CN114639533A - Novel coupling inductor structure design and manufacturing method thereof - Google Patents
Novel coupling inductor structure design and manufacturing method thereof Download PDFInfo
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- CN114639533A CN114639533A CN202011486715.4A CN202011486715A CN114639533A CN 114639533 A CN114639533 A CN 114639533A CN 202011486715 A CN202011486715 A CN 202011486715A CN 114639533 A CN114639533 A CN 114639533A
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/24—Magnetic cores
- H01F27/255—Magnetic cores made from particles
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/29—Terminals; Tapping arrangements for signal inductances
- H01F27/292—Surface mounted devices
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/34—Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
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Abstract
The invention discloses a novel coupling inductor structure which comprises a coil winding, a hardware material belt and a soft magnetic body, wherein the coil winding comprises a first coil and a second coil, the first coil and the second coil are wound in a parallel winding mode in a double-wire mode, the first coil, the second coil and the hardware material belt are welded, the soft magnetic body is coated on the outer side of the coil winding, and the soft magnetic body is made of a soft magnetic composite material with the magnetic conductivity of 15-120 and is formed by adopting heat transfer molding. In the invention, automation is easy to realize through the manufacturing forms of the coil and the hardware; the magnet adopts a transfer molding process, the molding pressure is less than 20Mpa, the deformation caused by overlarge stress of the coil can be avoided, and the problem of open and short circuit is effectively solved; the magnetic composite material for transfer molding leads the magnetic conductivity to be uniform, and the magnetic conductivity of the formed magnet is uniform and consistent and has small leakage inductance; the whole scheme can realize automatic production, and the product is hot stable, and the quality reliability is high.
Description
Technical Field
The invention relates to a novel coupling inductor structure design and a manufacturing method thereof.
Background
With the rapid development of information technology industry, manufacturing industry and electronic industry, the requirements for inductors in components are higher and higher. The failure rate of the corresponding device is improved to ppm level, and the difference between batches is small according to the characteristic stability of the product. The existing coupling inductors manufactured and sold in large quantities have the following structures:
traditional magnetic ring wire winding structure:
the structure is difficult to realize automation in wire winding and wire hanging at present, is basically carried out in a semi-manual mode at present, is low in efficiency, needs additional base or case in the process of manufacturing an SMD device, is large in size and occupies more PCB space;
DR magnetic core + sleeve + hardware or plastic part structure:
the structure has poor precision in the control of the assembly gap of the two magnetic cores and poor stability of the product characteristics, and meanwhile, the assembly gap is equivalent to an air gap, so that the leakage inductance of the product is large, and the coupling coefficient is relatively small;
NR magnetic core coating structure:
the main problem with this structure is that the relative permeability of the coating layer is low, only 3-5. The leakage inductance of the product is large, and the coupling coefficient is relatively smaller;
the structure is pressed to tradition dry powder an organic whole:
the dry powder mould pressing structure with the structure has large forming pressure, and is easy to cause coil deformation and further cause the problem of open short circuit.
Disclosure of Invention
In summary, the present invention provides a novel coupling inductor structure design with easy automation, small leakage inductance or magnetic flux, and high quality stability, and a method for manufacturing the same, in order to effectively and compatibly solve the above problems of the conventional coupling inductor structure.
In order to achieve the purpose, the invention adopts the following technical scheme:
the utility model provides a novel coupling inductance structure, includes coil winding, five metals material area and soft magnetic body, the coil winding includes first coil and second coil, and first coil and second coil double-line duplex winding to weld between first coil and second coil and the five metals material area, the cladding of soft magnetic body is in the outside of coil winding.
As a further description of the above technical solution:
the soft magnetic magnet is made of soft magnetic composite material with the magnetic conductivity of 15-120, the soft magnetic composite material mainly comprises spherical powder of soft magnetic material and thermosetting binder, and the soft magnetic composite material can be molded by heat transfer molding.
As a further description of the above technical solution:
the outer stable surface wall in five metals material area is provided with the outer electrode that forms after through mechanical treatment.
As a further description of the above technical solution:
a novel coupling inductance manufacturing method comprises the following steps:
the method comprises the following steps: forming a coil winding with a high coupling coefficient by the first coil and the second coil in a double-wire parallel winding mode;
step two: welding four lead wires of the first coil and the second coil with four corresponding welding points on the hardware material belt, so as to realize electrical connection and mechanical connection;
step three: placing the coil winding and the hardware material belt in the middle of the soft magnetic composite material, processing the soft magnetic composite material through a heat transfer molding process, and forming a required soft magnetic body after curing;
step four: and the hardware material belt is subjected to corner folding treatment to form a corresponding outer electrode on the outer surface of the soft magnetic body.
The invention has at least the following beneficial effects:
1) the automation is easy to realize through the manufacturing form of the coil and the hardware;
2) the magnet adopts a transfer molding process, the molding pressure is less than 20Mpa, the deformation caused by overlarge stress of the coil can be avoided, and the problem of open and short circuit is effectively solved;
3) the magnetic composite material for transfer molding leads the magnetic conductivity to be uniform, and the magnetic conductivity of the formed magnet is uniform and consistent and has small leakage inductance;
4) the whole scheme can realize automatic production, and the product is hot stable, and the quality reliability is high.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the description of the embodiments are briefly introduced below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without creative efforts.
FIG. 1 illustrates a coil winding block diagram provided in accordance with an embodiment of the present invention;
fig. 2 illustrates a coil and tape joining diagram provided in accordance with an embodiment of the present invention;
fig. 3 illustrates a structure of a cladding structure of a soft magnetic magnet provided according to an embodiment of the present invention;
fig. 4 illustrates an isometric view of an inductor provided in accordance with an embodiment of the present invention.
In the figure: 1. a coil winding; 101. a first coil; 102. a second coil; 2. a hardware material belt; 201. an outer electrode; 3. a soft magnetic magnet.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.
Example one
Referring to fig. 1-4, a novel coupling inductor structure comprises a coil winding 1, a hardware material belt 2 and a soft magnetic body 3, wherein the coil winding 1 comprises a first coil 101 and a second coil 102, the first coil 101 and the second coil 102 are wound in a double-wire parallel mode, the first coil 101, the second coil 102 and the hardware material belt 2 are welded with each other, an outer electrode 201 formed after mechanical treatment is arranged on the stable outer surface wall of the hardware material belt 2, the soft magnetic body 3 is coated on the outer side of the coil winding 1, the soft magnetic body 3 is made of a soft magnetic composite material with the magnetic conductivity of 15-120, the soft magnetic composite material mainly comprises a soft magnetic material spherical powder and a thermosetting binder, such as a ferromagnetic ferrite material powder and an iron-based soft magnetic metal material powder, and the soft magnetic composite material can be subjected to heat transfer molding;
a novel coupling inductance manufacturing method comprises the following steps:
the method comprises the following steps: forming the first coil 101 and the second coil 102 into a coil winding 1 with a high coupling coefficient by means of bifilar winding;
step two: welding four leads of the first coil 101 and the second coil 102 with four corresponding welding points on the hardware material belt 2, thereby realizing electrical connection and mechanical connection;
step three: the coil winding 1 and the hardware material belt 2 are placed in the middle of the soft magnetic composite material, the soft magnetic composite material is processed through a heat transfer molding process, a needed soft magnetic body 3 is formed after solidification, the heat transfer molding manufacturing process is adopted, the damage to the coil winding 1 and a welding connection point due to low forming pressure is small, the reliability is high, the production efficiency is high, and the product quality stability is high;
step four: the metal material strap 2 is subjected to corner folding treatment to form a corresponding outer electrode 201 on the outer surface of the soft magnetic body 3.
The working principle is as follows: forming the first coil 101 and the second coil 102 into a coil winding 1 with a high coupling coefficient by means of bifilar winding; four leads of the first coil 101 and the second coil 102 are welded with four corresponding welding points on the hardware material belt 2, so that the electrical connection and the mechanical connection are realized; the coil winding 1 and the hardware material belt 2 are placed in the middle of the soft magnetic composite material, the soft magnetic composite material is processed through a heat transfer molding process, a needed soft magnetic body 3 is formed after solidification, the heat transfer molding manufacturing process is adopted, the damage to the coil winding 1 and a welding connection point due to low forming pressure is small, the reliability is high, the production efficiency is high, and the product quality stability is high; the metal material strap 2 is subjected to corner folding treatment to form a corresponding outer electrode 201 on the outer surface of the soft magnetic body 3.
The foregoing shows and describes the general principles, principal features, and advantages of the invention. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are merely illustrative of the principles of the invention, but various changes and modifications may be made without departing from the spirit and scope of the invention, which is defined by the appended claims. The scope of the invention is defined by the appended claims and equivalents thereof.
Claims (4)
1. The utility model provides a novel coupling inductance structure, its characterized in that, includes coil winding (1), five metals material area (2) and soft-magnetic magnet (3), coil winding (1) includes first coil (101) and second coil (102), and first coil (101) and second coil (102) double-wire and duplex winding to weld between first coil (101) and second coil (102) and the five metals material area (2), soft-magnetic magnet (3) cladding is in the outside of coil winding (1).
2. The novel coupled inductor structure as claimed in claim 1, wherein the soft magnetic magnet (3) is made of soft magnetic composite material with permeability of 15-120, and the soft magnetic composite material is mainly made of soft magnetic material spherical powder and thermosetting binder, and the soft magnetic composite material can be molded by heat transfer molding.
3. The novel coupling inductor structure as claimed in claim 1, wherein the stable outer surface wall of the metal material strap (2) is provided with an outer electrode (201) formed by mechanical processing.
4. The method for manufacturing the novel coupled inductor according to claim 1, comprising the following steps:
the method comprises the following steps: forming a coil winding (1) with a high coupling coefficient by a first coil (101) and a second coil (102) in a double-wire parallel winding mode;
step two: four leads of the first coil (101) and the second coil (102) are welded with four corresponding welding points on the hardware material belt (2), so that the electrical connection and the mechanical connection are realized;
step three: placing the coil winding (1) and the hardware material belt (2) in the middle of the soft magnetic composite material, processing the soft magnetic composite material through a heat transfer molding process, and forming a required soft magnetic body (3) after solidification;
step four: the hardware material strap (2) is subjected to angle folding treatment to form a corresponding outer electrode (201) on the outer surface of the soft magnetic body (3).
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202011486715.4A CN114639533A (en) | 2020-12-16 | 2020-12-16 | Novel coupling inductor structure design and manufacturing method thereof |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202011486715.4A CN114639533A (en) | 2020-12-16 | 2020-12-16 | Novel coupling inductor structure design and manufacturing method thereof |
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| Publication Number | Publication Date |
|---|---|
| CN114639533A true CN114639533A (en) | 2022-06-17 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202011486715.4A Pending CN114639533A (en) | 2020-12-16 | 2020-12-16 | Novel coupling inductor structure design and manufacturing method thereof |
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| Country | Link |
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| CN (1) | CN114639533A (en) |
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2020
- 2020-12-16 CN CN202011486715.4A patent/CN114639533A/en active Pending
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