TWI671769B - Magnetic induction element and method of manufacturing same - Google Patents

Abstract

A method for manufacturing a magnetic induction element includes: deploying a conductive pattern on a printed circuit board to make a first set of coils and establish a first adapting hole; and using conductive material to make at least a second set of coils and establish a first Two fitting holes; covering the first group of coil surfaces that do not include the first fitting hole with an insulating material to cover the first isolation layer, while establishing a positioning mechanism to provide alignment of the first and second fitting holes; The core of the magnetic column is inserted into the first and second adapting holes, so that the core is coupled with the first and second sets of coils; thereby, it is easy to connect the transformer's The introduction of automation in the production process can further improve efficiency and reduce the defect rate of products.

Description

Magnetic induction element and manufacturing method thereof

The invention relates to a magnetic induction element such as a transformer, which can be applied and connected to a power source and a circuit to provide voltage conversion.

The main structure of the transformer includes two sets of independent coils, the so-called primary and secondary coils, and a common core for magnetic permeability. After being connected to the power supply, it is based on the principle of electromagnetic induction and two sets of coils. The ratio of voltage to voltage is converted. In addition, in practical applications, the transformer is usually constructed on a separate insulating base. The base is pre-arranged with a plurality of conductive pins connected to the coil to form a transformer assembly. The conductive pin is welded to the external circuit, so that the transformer assembly is used for conducting with the external circuit, and the base is used as an isolation to prevent the iron core from contacting the external circuit.

In order to meet the demand for miniaturization of consumer electronics, the thinner and thinner transformer design is an inevitable trend. Therefore, some developers use printed circuit board (PCB) circuit printing technology to make flat (or flat) transformers with coils. For example, as disclosed by the inventor's prior art 1, Chinese Patent Publication No. CN201138608, it is about a transformer assembly with printed conductive coil patterns printed on a PCB. The prior art 1 uses a PCB to produce a primary coil and a secondary coil. The surfaces of the two sets of coils are coated with an insulating varnish (see Figure 3, element number 3) to isolate them, and then assembled into a flat type by assembling with the core. (Planar) transformer.

Although the prior art 1 can reduce the size of the transformer, there are many defects in the manufacturing process and the manufactured product:

1. It should be noted that the method of printing conductive coil patterns using PCB manufacturing technology to produce the primary and secondary coils of the transformer is complicated and the cost burden is high. The manufactured products are difficult to have a price competitive advantage in the market.

2. The surface of the two sets of coils is coated with insulation paint to isolate them from each other. It is difficult to meet the requirements of safety regulations for transformer manufacturing, and it is easy to cause damage to the transformer during operation; especially for AC-DC transformers connected to mains, due to AC power The voltage difference between the terminals is large, and the primary coil and the secondary coil must be isolated with a certain safety distance.

3. In the transformer disclosed in Fig. 7 and Fig. 1 of the prior art, when a set of primary coils (5A) and two sets of secondary coils (4A, 6A) are assembled with the core (M1), the central guide of the core (M1) The magnetic column must pass through the assembly holes reserved in each group of coils, so the alignment of these coil assembly holes must be very accurate, otherwise it will cause difficulties in assembly; especially the three groups of coils (4A, 5A, 6A) are separate Independent units and components must be individually sheathed on the iron core in the manufacturing process. The process not only appears complicated, wastes man-hours, but also requires high precision. Otherwise, it may easily lead to an increase in the failure rate of assembly, or the coil and the iron core. The gap is too large. In particular, the two sets of secondary coils (4A, 6A) made of PCB shown in Figure 8 must also accurately communicate with each other's coil patterns through the conductive pins shown on the left to provide connection with external circuits, which is also a manufacturing process. Difficulty, unable to design the main factors to introduce automation, mass production according to this.

4. In the transformer disclosed in FIG. 8 of the prior art 1, there is no safety isolation mechanism design between the conductive pin of the transformer and the core (M1), and the core (M1) and the external circuit lack a safe distance isolation. planning.

Another prior art known to the inventor 2 is a planar transformer disclosed in U.S. Publication No. 2013/0278371, which is a plurality of pre-made transformers The flat coils (including the primary and secondary coils) are put on the central magnetic pole of the transformer in order, and a base with multiple conductive pins is provided. These coils, as well as external circuit connections, the base can be used as an isolation protection for the core and external circuits.

Obviously, the flat metal coils used in the prior art 2 can be directly molded through die casting or stamping, and the manufacturing cost is much lower than that of the coils made of PCBs; but the manufacturing process and the manufacturing process The following defects still exist in the finished product:

1. There is no isolation design for safe spacing between flat coils. As mentioned earlier, even if a layer of insulating varnish is applied on the surface of each coil as isolation, it is difficult to meet the requirements of transformer safety regulations, especially for AC- DC transformer, due to the large voltage difference at the AC power terminal, will easily cause damage to the transformer during operation.

2. Each coil is an independent unit and component. When assembling with the core, the central magnetic column of the core must sequentially pass through the assembly holes reserved in each group of coils, so the alignment of these coil assembly holes must be It is very accurate, which not only makes assembly difficult and prone to failure, but also wastes man-hours. It is also impossible to introduce automated processes and is not conducive to large-scale production operations.

3. The prior art 2 also lacks a safety isolation plan between the conductive pin and the iron core; in addition, the conductive pins are fixed in advance on an independent base, which not only adds an additional step in the manufacturing process, but also Also because of the addition of a transformer assembly component, the producer will increase an unnecessary burden on the management of materials.

[Explanation of the invention]

In order to improve the defects existing in the prior art, the present invention provides a novel method for manufacturing a magnetic induction element and a magnetic induction element manufactured by the method, which can be put into automated production operations, thereby improving efficiency and reducing the defective rate of products. In order to facilitate understanding, the following description will take “transformer” as an example for detailed explanation.

A method for manufacturing a transformer includes: step 1, printing a coil pattern on a circuit board to make a first group of coils, and establishing a first adapting hole in the first group of coils; step 2, manufacturing from a conductive material At least one second group of coils, and a second adapting hole is established in the second group of coils; step 3, injecting an insulating material on the outer surface of the first group of coils to form a covered first isolation layer, and A positioning mechanism is formed at the same time as the first isolation layer is formed. Step 4, the second set of coils is placed on the first isolation layer, and the positioning mechanism and the first and second coils are positioned through the positioning mechanism on the first isolation layer. The matching holes are aligned; step 5. Make an iron core with a magnetically conductive post, insert the magnetically conductive post into the first and second matching holes, and place the iron core with the first set of coils and the first Two sets of coils are coupled.

According to the manufacturing method of the transformer, since the printed circuit board outline of the first group of coils is square, using this as a platform to insulate the surface with insulating material to form the first isolation layer is easy to implement, which will facilitate the introduction of automated production processes; The second set of coils made of cast or stamped conductive material, compared with the transformer primary and secondary coils of the prior art 1, use PCBs, which can significantly reduce production costs and is easy to implement; and, forming on the first isolation layer The positioning mechanism enables the first and second adapting holes to be accurately aligned, which will further facilitate the assembly of the core and reduce the failure rate, which is the primary object of the present invention.

Preferably, the manufacturing method of the transformer of the present invention further comprises: deploying a plurality of first conductive pins in contact with the coil pattern on the circuit board, and establishing a first and a plurality of the same while the first isolation layer is formed in step 3 A first separator in the same direction as the conductive pins; and in step 3, the first isolation layer is formed while a carrier is made far from the plurality of first conductive pins, and a plurality of second conductive pins and The second group of coils are in contact, and a second insulation layer is covered with an insulating material on the surface of the second group of coils that does not include the first fitting hole and the second fitting hole. A second separator in the same direction as the electric needle. Thereby, the second group of coils is protected from being exposed by the second isolation layer, and the first (second) spacer can be established at the same time when the first (second) isolation layer is formed to isolate the core, which can not only simplify the manufacturing process, but also When the transformer is connected to an external circuit, the core is elevated to isolate it from the external circuit, eliminating the base used in the prior art 2.

Preferably, the manufacturing method of the transformer of the present invention further comprises: when the second isolation layer is formed, a through hole is reserved, and a conductive coating material is injected into the through hole to communicate the core with one of the second conductive pins; After the iron core is assembled, it can communicate with the second conductive pin connected to the external ground line to effectively reduce the electromagnetic wave interference generated by the transformer during operation.

1‧‧‧The first group of coils

10‧‧‧ Coil Pattern

11‧‧‧Circuit Board

12‧‧‧ the first conductive pin

13‧‧‧first adapter hole

2,2a‧‧‧The second group of coils

20‧‧‧Second adapter hole

3‧‧‧ the first isolation layer

30‧‧‧ first partition

31‧‧‧ carrier

32,32a‧‧‧Second conductive pin

4‧‧‧ Positioning agency

40‧‧‧ frame

41‧‧‧ positioning frame

42‧‧‧columns

43‧‧‧hole

5‧‧‧Second isolation layer

50‧‧‧Second partition

51‧‧‧through hole

52‧‧‧Conductive coating

6‧‧‧ Iron core

60‧‧‧ Magnetically permeable column

FIG. 1 to FIG. 6 are sequentially drawn according to the manufacturing method of the transformer of the present invention, wherein FIG. 1 is a schematic diagram of the appearance of the first group of coils of the transformer of the present invention.

FIG. 2 is a corresponding relationship diagram of a first set of coils and a second set of coils of a transformer of the present invention.

FIG. 3 is a combined external view of a first set of coils and a second set of coils of a transformer of the present invention.

FIG. 4 is a schematic diagram showing the appearance of a first set of coils and a second set of coils of a transformer according to the present invention.

Fig. 5 is a correspondence diagram of a transformer coil group and an iron core according to the present invention.

FIG. 6 is an assembly completion diagram of the transformer of the present invention.

FIG. 7 is a partial cross-sectional view of the transformer assembly of the present invention after completion.

The present invention relates to a magnetic induction element and a manufacturing method thereof. For the manufacturing method and steps, please refer to those disclosed in FIG. 1 to FIG. 6 in order, and mainly includes:

Step 1. As shown in FIG. 1, a coil pattern (10) is printed on a circuit board (11) through a printed circuit board (hereinafter collectively referred to as PCB) manufacturing technology to make a first group of coils (1). Preferably, the circuit board (11) is a multi-layer board, and the coil pattern (10) can be arranged in an interlayer of the multi-layer circuit board (11), so that the coil pattern (10) increases a distance from the outside; in addition, A plurality of first conductive pins (12) may be pre-arranged on the circuit board (11), through which the first conductive pins (12) may be in contact with the coil pattern (10), and be conductive with external circuits; and, A first adapting hole (13) is made in the first set of coils (1) to provide a core configuration (described later) and is coupled to the conductive pattern (10).

Step 2. A flat (or planar) second group of coils (2) is made from a conductive material through die casting, stamping, or other methods. A second suitable coil is established in the second group of coils (2). The distribution hole (20) provides an iron core configuration (described later) and is coupled thereto. As shown in FIG. 2, in the preferred embodiment disclosed in the present invention, there are two second sets of coils (2, 2 a), which are respectively disposed on different sides of the first set of coils (1), in a sandwich-like manner. Deployment; where the first set of coils (1) can be defined as the primary coil of the transformer, and the second set of coils (2, 2a) can be defined as the secondary coil of the transformer. Of course, the first group of coils (1) can also be defined as the secondary coil of the transformer, and the second group of coils (2, 2a) can be defined as the primary coil of the transformer.

In step 3, referring also to FIG. 2, the surface of the first group of coils (1) excluding the first adapter hole (13) is covered with an insulating material by the injection molding technology, and the first isolation layer (3) can be An isolation layer (3) is formed while a first partition (30) in the same direction as the plurality of conductive pins (12) is established adjacent to the plurality of conductive pins (12), and away from the plurality of conductive pins A protruding carrier (31) is made at (12), and a plurality of second conductive pins (32) are deployed on the carrier (31). Preferably, a positioning mechanism (4) is simultaneously established on the first isolation layer (3), and the positioning mechanism (4) may be a convex outer portion according to its contour at the first adapting hole (13). A frame (40) surrounds the first adapting hole (13), so, The second fitting hole (20) can be sleeved on the outer frame (40) so that the second group of coils (2) can be positioned, and the first and second fitting holes (13, 20) can be obtained directly. To the exact alignment; or according to the appearance contour of the second group of coils (2), a positioning frame (41) is established on the first isolation layer (3) to surround the second group of coils (2), and The first isolation layer (3) and the second set of coils (2) establish mutually interfering positioning members. This positioning member may be a pillar (42) and a hole (43) as shown in FIG. Continuing, as shown in FIG. 3, the second group of coils (2) is placed on the first group of coils (1) and connected to the plurality of second guide pins (32); if so, except through the first isolation The layer (3) not only increases the safety insulation distance between the first and second sets of coils (1,2), but also positions the second set of coils (2). In other words, the second set of coils (2) The two adapting holes (20) can also be accurately aligned with the first adapting holes (13) at the same time, which is beneficial to the assembly of the iron core described later.

Step 4, as shown in FIG. 4, the surface of the second group of coils (2) excluding the first adapter hole (13) and the second adapter hole (20) is covered with an insulating material by using injection molding technology. An isolation layer (5), and a second spacer in the same direction as the plurality of second conductive pins (32) can be established adjacent to the plurality of second conductive pins (32) while the second isolation layer (5) is being formed Plate (50); and a through hole (51) is reserved between the second isolation layer (5) and the second group of coils (2). Please refer to FIG. 7 at the same time, and the through hole (51) is injected with The conductive paint (52) is in contact with the second group of coils (2) and can communicate with one of the second conductive pins (32a).

Step 5, please refer to FIG. 5 to FIG. 7 to produce a magnetic core (6) for magnetic permeability. The core (6) may be an EE type or an EI type as disclosed in the present invention, which has at least one conductive A magnetic column (60), correspondingly inserting the magnetically conductive column (60) into the first and second adapting holes (13, 20), so that the core (6) and the first group of coils (1) and the second set of coils (2) are coupled. Please also refer to FIG. 7 at the same time, after the iron core (6) is assembled, it can be contacted with the conductive paint (52). When the second conductive pin (32a) is connected to the ground terminal of the external circuit, the transformer can be reduced in operation. Electromagnetic Interference (EMI) generated at the time.

The transformer manufactured by the above method and steps includes: a first set of coils, a coil pattern (10) is printed on a circuit board (11), which has a first adapting hole (13), and A plurality of first conductive pins (12) are arranged on the circuit board (11); at least one second set of coils (2) has a second adapting hole (20); a first isolation layer (3) is a package Covering the surface of the first group of coils (1) not including the first adapting hole (13), the first isolation layer (3) has a positioning mechanism (4) for providing the first and second adapting holes (13, 20) Alignment, and deploy a plurality of second conductive pins (12) in contact with the second group of coils (2) away from the plurality of first conductive pins (32); a second isolation layer (5), the package Covered on the surface of the second group of coils (1) not including the second adaptation hole (20), there is a through hole (51) between the second isolation layer (5) and the second group of coils (2), the through hole A conductive paint (52) is injected into the hole (51) to contact the second group of coils (2) and communicate with one of the second conductive pins (32a).

An iron core (6) having at least one magnetically conductive post (60), the magnetically conductive post (60) corresponding to and inserted into the first and second adapting holes (13, 20), so that the iron core (6) Coupling with the first group of coils (1) and the second group of coils (2), and contacting with the conductive paint (52).

In addition to the above, between the plurality of first conductive pins (12) and the core (6), a first separator (3) is established with the first isolation layer (3) in the same direction as the plurality of first conductive pins (12) ( 30); between the plurality of second conductive pins (32) and the iron core (6), a second separator is established with the second isolation layer (5) in the same direction as the plurality of second conductive pins (12) (50).

Compared with the prior art, it can be found that the advantages of the transformer and manufacturing method of the present invention include:

1. The first set of coils (1) is made of PCB. Since the outline of the PCB is square, using this as a platform to inject insulating material on the surface to form the first isolation layer (3) is easy to implement, which is more conducive to the introduction of automated production processes.

2. In the same process of forming the first isolation layer (3), a first partition (30) can be made to isolate the core (6), and a carrier (31) for forming a plurality of second conductive pins (32) can be formed. ), Has made considerable contributions to the simplification of the process.

3. The second group of coils (2) made of die-casting or stamping conductive material, compared with the primary and secondary coils of the transformer of the prior art 1, use PCBs, which can obviously reduce the production cost and is easy to implement.

4. The positioning mechanism (4) is formed on the first isolation layer (3) to obtain the positioning of the second group of coils (2), which can help step 4 to establish the second isolation layer (5); in particular, the second group After the coil (2) is positioned, its second adapting hole (20) can be accurately aligned with the first adapting hole (13), which helps the assembly of the core described in step 5 and reduces the failure rate.

5. The second group of coils (2) is protected from exposure by a second isolation layer (5), and a second partition (50) can be established to isolate the core (6) at the same time when the second isolation layer (5) is formed, To simplify the process.

6. The first partition plate (30) and the second partition plate (50) established in steps 3 and 4 can raise the iron core (6) and isolate the core plate from the external circuit when the transformer assembly is connected to the external circuit. The use of the base mentioned in the prior art 2 is eliminated.

7. After the iron core (6) is assembled, it can communicate with the second conductive pin (32a) connected to the external ground line, which can effectively reduce the electromagnetic interference (EMI) generated by the transformer during operation.

8. With the transformer manufacturing method and steps described above, it is easier to introduce the manufacturing process into automated production, which can not only increase productivity, reduce failure rates, but also reduce manufacturing costs.

The above description is only a series of preferred embodiments of the present invention, and is not intended to limit the substance of the present invention. Any equivalent arrangement performed by those skilled in the art using the present invention will be described. Change and simple modification, such as defining the position, number, and form of the primary / secondary coils of the transformer, the position, number, and form of the conductive pins, the position, number, and form of the core, or the forming of the first and second sets of coils Laws should still be covered by the scope of patent application described later.

Claims (10)

A method for manufacturing a magnetic induction element, comprising: step 1, printing a coil pattern on a circuit board to make a first group of coils, and establishing a first adapting hole in the first group of coils; step 2, using a conductive material Making at least one second group of coils, and establishing a second adapting hole in the second group of coils; step 3, covering the first group of coils with insulation material to form a first isolation layer, and A positioning mechanism is formed at the same time as the first isolation layer is formed. Step 4, the second set of coils is placed on the first isolation layer, and positioned through the positioning mechanism on the first isolation layer, and the first and The two matching holes are aligned; step 5. Make an iron core with a magnetically conductive post, insert the magnetically conductive post into the first and second adapting holes, and make the iron core and the first set of coils and The second set of coils is coupled. The manufacturing method according to claim 1, wherein the circuit board is a multilayer board, and the coil pattern is printed in an interlayer of the multilayer circuit board. The manufacturing method according to claim 1, wherein a plurality of first conductive pins are deployed in contact with the coil pattern on the circuit board, and a plurality of conductive pins are established while the first isolation layer is formed in step 3 First partition in the same direction. The manufacturing method according to claim 3, wherein, in step 3, the first isolation layer is formed while a carrier is made away from the plurality of first conductive pins, and the carrier is provided with a plurality of second conductive pins and The second group of coils are in contact; and a second isolation layer is coated on the outside of the second group of coils with an insulating material. The manufacturing method according to claim 4, wherein a second separator is formed in the same direction as the plurality of second conductive pins while the second isolation layer is being formed. The manufacturing method according to claim 4, wherein a through hole is reserved when the second isolation layer is formed, and a conductive paint is injected into the through hole to communicate the core with one of the second conductive pins. The manufacturing method according to any one of claims 1 to 6, wherein the positioning mechanism establishes a convex outer frame according to its contour at the first fitting hole to surround the first fitting hole. The manufacturing method according to any one of claims 1 to 6, wherein the positioning mechanism establishes a positioning frame surrounding the second group of coils according to an appearance contour of the second group of coils. The manufacturing method according to any one of claims 1 to 6, wherein the positioning mechanism is a post and a hole that establish mutual interference between the first isolation layer and the second group of coils. A magnetic induction element includes: a first set of coils having a first adapting hole; at least one second set of coils having a second adapting hole; a first isolation layer covering the first The group coil surface has a positioning mechanism to provide the positioning of the second group of coils and the alignment of the first and second adapting holes; an iron core having at least one magnetically conductive post inserted into the first and second adapting holes; The matching holes are coupled to the first group of coils and the second group of coils, wherein a plurality of first conductive pins are connected to the first group of coils, and a first conductive pin is in the same direction as the first conductive pin between the first coil and the core. First partition.