TWI705465B - Magnetic coil modules - Google Patents

Abstract

The present invention discloses a magnetic coil module comprising a first set of coils and a second set of coils. The first set of coils is externally coated with a first isolation layer. The second set of coils is a flat wire coil including an open first loop body to form two non-contacting end portions. One of end portions includes a first conductive portion protruding outward from the first loop body, and the other one includes a connecting end integrally extending outward to form an open second loop body. The terminal of the second loop body includes a protruding second conductive portion. Moreover, the aforementioned connecting end comprises a turning portion to make the second loop body opposite to the first loop body, and make the second set of coils position on the first isolation layer. Thereby, the assembly efficiency of the module will be improved, and the defect rate of module will be reduced.

Description

Magnetic induction coil module

The present invention relates to a coil module used in magnetic induction elements such as inductors and transformers.

For example, the structure of a magnetic induction element such as a transformer includes at least two independent coils, the so-called "primary coil" and "secondary coil". After the current is applied, the coils of the two sets of coils ( Turns) ratio performs voltage value conversion.

In practical applications, the transformer is usually constructed on an independent insulating base, which is pre-deployed with a plurality of conductive pins or contact pins connected to the coil to form a transformer assembly , And through these conductive pins or contact pins and the external circuit welding connection, so that the transformer assembly and the external circuit conduction use, at the same time the insulating base as a signal isolation to avoid interference Disturb.

In order to meet the miniaturization needs of consumer electronic products, it is inevitable that these transformers are designed to be thinner and lighter. In the known prior art, a printed circuit board (PCB) circuit printing technology is used to make a coil assembly. A flat (or flat) transformer, such as the one disclosed in the Chinese Patent Specification No. CN201138608, discloses a transformer assembly with conductive coil patterns printed on a PCB. The '608 patent uses a PCB to make a primary coil and a secondary coil, and coats the surfaces of the two sets of coils with a layer of insulating paint to isolate them, and is assembled with the magnetic core to form a flat transformer.

Although the prior art No. 608 can make the volume of the transformer thinner, there are still many defects in the manufacturing and assembly process as follows:

1. It should be noted that the use of PCB printing technology to make conductive coil patterns to become the primary and secondary coils of the transformer has a complicated construction method, low current resistance, and high cost burden. It is difficult for the products made to have a price competitive advantage in the market.

2. Coating insulating paint on the surface of the two sets of coils as isolation from each other, it is difficult to meet the safety requirements of transformer manufacturing, and it is easy to cause damage to the transformer during operation; especially the AC-DC transformer used to connect to the mains, due to the The voltage difference is large, and the isolation between the primary coil and the secondary coil must have a certain safety distance in the specification.

3. In the transformer disclosed in Figures 7 and 8 in the prior art No. '608, one set of primary coils (5A) and two sets of secondary coils (4A, 6A) are assembled with the magnetic core (M1), The central magnetic column of the magnetic core (M1) must pass through the assembly holes reserved on each set of coils, so the alignment of these coil assembly holes must be very precise, otherwise it will cause assembly difficulties, or cause the coil and the magnetic The core gap is too large. In particular, the two sets of secondary coils (4A, 6A) made of PCB as shown in Figure 8 of the case also need to be accurately connected to each other's coil patterns through the conductive pins shown on the left before providing them with The use of external circuit connection is the main factor that is difficult to introduce automation and mass production according to this design.

Another prior art known to the inventors related to the present invention is a planar transformer disclosed in US Patent No. 2013/0278371, which combines a plurality of pre-made plate coils (including primary and secondary coils) Put it on the magnetic core of the transformer in sequence, and provide a base with a plurality of conductive pins (pins) established, and connect the coils and external circuits by welding technology. The base can be As the isolation protection between the magnetic core and the external circuit.

Obviously, the flat metal coil used in the prior art No. '371 can be directly formed by die-casting or stamping in advance, and the manufacturing cost is much lower than that of the previously disclosed coil made of PCB and is more suitable. Mass production, and the thickness of the metal layer can withstand a larger current compared to PCB printed conductive coils; however, there are still some problems in the transformer manufacturing process and assembly process. The following defects:

1. There is a lack of isolation design for safe spacing between the flat coils. As mentioned above, even if a layer of insulating paint is applied to the surface of each group of coils as isolation, it is difficult to meet the requirements of transformer safety regulations, especially AC used to connect to the mains -DC transformer, due to the large voltage difference at the power supply terminal, it is easy to cause damage to the transformer during operation.

2. Each set of coils is an independent unit and component. When assembling with the magnetic core, the central magnetic pole of the magnetic core must pass through the assembly holes reserved on each set of coils in sequence, so these coil assembly holes The alignment must be very precise, which not only increases the difficulty of assembly and is prone to failure, but also wastes man-hours, making it more difficult to introduce automated processes to the disadvantage of large-scale production operations.

3. The conductive pins are fixed in advance on an independent base, and the wire ends of the coils of the primary or secondary must be connected to the conductive pins one by one for conduction. If the number of coils is required More (this is related to the turns ratio of the primary and secondary coils), it will inevitably affect the efficiency of production. Obviously, the more the number of connections, the more errors will occur, such as blind connection or wrong connection, which will increase the failure rate. .

In order to improve the shortcomings of the prior art, the present invention provides a more novel "magnetic induction coil module". Compared with the prior art, it is not only more conducive to manufacturing and assembly, but also in the application of magnetic induction components such as inductors or transformers. The time will be more convenient, and the defective rate of the terminal product can be reduced, which is the main purpose of the present invention.

In order to achieve the purpose of the invention, the coil module disclosed in the present invention includes a first set of coils and a second set of coils. The outside of the first set of coils is covered with a first isolation layer, and the second set of coils is a flat type. The coil has an open first loop body, so that two non-contact ends are formed, one of which has a first conducting portion protruding toward the body of the first loop, and the other end has a The connecting end integrally extends outward to form an open second loop body, the terminal of the second loop body has an outwardly convex second conductive portion, wherein the connecting end further includes a turning portion The turning portion makes the second loop body and the first loop body oppose in the same direction, so that the second set of coils are positioned on the first isolation layer in a clamping manner.

The second set of coils of the present invention can be made by die-casting or stamping conductive materials to reduce production costs. Among them, the first loop body and the second loop body are integrally connected to form the second set of coils, which reduces It eliminates the prior art using multiple independent coils in the assembly process and the trouble of precise alignment; in particular, it only needs to pass through the provided first conducting part and The two contacts of the second conducting part are connected, which reduces the chance of blind connection and improves the reliability of terminal products more effectively.

Furthermore, the first isolation layer is provided with a positioning groove adapted to the contours of the first loop body and the second loop body on the periphery of the adapter hole to facilitate their alignment and assembly. A boss is established as isolation between the connecting end and the first loop body and the second loop body.

Furthermore, another implementation manner can be derived from the structure of the second set of coils, that is, the second set of coils is also a flat coil with a plurality of continuous open first loop bodies, which It has a convex first conducting end and a plurality of connecting ends, the connecting ends integrally extend outward to form a plurality of continuous open second loop bodies, and the terminals of the continuous second loop bodies have an outer A convex second conducting end, wherein each of the connecting ends includes a turning portion, and the turning portions provide the plurality of second loop bodies and the plurality of first loop bodies facing in the same direction In this way, the number of turns of the second set of coils can be increased to correspond to and meet the requirements of the configured magnetic induction element.

As for the detailed structure and other detailed features of the present invention, please refer to the following embodiments and drawings for description.

2‧‧‧The first coil

10‧‧‧Conductive pattern

11‧‧‧Insulating substrate

12‧‧‧Contact

13‧‧‧Adapter hole

2,2a‧‧‧Second coil

20,20a‧‧‧The first loop body

200,200a‧‧‧First conducting part

201‧‧‧Circle hole

21,21a‧‧‧Second loop body

210,210a‧‧‧Second conducting part

211‧‧‧Circle hole

22, 22a‧‧‧Connecting terminal

220,220a‧‧‧turning part

3‧‧‧First isolation layer

30‧‧‧Locating slot

31‧‧‧Boss

32‧‧‧ Stage

4‧‧‧Second isolation layer

Figure 1 is an exploded view of the present invention.

Figure 2 is a structural diagram of the second set of coils of the present invention.

Figure 3 is a view of the combined appearance of the present invention.

Fig. 4 is a combined external view of the present invention from another perspective.

Fig. 5 is a cross-sectional view taken along the line A-A' in Fig. 3 of the present invention.

Fig. 6 is an external view of another embodiment of the present invention.

Fig. 7 is an expanded structural view of another embodiment of the second set of coils of the present invention.

The present invention is a coil module, which can be applied to magnetic induction elements such as inductors or transformers

Please refer to FIGS. 1 to 5 at the same time. The present invention includes a first set of coils (1) and a second set of coils (2), wherein the outside of the first set of coils (1) has a first isolation layer (3) ), the second set of coils (2) are positioned on the first isolation layer (3) in a clamping manner, thereby forming a coil module as shown in Figs. 3 and 4.

In the preferred embodiment disclosed in the present invention, referring to those disclosed in FIGS. 1 and 5, the first set of coils (1) is a conductive pattern (10) deployed on an insulating substrate (11), for example by printing Circuit board (hereinafter all referred to as PCB) manufacturing technology, the first set of coils (1) made by deploying the conductive pattern (10) on the PCB; or, laying the conductive pattern (10) directly on The insulating substrate (11) is formed It is the first set of coils (1), but not limited to this. In addition, a plurality of contact portions (12) can be pre-arranged on one side of the insulating substrate (11) to communicate with the conductive pattern (10) to provide electrical connection with the outside; and, in the first set of coils (1) There is a matching hole (13) in the preset, which can be used as the configuration with the magnetic core of the transformer.

The second set of coils (2) is a conductive material, which is made into a flat coil by die-casting, stamping, or other methods, which has an open first loop body (20), and the first loop body (20) There are two non-contacting ends, one of which has a first conducting portion (200) protruding toward the outside of the first loop body (20), and the other end is a connecting end (22 ), the connecting end (22) integrally extends outward to form an open second loop body (21), and the terminal of the second loop body (21) has a convex second conducting portion (210), Preferably, the shapes of the first loop body (20) and the second loop body (21) are symmetrical to each other; wherein, the connecting end (22) further includes a turning portion (220), the turning portion The portion (220) provides that the second loop body (21) is opposite to the first loop body (20) in the same direction.

The first isolation layer (3) provides insulation and isolation between the first set of coils (1) and the outside by covering the outside of the first set of coils (1), and exposes that the plurality of contact portions (12) can be The external circuit is connected. The coating method can be directly injected into the outside of the first set of coils (1) through the insulating material, or a mold frame is preformed with the insulating material to provide the first set of coils (1) to be inserted and sleeved therein; preferably, The first isolation layer (3) has a and a The positioning groove (30) of a loop body (20) and the second loop body (21) is contoured to facilitate their alignment and assembly. In addition, the connecting end (22) and the first conducting portion ( A boss (31) is established as isolation between each of the 200) and the second conducting portion (210). In addition, the first isolation layer (3) is provided with a carrier (32) at the opposite end away from the contact portion (12), and the carrier (32) can provide the first conducting portion of the second set of coils (2) (200), and the second conducting portion (210) configuration.

When assembling, the first loop body (20) is placed on one side of the first isolation layer (3) covered by the first set of coils (1), and by the formation of the turning portion (220), the second The loop body (21) is bent in the direction of the first loop body (20) and opposes the same direction, so that the first set of coils (1) is sandwiched between the first loop body (20) and the The second loop body (21) forms a coil module as shown in Figures 3 and 4; at the same time, the loop holes of the first loop body (20) and the second loop body (21) 201,211) naturally corresponds to the matching hole (13) of the first set of coils (1), as the configuration with the magnetic core of the transformer. Preferably, the first loop body (20) and the second loop body (21) are filled in the positioning groove (30) on the first isolation layer (3) to enhance the positioning effect, and the The first conductive portion (200) and the second conductive portion (210) are arranged on two opposite sides of the carrier (32) to provide conductive pin insertion with external circuits, or solder by SMT (surface mount) method, As for the connecting end (22) and the turning portion (220), they are straddled on the carrier (32) to make the positioning of the second set of coils (2) more compact and stable. At the same time, please refer to FIG. 4, the first conducting portion (200) and The second conducting portion (210) can also be bent vertically toward the first loop body (20) in the same direction and welded to the external circuit socket.

As a preference, please refer to Fig. 6. After the assembly of the coil module is completed, a second isolation layer (4) can be covered with an insulating material through injection on the outside of the coil module, and the The contact portion (12) of a set of coils (1), and the first and second conducting portions (200, 210) of the second set of coils (2) are exposed, providing connection with external circuits.

Finally, please refer to FIG. 7, which is another preferred embodiment of the second set of coils of the present invention. The second set of coils (2a) are also made of a conductive material and made by molding, stamping, or other methods. The flat coil has a plurality of continuous open first loop bodies (20a), the plurality of first loop bodies (20a) have a convex first conducting portion (200a), and a plurality of connections The connecting ends (22a) extend outward in the same direction and integrally form a plurality of continuous open second loop bodies (21a), and the terminals of the continuous second loop bodies (21a) protrude outward There is a second conducting portion (210a). Preferably, the shapes of the plurality of first loop bodies (20a) and the plurality of second loop bodies (21a) are symmetrical to each other, and the connecting ends (22a) each includes a turning portion (220a), the turning portions (220a) are provided for the plurality of second loop bodies (21a) and the plurality of first loop bodies (20a) to be aligned in the same direction In this way, the number of turns of the second set of coils (2a) can be increased to meet the requirements of the configured magnetic induction elements.

Compared with the prior art, it can be found that the advantages of the coil module disclosed in the present invention include:

1. The second set of coils (2) are made of die-casting or stamping conductive materials. Compared with the prior art transformer primary and secondary coils both use PCB, the production cost can be obviously reduced and the implementation is easy.

2. The first loop body (20) and the second loop body (21) are integrally connected to form the second set of coils (2), which reduces the assembly process of using multiple independent coils in the prior art, and the need The trouble of precise alignment; especially when connecting with external circuits, it only needs to be connected with the provided first conducting part (200) and second conducting part (210), which reduces the chance of blind connection. Improved reliability.

3. The second set of coils (2) are positioned on the first isolation layer (3) in a similar way as a clamping method to become a coil module, which is more conducive to subsequent coating of the second isolation layer (4) In particular, a positioning groove (30) that matches the contours of the first loop body (20) and the second loop body (21) is established on the first isolation layer (3) in advance to provide filling , And strengthen the positioning effect of the two in the assembly.

4. When the coil module of the present invention is used as a transformer, the magnetic core of the transformer only needs to be assembled to the matching holes (13) located in the first set of coils, which reduces the manufacturing process and reduces the failure rate.

The above description is only a series of one of the preferred embodiments of the present invention, and is not intended to limit the essence of the present invention. Any equivalent replacement and simple modification made by those skilled in the art using the present invention, such as defining the coil pattern The position, quantity, and form of the primary or secondary coils of the group, or the forming method of the first and second groups of coils, should still be covered by the scope of patent application described later.

1‧‧‧The first coil

11‧‧‧Insulating substrate

12‧‧‧Contact

13‧‧‧Adapter hole

2‧‧‧Second coil

20‧‧‧The first loop body

200‧‧‧The first conduction part

21‧‧‧Second loop body

210‧‧‧Second conduction part

22‧‧‧Connecting terminal

220‧‧‧Turnover

3‧‧‧First isolation layer

30‧‧‧Locating slot

31‧‧‧Boss

32‧‧‧ Stage

Claims (10)

A magnetic induction coil module includes: a first set of coils with a first isolation layer on the outside; a second set of coils with an open first loop body, the first loop body has two mutual The non-contact end, one end has a first conducting portion protruding toward the body of the first loop, and the other end has a connecting end that extends outward to form an open second loop integrally The main body, the terminal of the second loop body has an outwardly convex second conductive portion; wherein the connecting end includes a turning portion that makes the second loop body and the first loop body the same The directions are opposite, so that the second set of coils are positioned on the first isolation layer in a clamping manner to form a coil module. The magnetic induction coil module according to claim 1, wherein the first isolation layer is directly overmolded outside the first set of coils with an insulating material. The magnetic induction coil module according to claim 1, wherein the first isolation layer is covered by forming a mold frame with an insulating material to provide the first set of coils. The magnetic induction coil module according to claim 1, wherein the first set of coils and the first isolation layer outside thereof have a matching hole corresponding to the loop hole of the first loop body and the second loop body. The magnetic induction coil module according to claim 4, wherein the first isolation layer on the periphery of the adapting hole is each deployed with a positioning groove adapted to the contours of the first loop body and the second loop body. The magnetic induction coil module according to claim 1, wherein the first set of coils is formed by deploying a conductive pattern on an insulating substrate, and a plurality of contact portions are arranged on one side of the conductive pattern to communicate with the conductive pattern and exposed to Outside the first isolation layer. The magnetic induction coil module according to claim 1, wherein a carrier is deployed at one end of the first isolation layer, and the first conducting part and the second conducting part of the second set of coils are arranged opposite to the carrier side. The magnetic induction coil module according to claim 1, wherein the first isolation layer establishes a boss as isolation between the connection ends of the second set of coils and the first conductive portion and the second conductive portion. The magnetic induction coil module according to any one of claims 1 to 8, wherein the outside of the coil module is further covered with a second isolation layer, and the first and second conductive portions are exposed. A magnetic induction coil module includes: a first set of coils with a first isolation layer outside; a second set of coils with a plurality of continuous open first loop bodies, the plurality of first loops The main body has a convex first conducting portion and a plurality of connecting ends, the connecting ends extend in the same direction and integrally form a plurality of connecting ends. The continuous open-type second loop body has a second conducting portion protruding from the end of the continuous second loop body; wherein each of the connecting ends includes a turning portion, and the turning portion makes the second The loop body is opposite to the first loop bodies in the same direction, so that the second set of coils are positioned on the first isolation layer in a clamping manner to form a coil module.

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