CN212570657U - Ultra-thin type mould pressing small volume heavy current inductor - Google Patents

Abstract

The utility model relates to the technical field of inductors, and discloses an ultra-thin molded small-volume high-current inductor, which comprises an inductor, wherein the inductor comprises a strip-shaped magnetic core and a copper sheet, the strip-shaped magnetic core and the copper sheet are molded integrally, the left side and the right side of the strip-shaped magnetic core are both fixedly provided with an L-shaped electrode copper sheet, the strip-shaped magnetic core and the copper sheet are molded directly by molding by adopting a high-magnetic-flux high-permeability alloy material, the problems that the traditional assembled high-current inductor generally uses a single-turn copper sheet and an EI magnetic core is assembled to realize, the process of a miniaturized product is difficult to operate, and the inductance and the saturation current can not be made higher are solved, and the problems that the molding pressure intensity can not be made too high and the turn-to-turn short circuit can be easily caused by the stripping of an enameled wire of the traditional molded, the magnetic core density can be made very high, and inductance and saturation current are improved.

Description

Ultra-thin type mould pressing small volume heavy current inductor

Technical Field

The utility model relates to a technical field of inductor specifically is a little volume heavy current inductor of ultra-thin type mould pressing.

Background

The inductor is an element capable of converting electric energy into magnetic energy to be stored, a traditional assembled high-current inductor is generally realized by assembling a single-turn copper sheet and an EI magnetic core, the process of a miniaturized product is difficult to operate, the inductance and the saturation current cannot be made higher, the traditional molded inductor is generally molded by adopting a multi-turn enameled wire and common alloy, the molding pressure cannot be made too high normally in order to prevent short circuit caused by enameled wire stripping, and the turn-to-turn short circuit is also easily caused in the using process.

SUMMERY OF THE UTILITY MODEL

Technical problem to be solved

The utility model is not enough to prior art, the utility model provides an ultra-thin type mould pressing small size heavy current inductor has solved traditional assembled heavy current inductor and has generally used the single turn copper sheet, the EI magnetic core equipment is realized, miniaturized product technology is difficult to the operation, inductance value and saturated current can't be done higher problem, and solved traditional mould pressing inductor simultaneously and can not be done too high in order to prevent that enameled wire depainting skin from causing the ordinary mould pressing pressure of short circuit, cross in the use, also cause the problem of turn-to-turn short circuit easily.

(II) technical scheme

For the purpose of realizing solving above-mentioned traditional assembled and mould pressing heavy current inductor problem, the utility model provides a following technical scheme: an ultrathin molded small-size large-current inductor comprises an inductor, wherein the inductor comprises a strip-shaped magnetic core and a copper sheet, notches are formed in two sides of the lower surface of the strip-shaped magnetic core, the strip-shaped magnetic core is made of an alloy material and can adjust inductance according to the magnetic conductivity of the alloy material, the copper sheet is rectangular and is molded integrally, two ends of the copper sheet are located on the left side and the right side of the outer portion of the strip-shaped magnetic core, the strip-shaped magnetic core and the copper sheet are molded integrally and are directly molded through the strip-shaped magnetic core and the copper sheet, the design space is fully utilized, the occupied space of an electrode in the strip-shaped magnetic core is reduced, the effective area of a center column of the strip-shaped magnetic core is enlarged as much as possible, the inductance value and the saturation current are greatly improved, the efficiency of the inductor is improved, the material is the same, the, the bottleneck that traditional slim inductor inductance can't improve, saturation current can't improve is solved, and simultaneously because adopt copper sheet and the integrative compression molding of bar magnetic core, need not open the air gap, reduce production technology, the inductance is stable, the product reliability is strengthened, the equal fixed mounting in the left and right sides of bar magnetic core has an L type electrode copper sheet, L type electrode copper sheet mainly uses as the pad, two L type electrode copper sheets pass through the welding intercommunication with the copper sheet after the mould pressing respectively, and two L type electrode copper sheets are fixed through the epoxy adhesion with the bottom of bar magnetic core, increase product mechanical strength through designing two L type electrode copper sheet welding, avoid bar magnetic core to break, the assembly is difficult not hard up, and production efficiency is high.

The two ends of the copper sheet are respectively welded with the two L-shaped electrode copper sheets to obtain the tin cones, and the parts, connected with the ports of the L-shaped electrode copper sheets and the copper sheet, are filled through the tin cones, so that the L-shaped electrode copper sheets and the copper sheets are fixed more tightly.

Preferably, the shape of the copper sheet is single pound I type, S type or U type.

Preferably, each L-shaped electrode copper sheet comprises a vertical plate, a transverse plate and a bent plate, wherein the vertical plate is vertical, the transverse plate is vertical to the vertical plate, the transverse plate is perpendicular to the vertical plate, the transverse plate and the vertical plate are fixedly connected through the bent plate, the bent plate is arc-shaped, and the surface of the outer side of the transverse plate is fixedly connected with the lower end of the bent plate.

Preferably, the upper end of bent plate and the lower extreme fixed connection of riser, the square groove has been seted up on the surface in the riser outside, and the square groove is used for spacing the port of copper sheet, and the square groove cup joints in the outside of copper sheet, and the inboard surfacing welding of riser is on the surface of bar magnetic core one end, and the upper surface of diaphragm passes through epoxy and glues the inside at the notch.

Preferably, the copper sheet and the strip-shaped magnetic core are molded integrally.

Preferably, the copper sheet and the E-shaped magnetic core are in a die-pressing thin horizontal design, the height dimension can be below two millimeters at the lowest, the inductance value range can be 1000nH at the maximum according to the dimension setting, and the saturation current can be above 100A.

(III) advantageous effects

Compared with the prior art, the utility model provides a little volume heavy current inductor of ultra-thin type mould pressing possesses following beneficial effect:

1. this ultra-thin type mould pressing small size heavy current inductor, adopt high magnetic flux high magnetic conductivity alloy material through the bar magnetic core, bar magnetic core and the direct compression molding of copper sheet, it generally uses the single circle copper sheet to have solved traditional assembled heavy current inductor, the EI magnetic core equipment is realized, miniaturized product technology is difficult to operate, the inductance value can't be done with the saturated current problem higher, the shortcoming that traditional mould pressing inductance need use multiturn coil to satisfy because of using the magnetic conductivity end has been solved, and solved traditional mould pressing inductor simultaneously and caused the short circuit generally mould pressing pressure intensity too high in order to prevent that the enameled wire from taking off the paint skin and can't be done too high, in the use, also cause the problem of turn-to-turn short circuit easily, thereby make pressure can do very high, magnetic core density can be done very high, promote inductance value and saturated.

2. This little volume heavy current inductor of ultra-thin type mould pressing, through setting up bar magnetic core and copper sheet, bar magnetic core and copper sheet mould pressing back are as a whole, through bar magnetic core and the direct compression molding of copper sheet, make full use of the design space, reduce the occupation space of electrode in bar magnetic core the inside, increase the effective area of the center pillar of bar magnetic core as far as possible, great improvement inductance value and saturation current, improve inductor efficiency, equal material, under the same size, under the condition of equal number of turns resistance, the biggest inductance volume can be accomplished and the biggest saturation current is obtained to this design, the unable improvement of traditional slim inductor inductance volume has been solved, the bottleneck that saturation current can't improve, and because adopt the integrative compression molding of copper sheet and bar magnetic core simultaneously, need not open the air gap, reduce production technology, the inductance volume is stable, strengthen product reliability.

3. This small big current inductor of ultra-thin type mould pressing increases product mechanical strength through designing two L type electrode copper sheet welding, avoids the bar magnetic core to break, and the assembly is difficult not hard up, and production efficiency is high.

4. The copper sheet used by the ultrathin die-pressed small-volume large-current inductor can be in a single-smashing I shape, an S shape and a U shape, and can be adjusted according to the requirement of an uninductive quantity, so that the adaptability of the inductor in use is improved.

5. According to the ultrathin die-pressed small-volume high-current inductor, the copper sheet and the E-shaped magnetic core are in die-pressed thin horizontal design, the height size can be below two millimeters at the lowest, and the inductance can be higher than that of a traditional inductor in the same size.

6. This little volume heavy current inductor of ultra-thin type mould pressing, inductor simple process only need several processes alright in order to accomplish, and very easy assembly, the quality is very reliable, and antidetonation compressive capacity is strong, and the electrode coil that the inductor used is the mould punching press and forms, and the product laminating roughness can obtain guaranteeing, and electrode laminating area is big, assembles easily on the PCB board, and the customer application that is particularly suitable for uses on the PCB bottom surface board, can not fall the piece.

7. This little volume heavy current inductor of ultra-thin type mould pressing, the magnetic core that the inductor used generally uses high magnetic flux alloy material, and under the not high condition of inductance requirement, also can use ordinary alloy material, the universality is strong, and compares traditional equipment preparation, and traditional mould pressing heavy current inductance preparation receives the shaping pressure restriction, compares that prior art advantage is huge.

8. Compared with the traditional mould pressing inductance, the ultra-thin mould pressing inductor with small volume and large current generally uses alloy powder to coat an enameled wire coil for mould pressing, because the enameled wire needs to ensure that an insulating paint film cannot be damaged to cause short circuit and the coil cannot deform badly, the forming pressure cannot be too large, the sintering temperature cannot be too high and is generally below 200 ℃, therefore, the magnetic conductivity of the traditional mould pressing inductance can only achieve about 60U, the inductance cannot be increased, the inductance is increased by the number of turns, the resistance is generally larger, the single-turn copper sheet adopted by the scheme does not need the insulating paint film, the deformation is not worried about, the used alloy powder can select high density and high-temperature sintered alloy materials, the materials can be selected according to design requirements, the magnetic conductivity can achieve more than 125U, is twice of the traditional mould pressing inductance, the resistance is also reduced, the volume can be smaller, and, the design has the same size, inductance and resistance, and the current is optimized in all inductor products.

9. The ultra-thin molded small-volume large-current inductor is compared with the traditional assembled large-current inductor, the traditional assembled large-current inductor is generally realized by combining and assembling an upper magnetic core and a lower magnetic core through glue, when the ultra-thin small-size large-current inductor is manufactured, the magnetic core is influenced by the strength of the magnetic core because the magnetic core is thinner, is easy to break, is easy to deform, influences the appearance, is unstable in inductance and difficult to assemble, has very high requirement on the precision of the production process and high operation difficulty, can solve the problem by integrally molding and molding a single-turn copper sheet and alloy powder, can be used for cutting and soldering tin by pre-positioning the copper sheet in the middle of a mold before molding, and is unnecessary to assemble, has high strength of the magnetic core, has no air gap, can realize twice assembly with the same size inductance and has very obvious advantages, and, can be thinner than what the equipment was made, can accomplish 1.5mm minimum, traditional minimum of assembling can only accomplish 2.5mm, and can optimize the defect of traditional mould pressing inductance and equipment inductance simultaneously, therefore this product has very big advantage than these two fields.

Drawings

Fig. 1 is a schematic diagram of the explosion structure of the present invention;

fig. 2 is a schematic view of the assembly structure of fig. 1 according to the present invention.

In the figure: 1 inductor, 2 strip-shaped magnetic cores, 3 copper sheets, 4L-shaped electrode copper sheets and 5 tin cones.

Detailed Description

The present invention will be described in further detail with reference to the drawings, wherein like elements are designated by like reference numerals, wherein the terms "front", "rear", "left", "right", "upper" and "lower", "bottom" and "top" used in the following description refer to the orientation in the drawings, and the terms "inner" and "outer" refer to the orientation toward or away from the geometric center of a particular element, respectively.

The technical solutions in the embodiments of the present invention will be described clearly and completely with reference to the accompanying drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments in the present invention, all other embodiments obtained by a person skilled in the art without creative work belong to the protection scope of the present invention.

Referring to fig. 1-2, the present invention provides a technical solution: an ultra-thin type die-pressing small-volume large-current inductor comprises an inductor 1, wherein the inductor 1 comprises a strip-shaped magnetic core 2 and a copper sheet 3, notches are formed in two sides of the lower surface of the strip-shaped magnetic core 2, the strip-shaped magnetic core 2 is made of an alloy material, the inductance can be adjusted according to the magnetic permeability of the alloy material, the copper sheet 3 is in a single-smashing I type, an S type or a U type and can be adjusted according to different inductance requirements, the copper sheet 3 is in a rectangular shape, the strip-shaped magnetic core 2 and the copper sheet 3 are integrally formed by die pressing, two ends of the copper sheet 3 are located on the left side and the right side of the outer portion of the strip-shaped magnetic core 2, the strip-shaped magnetic core 2 and the copper sheet 3 are integrally formed after die pressing, the strip-shaped magnetic core 2 and the copper sheet 3 are directly die-pressed, great improvement inductance value improves inductor 1 efficiency, and equal material, under the equal size, under the condition of equal number of turns resistance, the biggest inductance volume can be accomplished and the biggest saturation current is obtained to this design, has solved the unable improvement of slim inductance volume, the unable bottleneck that improves of saturation current, and is simultaneously because adopt copper sheet 3 and 2 integrative compression molding of bar magnetic core, need not open the air gap, reduces production technology, and the inductance volume is stable, reinforcing product reliability.

The equal fixed mounting in the left and right sides of bar magnetic core 2 has an L type electrode copper sheet 4, and L type electrode copper sheet 4 mainly uses as the pad, and two L type electrode copper sheets 4 communicate through the welding with copper sheet 3 after the mould pressing respectively, and two L type electrode copper sheets 4 are fixed through the epoxy adhesion with the bottom of bar magnetic core 2, increase product mechanical strength through designing two L type electrode copper sheets 4 welding, avoid bar magnetic core 2 to break, the assembly is difficult not hard up, and production efficiency is high.

Every L type electrode copper sheet 4 all includes the riser, diaphragm and kickboard, the riser is vertical form, the shape size of diaphragm is the same with the shape size of riser, and diaphragm and riser are perpendicular setting, diaphragm and riser carry out fixed connection through the kickboard, the kickboard is convex, the surface in the diaphragm outside and the lower extreme fixed connection of kickboard, the upper end of kickboard and the lower extreme fixed connection of riser, the square groove has been seted up to the surface in the riser outside, the square groove is used for carrying on spacingly to the port of copper sheet 3, the square groove cup joints the outside at copper sheet 3, the inboard surfacing welding of riser is on the surface of 2 one ends of bar magnetic core, the upper surface of diaphragm passes through epoxy and glues the inside at the notch.

The two ends of the copper sheet 3 are respectively welded with the two L-shaped electrode copper sheets 4 to obtain the tin cones 5, the welding modes of the copper sheet 3 and the L-shaped electrode copper sheets 4 can be solder paste reflow welding, electric welding or laser welding, and the like, and the parts connected with the ports of the L-shaped electrode copper sheets 4 and the ports of the copper sheet 3 are filled through the tin cones 5, so that the L-shaped electrode copper sheets 4 and the copper sheet 3 are fixed more tightly.

The utility model provides an inductor manufacture craft as follows, copper sheet 3 is the good copper strip of mould stamping forming, need prevent the copper sheet material area at specific mould before the suppression, single circle copper sheet 3 places for the shape through the material area, put the powder afterwards and carry out the punching press, the back is via the thermal treatment, directly to next solidification after the thermal treatment, the inspection is with selecting separately the same step, equipment L type terminal after the intensity inspection, then through the frock pin-cutting of special design and through last tin equipment soldering tin, at last to select separately the inspection, thereby to fashioned inductor.

The working principle is as follows: bar magnetic core 2 adopts high magnetic flux high magnetic conductivity alloy material, bar magnetic core 2 and 3 direct compression molding of copper sheet, it generally uses single circle copper sheet to have solved traditional assembled large current inductor, the EI magnetic core equipment is realized, miniaturized product technology is difficult to the operation, the inductance value can't be done with saturated current higher problem, the shortcoming that traditional mould pressing inductance need use many turns coil to satisfy because of using the magnetic conductivity end has been solved, copper sheet 3 that uses is the single circle copper sheet, needn't worry the problem that the enameled wire takes off the lacquer leather, pressure can be done very high, magnetic core density can be done very high, promote inductance value and saturated current.

Strip magnetic core 2 and 3 mould pressing backs of copper sheet are as a whole, through strip magnetic core 2 and 3 direct compression molding of copper sheet, make full use of the design space, reduce the occupation space of electrode in strip magnetic core 2 the inside, increase the effective area of the center pillar of strip magnetic core 2 as far as possible, great improvement inductance value, improve inductor 1 efficiency, equal material, under the same size, under the condition of equal number of turns resistance, the biggest inductance volume can be accomplished in this design and the biggest saturation current is obtained, the unable improvement of slim inductance volume has been solved, the bottleneck that saturation current can't improve, and simultaneously because adopt copper sheet 3 and 2 integrative compression molding of strip magnetic core, need not open the air gap, reduce production technology, the inductance volume is stable, strengthen product reliability.

Through designing two L type electrode copper sheets 4 welding and increasing product mechanical strength, avoid bar magnetic core 2 to break, the assembly is difficult not hard up, and production efficiency is high.

Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.

Claims (7)

1. An ultra-thin type mould pressing small volume heavy current inductor includes inductor (1), its characterized in that: inductor (1) is including bar magnetic core (2) and copper sheet (3), and the notch has all been seted up to the both sides of bar magnetic core (2) lower surface, and bar magnetic core (2) and copper sheet (3) are mould pressing integrated into one piece, and the both ends of copper sheet (3) are located the outside left and right sides of bar magnetic core (2), and the equal fixed mounting in both sides has one L type electrode copper sheet (4) about bar magnetic core (2), and two L type electrode copper sheets (4) communicate through the welding with copper sheet (3) after the mould pressing respectively.

2. The ultra-thin molded small-volume high-current inductor as claimed in claim 1, wherein: the strip-shaped magnetic core (2) is made of alloy materials.

3. The ultra-thin molded small-volume high-current inductor as claimed in claim 1, wherein: the copper sheet (3) is in a single-smashing I shape, an S shape or a U shape.

4. The ultra-thin molded small-volume high-current inductor as claimed in claim 1, wherein: and the two L-shaped electrode copper sheets (4) are fixedly adhered to the bottom of the strip-shaped magnetic core (2) through epoxy resin.

5. The ultra-thin molded small-volume high-current inductor as claimed in claim 1, wherein: every L type electrode copper sheet (4) all includes riser, diaphragm and bent plate, and the riser is vertical form, and the shape size of diaphragm is the same with the shape size of riser, and diaphragm and riser are perpendicular setting, and diaphragm and riser carry out fixed connection through the bent plate, and the bent plate is arc, the surface in the diaphragm outside and the lower extreme fixed connection of bent plate, the upper end of bent plate and the lower extreme fixed connection of riser.

6. The ultra-thin molded small-volume high-current inductor as claimed in claim 5, wherein: the surface in the riser outside has been seted up the square groove, and the square groove is used for spacing to the port of copper sheet (3), and the square groove cup joints in the outside of copper sheet (3), and the inboard surface welding of riser is on the surface of bar magnetic core (2) one end, and the upper surface of diaphragm passes through epoxy and glues the inside at the notch.

7. The ultra-thin molded small-volume high-current inductor as claimed in claim 1, wherein: two ends of the copper sheet (3) are respectively welded with the two L-shaped electrode copper sheets (4) to obtain tin cones (5), and the parts of the L-shaped electrode copper sheets (4) connected with the ports of the copper sheet (3) are filled through the tin cones (5).

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