

Injection molding skeleton 100 includes: a body 141 having a side surface slidably coupled to the magnetic core 220 and a core coupling hole 112 formed therein; and a flange 142 surrounding one outer circumferential surface of the body 141 and protruding with a predetermined width so that the core 220 is slid to an accurate position. When the magnetic core 220 is combined with the body 141, the side surface is in contact with the flange 142.

In the injection molded bobbin 100, the flange 142 is formed to surround only one side outer circumference of the body 141. This is because the magnetic core 220 is slidably coupled to the body 141, and the body 141 corresponds to a position opposite to a portion where the flange 142 is formed.

In the injection-molded skeleton 100, an appearance is formed by an injection-molded part 140 including a body 141 and a flange 142. Specifically, in the injection-molded bobbin 100, the appearance is formed by the injection-molded portion 140 injection-molded in the base bobbin 110 around which the coils 120, 130 are wound.

The injection part 140 is a part injected to the base bobbin 110, thereby surrounding the coils 120 and 130 wound around the base bobbin 110 and drawing the ends of the coils 120 and 130 to the outside. Since the edge of the body 141 is formed in a circular arc shape, the injection-molded bobbin 100 may facilitate the side insertion of the magnetic core 220.

As shown in fig. 4, the basic skeleton 110 includes: a winding portion 111 around which a coil is wound; and a core coupling hole 112 penetrating the center of the winding portion 111 in the vertical direction. The basic bobbin 110 includes an upper flange portion 113 and a lower flange portion 114 formed to be expanded in the outer diameter direction at the upper and lower ends of the winding portion 111. A coil (see reference numerals 120 and 130 in fig. 8) is wound around the winding portion 111 between the upper flange portion 113 and the lower flange portion 114.

The winding portion 111 can improve the internal pressure by forming a portion connecting the upper flange portion 113 and the lower flange portion 114 into a circular arc shape (forming an R-angle). The internal pressure is a level to which overload is prevented when a high voltage is applied. The formation of the R-angle has an effect that not only internal voids generated after injection molding can be eliminated, but also internal pressure can be improved by increasing strength.

The basic bobbin 110 includes a lead-out groove 115 and a fixing portion 116.

The lead-out groove 115 can lead out each end portion of the coils 120, 130 wound around the winding portion 111 to the upper portion of the basic bobbin 110 by inserting each end portion. The drawing groove 115 is formed to be recessed inward from one side of the upper flange portion 113, and is composed of a plurality of grooves opened in the vertical direction.

The fixing portion 116 is disposed at each end of the coils 120 and 130 drawn to the upper portion of the upper flange portion 113 and arranged at a predetermined interval. The fixing portion 116 is disposed at the entrance of the lead-out groove 115 such that the entrance of the lead-out groove 115 and the end of the lead-out groove 115 are offset from each other, and the end portions 120a, 130a of the respective coils are hung on the fixing portion 116. The fixing portion 116 has a C-shaped groove 117, and the groove 117 can position-fix the ends 120a and 130a of the coil wound around the winding portion 111.

As shown in fig. 5, specifically, the fixing portion 116 is formed at a front end of one sidewall among both sidewalls of the lead-out groove 115 formed in a curved shape, in parallel with an inlet of the lead-out groove 115. The fixing portion 116 has a C-shaped groove 117, and ends 120a and 130a of the respective coils inserted into the lead-out groove 115 are hung through the entrance, whereby the positions of the ends 120a and 130a of the respective coils can be aligned in the C-shaped groove 117.

The coil ends 120a and 130a are inserted into the lead-out groove 115 and hung on the fixing portion 116, and are placed on the C-shaped groove 117 of the fixing portion 116 and fixed in position. For this reason, the drawing groove 115 is curved such that the positions of the inlet and the end are shifted from each other, and the end of the drawing groove 115 and the fixing portion 116 are arranged on the same straight line.

The fixing portions 116 are provided in plurality on one side of the upper flange portion 113 of the base frame 110, and are used for fixing the positions of the coil ends 120a and 130a by hanging them. The fixing portions 116 are arranged with a predetermined interval therebetween, thereby maintaining the insulation distance between the ends 120a and 130a of the coil as the terminal pins. The number of the lead grooves 115 and the fixing portions 116 is twice the number of the coils 120 and 130 wound around the winding portion 111. In the embodiment, the main coil 120 and the auxiliary coil 130 are wound around the winding part 111 in the number of 2 coils, and thus, have 4 lead-out grooves 115 and the fixing part 116.

A fixing shoulder 118 for fixing an insertion position of the center core 210 is protrudingly formed at the core coupling hole 112 of the basic bobbin 110. The fixing shoulder 118 allows the center core 210 to be located at an intermediate position with respect to the height of the core coupling hole 112 by supporting the bottom surface of the center core 210 inserted into the core coupling hole 112. The fixing shoulder 118 allows the center core 210 to be located at a predetermined position within the core coupling hole 112 by supporting the bottom surface of the center core 210.

As shown in fig. 6, the basic skeleton 110 is placed in a mold and subjected to a second injection molding, so that the appearance of the injection molded skeleton 100 is formed. The basic bobbin 110 is formed by the first injection molding. The injection molded part 140 surrounding the coils 120 and 130 is formed on the basic bobbin 110 by the second injection molding. If the basic frame 110 is subjected to the second injection molding, the injection molded frame 100 is formed. The injection-molded bobbin 100 includes a base bobbin 110 and an injection-molded part 140.

The coils 120 and 130 wound around the winding portion 111 of the basic bobbin 110 are surrounded by the injection molded portion 140 and thus cannot be exposed to the outside. The ends 120a and 130a of the coil wound around the base bobbin 110 are drawn out to the outside through the one-side upper portion of the injection-molded bobbin 100. The coil ends 120a and 130a are drawn out in a state of being arranged at a predetermined interval by the fixing portion 116. After the coils 120 and 130 are wound around the basic bobbin 110, the outer appearance of the injection molded bobbin 100 is formed by injection molding, so that the uniformity of the thickness can be secured.

Terminal guide grooves 143 are formed in one side surfaces of the ends 120a and 130a of the injection bobbin 100 from which the coil is drawn. The terminal guide grooves 143 are used to position the end portions 120a, 130a of the coil. The terminal guide grooves 143 are formed in a recessed shape along the vertical direction, have openings at the lower portions, and are formed in plural at predetermined intervals. The ends 120a and 130a of the coil drawn out from the upper portion of the injection-molded bobbin 100 on one side to the outside may be lowered to the lower end of the injection-molded bobbin 100 on one side through the terminal guide groove 143.

As shown in fig. 7, the injection molded frame 100 includes a base frame 110 and an injection molded part 140 that is injection molded on the base frame 110 for the second time. The injection molding part 140 is injection molded in combination with the base frame 110 and the coils 120 and 130 so as to surround the coils 120 and 130.

In the injection molded frame 100, a joint surface between the base frame 110 and the injection molded part 140 that is secondarily molded in the base frame 100 has a stepped shape. The stepped shape engagement of the basic bobbin 110 and the injection molded part 140 may increase the external insulation voltage of the coils 120, 130 built in between the basic bobbin 100 and the injection molded part 140. Further, since the injection part 140 fills the gap between the coils 120 and 130, the insulation property can be greatly improved while maintaining the stable winding.

Preferably, when the second injection molding is performed, the basic bobbin 110 should have a double-step structure with a height difference at the end sides, so that the joint surfaces of the basic bobbin 110 and the injection molded part 140 form a stepped shape. The structure having the level difference has an effect of improving the internal pressure as the contact area increases after the second injection.

As shown in fig. 6 and 7, a flange 142 is formed on one side of the injection mold frame 100, and a body 141 is formed on the opposite side. The core 220 is combined with the body 141 in a sliding manner. The flange 142 is a portion where the injection portion 140 surrounds the upper flange portion 113 and the lower flange portion 114 of the basic frame 110 at one side with a predetermined thickness.

The core coupling hole 112 has the same structure as the core coupling hole 112, the core coupling hole 112 is formed at the central portion of the basic bobbin 110, and the central core 210 is coupled to the core coupling hole 112 in an insertion manner. The width and height of the core coupling hole 112 are pre-designed based on the size of the central core 210 coupled with the core coupling hole 112.

The coils 120, 130 include a main coil 120 and an auxiliary coil 130. The main coil 120 is formed by winding a wire around the winding portion 111 several times or more, and the auxiliary coil 130 is formed by additionally winding a wire around the outside of the main coil 120. The main coil 120 may form a power factor compensation circuit by being electromagnetically combined with the core 200. The auxiliary coil 130 can drive the IC driver by effectively detecting magnetism generated when the product operates and using the detected signal.

When the winding portion 111 is wound with a wire, the wire becomes a coil, and in this case, when the center core 210 and the magnetic core 220 are combined, the inductance values of the coils 120 and 130 can be increased to form a power factor compensation circuit. The wire may use copper wire.

Since the injection molded bobbin 100 completely seals the main coil 120 and the auxiliary coil 130, it has a function of moisture resistance and greatly increasing insulation, and can be manufactured by reducing the thickness of the basic bobbin 110 and the thickness of the injection molded part 140 to the maximum.

The magnetic core 220 is combined with the side of the injection-molded bobbin 100 in a sliding manner. The core 220 is an integral body which is not separated vertically, and has a structure of shielding itself by surrounding the outer contour of the body 141 of the injection mold frame 100, thereby effectively blocking electromagnetic waves in a circuit and blocking the release of electromagnetic interference (EMI) of the electromagnetic waves.

Further, the core 220 is an integrated type which is not separated vertically, and is easy to manufacture because it has a simple shape. Such an integrated type magnetic core 220 has a strong thermal shock resistance compared to a method of assembling vertically separated magnetic cores using epoxy or tape.

On the other hand, the end portions 120a, 130a of the coil drawn out to the outside through the one-side upper end of the injection mold bobbin 100 may be made into terminal pins and used as terminal portions. Specifically, the end portions 120a, 130a of the coil may be immersed in a lead solution to be manufactured as terminal pins 120b, 130b and used as the terminal portions 160 for power supply connection.

As shown in fig. 6, more specifically, the end portions 120a and 130a of the coil drawn out to the outside are immersed in a high-temperature lead solution to manufacture the terminal pins 120b and 130b, and as shown in fig. 7, the terminal pins 120b and 130b are disposed in the terminal guide grooves 143, whereby the terminal pins 120b and 130b can be lowered to the one-side lower end of the injection mold frame 100.

When the coil ends 120a and 130a are immersed in a high-temperature lead solution, the lead melts and removes the outer covering of the coil ends 120a and 130a, and the lead adheres to the copper wire from which the outer covering is removed, thereby facilitating the formation of the terminal pins 120b and 130 b. Also, when the ends 120a, 130a of the coil are immersed in a high temperature lead solution, the copper wire will obtain a prescribed strength as lead adheres to the copper wire. In addition to the high-temperature lead, various other materials may be used as long as they can melt the outer skins of the coil ends 120a and 130a and adhere to the copper wire so that the copper wire has a predetermined strength and conductivity.

When the coil ends 120a and 130a are used as the terminal portions 160 as the terminal pins 120b and 130b, the conventional soldering work for connecting the coil ends and the terminal portions is not required, and therefore, the problems of soldering failure and contact failure can be prevented.

Although not shown, reinforcing pins for reinforcing the strength may be joined to the terminal pins 120b and 130 b. When the copper wires of the coils 120 and 130 are thin, problems such as bending may occur when they are used as the terminal portions 160. Therefore, strength is increased by joining the reinforcement pins to the terminal pins 120b and 130b, and bending deformation or the like of the terminal portions can be prevented. After the reinforcement pins are joined to the terminal pins 120b and 130b, the reinforcement pins are disposed in the terminal guide grooves 143 together with the terminal pins 120b and 130b, so that the reinforcement pins can be lowered to the lower side of the injection-molded frame 100. In this case, as the reinforcing pins are disposed in the terminal guide grooves 143 and reinforce the terminal pins 120b, 130b, the strength of the terminal pins 120b, 130b can be further effectively reinforced.

Terminal pins 120b and 130b formed to protrude downward along one side lower end of the injection-molded frame 100 are used as the terminal portions 160. The reinforcement pins may be applied to all the terminal pins 120b, 130b made by immersing the ends 120a, 130a of the coil in a high-temperature lead solution, and may also be applied to only a thin portion of the copper wire as required.

The terminal pins 120b and 130b, which are formed to protrude downward along one side lower end of the injection-molded frame 100, may be integrally formed by immersing in high-temperature lead together with reinforcing pins disposed in the terminal guide grooves 143 to reinforce the terminal pins 120b and 130b, and may be used as the terminal portion 160.

Referring to fig. 3 and 6, the injection-molded bobbin 100 includes a tail portion 150 for covering the ends 120a and 130a of the coil disposed in the terminal guide groove 143. The tail portions 150 prevent the coils 120 and 130 from being exposed to the outside at the side of the injection-molded bobbin 100. The tail portions 150 may be formed in such a manner as to cover the terminal guide grooves 143 by attaching epoxy resin to the terminal guide grooves 143 or performing additional injection molding, and the end portions 120a, 130a of the coils made into the terminal pins 120b, 130b are inserted into the terminal guide grooves 143.

Alternatively, the footer 150 may be formed in such a manner as to cover the terminal guide groove 143 by attaching epoxy to the terminal guide groove 143 or performing additional injection molding in a state where the terminal guide groove 143 is inserted with the terminal pins 120b, 130b and the reinforcement pin. The base bobbin 110 and the injection-molded bobbin 100 may be made of a non-magnetic, insulating material that does not affect electrical characteristics and has high heat resistance and high voltage resistance.

In a state where the center core 210 is inserted into the core coupling hole 112 of the injection-molded bobbin 100, the magnetic core 220 is coupled to the injection-molded bobbin 100 in a sliding manner from a side surface.

As shown in fig. 8, in the power factor correction coil device 10, a predetermined gap is formed between the upper portion and the lower portion of the center core 210 facing the magnetic core 220. The gap formed at the upper and lower portions of the central core 210 may maximize the functions of the coils 120, 130 to reduce the hollow ratio of the magnetic core 220 and improve the heat generation problem generated when the product operates. Since the oscillation frequency is likely to vary due to minute vibrations of the coils 120 and 130 as the frequency used is higher, the vertical gap between the center core 210 and the magnetic core 220 serves to prevent the coils 120 and 130 from vibrating.

When the magnetic core is vertically coupled, a gap is formed between the upper core and the lower core, and thus, a heat generation problem may occur during driving, and also, since the magnetic core is attached by epoxy resin or the like, a product performance may be lowered, a manufacturing process may be complicated, and environmental reliability may be easily affected.

The following describes a method for manufacturing a power factor correction coil device according to an embodiment of the present invention.

The power factor correction manufacturing method comprises the following steps: preparing a basic bobbin 110 around which coils 120 and 130 are wound; a step of forming the injection-molded bobbin 100 by performing a second injection molding of the base bobbin 110, thereby surrounding the coils 120, 130 wound around the base bobbin 110 and causing the ends 120a, 130a of the coils to be drawn out to the outside; a step of manufacturing terminal pins 120b, 130b by immersing the ends 120a, 130a of the coil in a lead solution; forming a terminal portion 160 by lowering the terminal guide grooves 143 formed in the side surfaces of the injection-molded bobbin 100 downward to form the end portions 120a and 130a of the coil of the terminal pins 120b and 130 b; and a step of combining the cores 210, 220 with the injection molded skeleton 100.

The following describes a procedure for preparing a basic bobbin around which a coil is wound.

As shown in fig. 9, the basic bobbin 110 is formed into a shape having a core coupling hole 112 and a winding portion 111 by a first injection molding. The basic frame 110 has an upper flange portion 113 at an upper portion, a lower flange portion 114 at a lower portion, and a winding portion 111 formed between the upper flange portion 113 and the lower flange portion 114 with respect to the core coupling hole 112 at the center. Further, a lead groove 115 and a fixing portion 116 are formed on one side of the flange 142. A fixing shoulder 118 is formed at the core coupling hole 112 of the basic bobbin 110.

Main coil 120 is wound around winding portion 111 of basic bobbin 110, and auxiliary coil 130 surrounding main coil 120 is additionally wound. The ends 120a and 130a of the main coil 120 and the auxiliary coil 130 wound around the winding portion 111 are drawn out to the upper portion of the upper flange portion 113 through the drawing grooves 115, and then fitted into the grooves 117 of the C-shaped fixing portions 116.

Next, the basic bobbin 110 around which the main coil 120 and the auxiliary coil 130 are wound is put into a mold and is subjected to a second injection molding in an insert injection manner such that the injection molded part 140 is formed to surround the main coil 120 and the auxiliary coil 130.

After the second injection molding, the ends 120a and 130a of the main coil 120 and the auxiliary coil 130 are drawn out to the outside through the one-side upper portion of the injection molded bobbin 100. The ends 120a and 130a of the main coil 120 and the auxiliary coil 130, which are drawn out to the outside through the one-side upper portion of the injection-molded bobbin 100, are drawn out with a predetermined interval by the fixing portion 116 for aligning the ends 120a and 130a of the coils.

The ends 120a, 130a of the main coil 120 and the auxiliary coil 130, which are drawn out from the one-side upper portion of the injection-molded bobbin 100 to the outside, are made into terminal pins 120b, 130b by dipping in a high-temperature lead solution. The high temperature lead solution may be a high temperature lead solution at a temperature of about 400 ℃ to 600 ℃.

Subsequently, the terminal pins 120b and 130b having lead adhered thereto and having a predetermined strength are bent and inserted into the terminal guide grooves 143, so that the terminal pins 120b and 130b are lowered to one side lower end of the injection-molded frame 100. In this case, in order to further increase the strength of the terminal pins 120b, 130b, the terminal pins 120b, 130b may be overlapped by inserting reinforcement pins into the terminal guide grooves 143.

The following describes the steps of combining the core with the injection molded backbone 100.

The center core 210 is inserted into the core coupling hole 112 of the injection mold frame 100, and the magnetic core 220 is slidably coupled to a side surface of the injection mold frame 100. When the center core 210 is inserted into the core coupling hole 112 of the injection mold frame 100 and the magnetic core 220 is coupled to the side surface of the injection mold frame 100 in a sliding manner, the center core 210 and the magnetic core 220 face each other in the vertical direction to form a magnetic circuit.

In this case, the flange 142 formed to protrude at one side of the injection-molded bobbin 100 will function as a stopper to limit the sliding position of the magnetic core 220, and thus, the magnetic core 220 can be slid to an accurate position corresponding to the center core 210.

After the step of slidably coupling the magnetic core 220 to the injection-molded bobbin 100 is performed, a dummy terminal portion 170 is attached to the other end of the injection-molded bobbin 100 facing the position where the terminal portion 160 is provided, and the dummy terminal portion 170 is used to maintain balance with the terminal portion 160. Before the magnetic core 220 is slidably coupled to the injection-molded bobbin 100, if the dummy terminal portion 170 is attached to the injection-molded bobbin 100, it is difficult to slidably couple the magnetic core 220 to the injection-molded bobbin 100. Therefore, after the magnetic core 220 is slidably coupled to the injection-molded bobbin 100, the dummy terminal portion 170 is attached to the injection-molded bobbin 100.

Next, the tails 150 covering the terminal guide grooves 143 are formed by attaching epoxy resin to the terminal guide grooves 143 or performing additional injection molding, whereby the tails 150 prevent the terminal pins 120b, 130b from being exposed from the side of the injection molded frame 100.

After the tail portions 150 are formed, when the reinforcement pins are joined to the terminal pins 120b, 130b, the terminal pins 120b, 130b protruding toward the lower portion of the injection-molded frame 100 and the reinforcement pins joined to the terminal pins 120b, 130b are again immersed in the lead solution, and lead is attached to the terminal pins 120b, 130b and the reinforcement pins, whereby they can be used as the integrated terminal portions 160.

The finally manufactured power factor correction coil device 10 has a structure in which the terminal portion 160 and the dummy terminal portion 170 have a protruding shape in the bottom double pole, and the integrated magnetic core 220 is tightly coupled to the injection mold frame 100 without a gap on the outer peripheral surface of the injection mold frame 100.

The operation of the present invention will be described below.

In the present invention, the injection-molded bobbin 100 is formed by the second injection molding and has a structure surrounding the coil wound around the base bobbin 110, so that it is possible to maintain stable winding, reinforce the insulation voltage of the coils 120 and 130, and greatly improve the insulation.

Also, the present invention increases insulation and prevents noise and heat generation by completely sealing the coils 120 and 130, and thus, the basic bobbin 110 and the injection part 140 can have a thin thickness.

Also, in the present invention, the appearance of the injection-molded bobbin 100 is formed by the second injection molding after the coil is wound, and therefore, the uniformity can be secured, and the core parts 210 and 220 can be closely coupled in a position-fixed manner, so that the structural stability can be improved.

Also, in the present invention, the core 220 is coupled to the injection-molded bobbin 100 in a sliding manner, so that the assembly of the core 220 can be facilitated and the core manufacturing process can be simplified, and thus the core 220 can have uniform quality characteristics without assembly variation.

In the present invention, the terminal pins 120b and 130b are manufactured by immersing the end portions 120a and 130a of the coil wound around the basic bobbin 110 and drawn out by the second injection molding into a lead solution and are used as the terminal portions 160 of the injection molding bobbin 100, so that the degree of bonding of the boards (e.g., substrates) can be improved, and the problem of short circuit due to poor soldering can be prevented, thereby improving the operational reliability of the power factor correction coil device.

Also, in the case where the copper wire forming the coil is thin, the present invention can increase the strength of the copper wire by applying the reinforcement pin, and thus, the occurrence of problems such as bending can be prevented, and the coil can be used as a terminal.

In addition, the invention can improve the allowable drive current capacity, improve the heating problem of the copper wire, ensure the stable winding pressure resistance and greatly improve the insulation between the coil and the core.

Also, the present invention has an advantage in that a complete molding process is performed without an impregnation process by the second injection molding, and thus, the size (area) of the power factor correction coil apparatus can be reduced by forming a thinner thickness, and a process of attaching a tape or epoxy resin can be omitted by applying the east China magnetic core, thereby simplifying a process.

The length of the present invention was 43mm, the width was 35mm, and the thickness was 16mm, and the electrical characteristics were measured. The distance between the pins of identical terminals is about 5 mm.

As a result of the measurement, the inductance (inductance) of the present invention was higher and the leakage was reduced by about 18% as compared with a power factor correction coil device of the same specification which was not subjected to the double injection (first injection, second injection), and thus, the superiority of the present invention was confirmed to be due to the drop in output inductance (DCR).

On the other hand, the power factor correction coil device according to another embodiment of the present invention may adopt a top-bottom combination method, rather than a magnetic core sliding combination method.

As shown in fig. 10, when the magnetic cores are coupled up and down, the injection-molded bobbin 100-1 is formed with flanges 142-1 at both sides and a core coupling portion 141-1 therebetween. The both-side flanges 142-1 and the core connecting portion 141-1 are portions formed by surrounding a basic bobbin (not shown) around which a coil is wound with a predetermined thickness by the injection molding portion 140. A core coupling hole 112-1 is formed at the center of the core coupling portion 141-1.

In contrast to one embodiment, the basic bobbin of the other embodiment symmetrically forms terminal guide grooves for guiding the ends of the coil at both sides, and thus, terminal portions 160-1 are formed at both lower ends of both sides of the injection-molded bobbin 100-1.

As shown in fig. 11, the magnetic cores 230, 240 include an upper core 230 and a lower core 240, the upper core 230 and the lower core 240 are combined with a prescribed gap at upper and lower sides of the injection-molded bobbin 100-1, and the upper core 230 and the lower core 240 may be formed in an E-shape including a cross-sectional portion, both side leg portions vertically protruding from the cross-sectional portion, and a center leg portion vertically protruding at both side leg portions.

In the upper core 230 and the lower core 240, in a state where the cross-sectional portion is closely attached to the core coupling portion 141-1 on the upper surface or the lower surface of the injection-molded bobbin 100-1, both side leg portions are closely attached to both sides of the injection-molded bobbin 100-1, the center leg portion is coupled to the injection-molded bobbin 100-1 in a manner of being inserted into the core coupling hole, and in a state of being coupled to the injection-molded bobbin 100-1, the center of the outer circumference of the injection-molded bobbin 100-1 is surrounded.

The upper core 230 and the lower core 240 of the E-shape correspond to the core coupling hole 112-1 formed at the injection-molded bobbin 100-1 so that the upper core 230 and the lower core 240 are closely coupled to the outer circumference of the injection-molded bobbin 100-1 in a gapless manner. The upper core 230 and the lower core 240 are fixed by epoxy welding. Epoxy welding has advantages of improving water resistance, reducing fragments generated when damaged, and easily inspecting cracks.

However, since the gap is formed between the upper core 230 and the lower core 240, the upper and lower coupling type cores 230 and 240 may generate heat during driving, and may be attached using epoxy resin or the like, thereby having disadvantages of low product performance, complicated manufacturing process, and being easily affected by environmental reliability, compared to one embodiment.

However, if the cores 230 and 240 of the top-bottom coupling type are applied, the terminal portions 160-1 may be formed at both lower ends of the injection molded bobbin 100-1, and thus, it is not necessary to additionally provide dummy terminal portions (reference numeral 170 of fig. 1) in order to maintain balance.

In another embodiment, the coil is used as a terminal and used as the terminal portion 160-1, and thus, not only the problem of poor contact due to soldering can be prevented, but also the insulation of the coil can be improved, so that the power factor correction coil device 10-1 having high insulation and high structural stability can be provided.

The difference between the embodiment of the present invention and the other embodiment of the present invention is that the embodiment of the present invention has a structure in which the magnetic core is slidably coupled to the injection-molded bobbin by surrounding the coil by the second injection molding and using the end of the coil as the terminal portion, and the embodiment of the present invention has a structure in which the magnetic core is coupled to the injection-molded bobbin up and down by surrounding the coil by the second injection molding and using the end of the coil as the terminal portion.

The difference between the embodiment of the present invention and the other embodiment of the present invention is in the way that the magnetic core is combined with the injection-molded frame, and preferably, the same structure should be applied to the remaining portion. Therefore, the basic bobbin shape, the injection-molded bobbin shape, and the magnetic core shape may be different from each other in one embodiment of the present invention and another embodiment of the present invention.

The power factor correction coil device may reduce a power factor by being provided in a Light Emitting Diode (LED) driving power supply device, a power supply device of a Personal Computer (PC), or the like. In addition to power factor correction, the above power factor correction coil device can be applied to various devices used only by first winding.

In the foregoing, the preferred embodiments of the present invention are disclosed in the accompanying drawings and the description. Although specific terms are used herein, they are used only for the purpose of describing the present invention, and do not have meanings that limit or restrict the scope of the present invention described in the claims. It is therefore to be understood that numerous modifications may be made by those skilled in the art and that other embodiments may be devised which are equivalent by those skilled in the art. Therefore, the true technical scope of the present invention should be defined according to the technical idea of the appended claims.