TWI761182B - Magnetic core structure and manufacturing method thereof - Google Patents

Abstract

A magnetic core structure and a manufacturing method thereof are provided. The magnetic core structure includes a magnetic core, a plurality of conductive layers, and two wires. The magnetic core has a winding column, and a first side column and a second side column that are connected to both ends of the winding column. The winding column includes two outer protrusions each having an accommodating groove. The first side column has two first setting stations, and the second side column has two second setting stations. The conductive layers are disposed on the two first setting stations and the two second setting stations. The two wires are wound on the winding column, and a part of the two wires are respectively located in the two accommodating grooves. In one of the two first setting stations and one of the two second setting stations that are located on one of both sides, one of the two wires is electrically coupled to one of the conductive layers on the first setting station and one of the conductive layers on the second setting station. In one of the two first setting stations and one of the two second setting stations that are located on another one of the both sides, another one of the two wires is electrically coupled to one of the conductive layers on the first setting station and one of the conductive layers on the second setting station. Accordingly, the magnetic core structure can improve production efficiency.

Description

Magnetic core structure and method of making the same

The present invention relates to a magnetic core structure, in particular to a magnetic core structure and a manufacturing method thereof which can greatly improve the manufacturing efficiency.

The existing magnetic core structure includes a primary coil, a secondary coil, and a magnetic core, and the magnetic core has a central column, a middle step connecting both sides of the central column, and a first step and a second step connecting both ends of the central column. . During the production process, the primary coil and the secondary coil will be first spot welded on both ends of the first step, then wound to the middle step for the second spot welding, and finally wound to the second step. Both ends of the magnetic core are spot welded for the third time, thereby completing the fabrication of the existing magnetic core structure.

However, due to the elastic restoring force of the material of the primary coil and the secondary coil, the step and sequence of the second spot welding cannot be omitted. For example, when the second spot welding step is omitted in the manufacturing process, the primary coil and the secondary coil will be scattered due to the lack of fixation (spot welding) at the part located in the middle step, resulting in the primary coil and the secondary coil. The third spot welding could not be carried out smoothly. Furthermore, even if the third spot welding is completed, the primary coil and the secondary coil are loosened or scattered because the winding path on the magnetic core is too long.

Therefore, the inventor believes that the above-mentioned defects can be improved. Nate has devoted himself to research and application of scientific principles, and finally proposes an invention with reasonable design and effective improvement of the above-mentioned defects.

The technical problem to be solved by the present invention is to provide a magnetic core structure and a manufacturing method thereof in view of the deficiencies of the prior art, which can effectively improve the possible defects of the existing magnetic core structure.

An embodiment of the present invention discloses a method for manufacturing a magnetic core structure, which is applicable to a magnetic core structure, wherein the magnetic core structure includes a magnetic core, the magnetic core has a winding column, and two ends of the winding column are connected to each other. a first side post and a second side post; the winding post has an extension direction and a width direction perpendicular to the extension direction, and the winding post includes a main body part and two parts connected to the main body part Each of the outer protrusions includes an accommodating groove and two coupling platforms located on both sides of the accommodating groove; the first side post and the second side post have mutually Two setting tables arranged at intervals, the manufacturing method includes the following steps: implementing a plane electroplating step: using plane electroplating to print on the two setting tables of the first side pillar and two of the second side pillars A conductive layer is formed on the setting table and the two coupling tables of the two outer protrusions; a first welding step is performed: a first end of two wires is respectively fixed to the the conductive layers on the two setting platforms of the first side post; implementing a first winding step: winding a part of the body portion along the extending direction with a second end of the two wires , and respectively pass through the two accommodating grooves; implement a second winding step: use the second ends of the two wires to wind the other part of the body part along the extending direction; implement a first Two welding steps: using welding to fix the second ends of the two wires on the conductive layers on the two setting tables of the second side posts; and implementing a conducting step: using conductive materials It is arranged between any one of the wires and the conductive layers on the adjacent two coupling stages, so that the two wires are respectively electrically coupled to the two adjacent couplings. the conductive layer on the stage.

An embodiment of the present invention discloses a magnetic core structure, which includes: a magnetic core, including: a winding column having an extending direction, the winding column includes a main body part and two outer convex parts connected to the main body part , each of the protruding portions includes an accommodating groove; and a first side post and a second side post, respectively connecting the two ends of the body portion along the extending direction, and the first side posts have mutually two first setting platforms arranged at intervals, the second side pillars have two second setting platforms arranged at intervals from each other; a plurality of conductive layers are arranged on the two first setting platforms and the two second setting platforms the setting table, and the two outer protrusions; and two wires wound on the main body, the parts of the two wires are respectively located in the two accommodating grooves, and one of the wires is The two ends of the wire are respectively electrically coupled to the conductive layers on the first setting table and the second setting table on the same side, and the two ends of the other wire are respectively electrically coupled to the same other side. The conductive layer on the first setting stage and the second setting stage on the side.

An embodiment of the present invention discloses a magnetic core structure, which includes: a magnetic core, including: a winding column having an extending direction, the winding column includes a main body part and two outer convex parts connected to the main body part , each of the protruding parts has four coupling platforms, a tangent slot, and an accommodating slot, the four coupling platforms are spaced apart from each other, and the accommodating slot and the tangent slot communicate with each other, and is arranged between the four coupling platforms; a first side post and a second side post are respectively connected to both ends of the main body along the extending direction, and the first side posts are spaced apart from each other. two first setting platforms, the second side pillars have two second setting platforms spaced apart from each other; a plurality of first conductive layers are provided with two first setting platforms and two second setting platforms a plurality of second conductive layers, disposed on the four coupling stages of the two outer protrusions; two first wires, respectively wound around the main body and located on the first side post Parts of the two first wires are respectively located in the two accommodating grooves between the two protruding parts, and two ends of one of the first wires are electrically coupled to the same one. The first conductive layer and the two second conductive layers of the first setting stage are adjacent to each other, and two ends of the other first wire are electrically coupled to the same other side and The first conductive layer and the two second conductive layers of the first setting platform adjacent to each other; two second wires are respectively wound around the main body and located on the second side post and the two second conductive layers. Parts of the two second wires are respectively located in the two accommodating grooves between each of the protruding portions, and two ends of one of the second wires are electrically coupled on the same side and located on the same side respectively. The first conductive layer and the two second conductive layers of the second setting stage adjacent to each other, and two ends of the other second wire are electrically coupled to the same other side and are in phase with each other. The first conductive layer and the two second conductive layers of the adjacent first setting stage.

To sum up, the magnetic core structure and the manufacturing method thereof disclosed in the embodiments of the present invention can pass through “the accommodating grooves of the two outer protrusions” and “the parts of the two wires are located in the two The design of "inside the accommodating groove" enables the magnetic core structure to prevent the two wires from being scattered or loosened in the case of two welding steps. Accordingly, the magnetic core structure can improve the manufacturing efficiency.

For a further understanding of the features and technical content of the present invention, please refer to the following detailed descriptions and drawings of the present invention. However, the drawings provided are only for reference and description, and are not intended to limit the present invention.

The following are specific embodiments to illustrate the embodiments of the "magnetic core structure and its manufacturing method" disclosed in the present invention. Those skilled in the art can understand the advantages and effects of the present invention from the content disclosed in this specification. The present invention can be implemented or applied through other different specific embodiments, and various details in this specification can also be modified and changed based on different viewpoints and applications without departing from the concept of the present invention. In addition, the accompanying drawings of the present invention are merely schematic illustrations, and are not drawn according to the actual size, and are stated in advance. The following embodiments will further describe the related technical contents of the present invention in detail, but the disclosed contents are not intended to limit the protection scope of the present invention.

It should be understood that although terms such as "first", "second" and "third" may be used herein to describe various elements or signals, these elements or signals should not be limited by these terms. These terms are primarily used to distinguish one element from another element, or a signal from another signal. In addition, the term "or", as used herein, should include any one or a combination of more of the associated listed items, as the case may be.

[First Embodiment]

Referring to FIGS. 1 to 9 , the present embodiment provides a method for fabricating a magnetic core structure 100 including steps S101 to S113 , but in practical applications, one of the above steps S101 to S113 can be determined according to the needs of the designer and omit or replace with reasonable variations.

A preparation step S101 is performed, as shown in FIG. 2 and FIG. 3 , to provide a magnetic core 1 . For the convenience of subsequent description, the magnetic core 1 has (or defines) an extending direction D1 and a width direction D2 perpendicular to the extending direction D1, and the extending direction D1 is the direction of the magnetic core 1 in FIG. 3 . The width direction D2 is the vertical direction of the magnetic core 1 in FIG. 3 , but the present invention is not limited thereto.

Further, in this embodiment, the magnetic core 1 is a substantially "King"-shaped magnetic conductive member, and has a winding column 11 and a first side column connecting both ends of the winding column 11 12 and a second side post 13 . The winding column 11 includes a main body portion 112 and two convex portions 111 connected to the main body portion 112 . Both ends of the main body portion 112 along the extending direction D1 are connected to the first side column 12 . and the second side pillar 13 , the two protruding portions 111 are disposed on both sides of the body portion 112 along the width direction D2 , and are located on the first side pillar 12 and the second side pillar between 13. Each of the protruding portions 111 includes an accommodating groove 1111 and two coupling platforms 1112 located on both sides of the accommodating groove 1111 .

Further, each of the accommodating grooves 1111 is generally disposed along the extending direction D1, and the two ports of any of the accommodating grooves 1111 face the first side post 12 and the second side respectively. Column 13. That is to say, each of the accommodating grooves 1111 communicates with the outside of the outer convex portion 111 corresponding to its position, but the invention is not limited thereto. For example, the two accommodating grooves 1111 can also be arranged obliquely with respect to the extending direction D1, and the two ports are not simultaneously located on an imaginary line along the extending direction D1 (as shown in FIG. 4 shown).

In addition, the first side column 12 and the second side column 13 each have two setting platforms spaced apart from each other, and each of the setting platforms of the first side column 12 is further defined as a first The setting table 121 is defined as a second setting table 131 for each setting table of the second side column 13 . The top surfaces of the two first setting platforms 121 and the two second setting platforms 131 are coplanar with each other, which means that the height of the top surface of any one of the first setting platforms 121 is the same as the height of any one of the second setting platforms. The heights of the top surfaces of the tables 131 are the same, and the heights of the top surfaces of the two first setting tables 121 or the two second setting tables 131 are also the same as each other. It should be noted that the aforementioned height refers to a height direction D3 perpendicular to the extending direction D1 and the width direction D2 as the measurement direction, that is, the vertical direction of the magnetic core 1 in FIG. 2 .

A plane electroplating step S103 is performed. Referring back to FIG. 2 , the two first setting stages 121 of the first side pillars 12 and the two first setting stages 121 of the second side pillars 13 are printed on the two side pillars 13 by plane plating. A conductive layer 2 is formed on the two setting stages 131 and the two coupling stages 1112 of the two outer protrusions 111 .

Generally speaking, the aforementioned planar electroplating printing is one-time printing, that is, the two first setting stages 121 , the two second setting stages 131 , and two of the two outer convex portions 111 are printed at one time. The coupling stage 1112 simultaneously forms the conductive layer 2 . For example, one side of the magnetic core 1 is immersed in the electroplating solution, and the two first setting tables 121 , the two second setting tables 131 , and the two outer protrusions 111 are The top surfaces of the two coupling stages 1112 can be electroplated at the same time, so that the magnetic core 1 forms a plurality of the conductive layers 2 , but the invention is not limited thereto.

A first welding step S105 is performed. As shown in FIG. 5 , a first end 31 of the two wires 3A and 3B is respectively fixed to the two first setting tables (of the first side post 12 ) by welding. The conductive layer 2 on 121. In practice, the aforementioned welding methods can be spot welding, gas welding, resistance welding, etc., which means that the first ends 31 of the two wires 3A and 3B are fixed by the solder 5 and electrically coupled to the two wires 3A and 3B. The first setting table 121 is sufficient, and is not limited by any welding method.

A first winding step S107 is performed. As shown in FIG. 6 , a second end 32 of the two wires 3A, 3B is used to wind a part of the body portion 112 along the extending direction D1, and respectively pass through the two wires 3A and 3B. each of the accommodating grooves 1111 . Specifically, the second ends 32 of the two wires 3A and 3B are first wound at the portion of the body portion 112 between the first side post 12 and the two protruding portions 111 ( or winding) several times, and then let the two second ends 32 pass through the two accommodating grooves 1111 respectively. Accordingly, parts of the two wires 3A, 3B are accommodated in the two accommodating grooves 1111 to be limited, and the two second ends 32 pass through the two accommodating grooves 1111 The port is located between the two outer protrusions 111 and the second side post 13 .

A second winding step S109 is performed. As shown in FIG. 7 , the second ends 32 of the two wires 3A and 3B are used to wind another part of the main body 112 along the extending direction D1 . That is to say, the two wires 3A and 3B are wound several times along the body portion 112 and are located between the two outer protruding portions 111 and the second side post 13 .

It is worth noting that the two wires 3A, 3B are located in the two accommodating grooves 1111 based on their parts, so when the second winding step S109 is completed, the two wires 3A, 3B can be The two wires 3A and 3B are pressed against the inner edges of the two accommodating grooves 1111 by the tension generated during winding. Accordingly, the two wires 3A, 3B can be fixed on the two outer protrusions 111 , and the magnetic core 1 in FIG. 4 has the best effect.

A second welding step S111 is performed. As shown in FIG. 8 , the second ends 32 of the two wires 3A and 3B are respectively fixed to the two second devices of the second side post 13 by welding. The conductive layer 2 on the stage 131 . In practice, the welding method used in the second welding step S111 is the same as that in the first welding step S105, so as to facilitate the maintenance of the production line, but of course it can be different.

A conducting step S113 is performed, as shown in FIG. 9 , a conductive material is disposed between the conductive layers 2 on any one of the wires 3A, 3B and the two adjacent coupling stages 1112 , so that the two Each of the wires 3A, 3B is electrically coupled to the conductive layers 2 on the two adjacent coupling stages 1112, respectively. Accordingly, the magnetic core structure 100 forms two windings, and when used as a transformer, the position of the center tap is located at the first side leg 12 and the second side leg 13 .

Further, the two wires 3A and 3B are directly welded enameled wires in this embodiment, so in the conducting step S113 , the personnel only need to use a high-temperature conductive material 6 to set any one of the wires and their wires. Between the conductive layers 2 on the adjacent two coupling stages 1112, the high temperature of the conductive material 6 can directly melt the insulating layers of the two wires 3A, 3B, and make each of the conductive layers 3A and 3B melt. The wires 3A and 3B are electrically coupled to the conductive layers 2 of the two adjacent coupling stages 1112 .

It should be noted that the conducting step S113 can be omitted in practice, that is, the two wires 3A and 3B are only connected to the plurality of wires on the first side post 12 and the second side post 13 . Each of the conductive layers 2 is electrically coupled. In addition, the conducting step S113 is different from the welding method used in the first welding step S105 and the second welding step S111 , and the conducting step S113 adopts a soldering method, but the invention is not limited thereto.

In addition, it should be noted that welding is the most time-consuming process in the art, especially the king-shaped magnetic core structure 100 must be welded at least three times, so it can save any welding times and greatly increase the manufacturing process. efficiency. It can be seen from the above-mentioned steps S101 to S113 of this embodiment that in the manufacturing process of the magnetic core structure 100 , only two weldings are used in total, which means that only the first welding step S105 and the second welding step S111 are performed. Thus, the two conducting wires 3A and 3B can be fixed to the magnetic core 1 in the shape of a "king". In other words, any fabrication method in which the "king"-shaped magnetic core is soldered for more than two times is not the fabrication method referred to in the present invention.

[Second Embodiment]

As shown in FIG. 10 and FIG. 11 , which are the second embodiment of the present invention, this embodiment is similar to the above-mentioned first embodiment, and the similarities between the two embodiments will not be repeated. The main difference between the above-mentioned first embodiment is that the turn-on step S113 further includes a sub-step S1131 and a sub-step S1132.

A peeling sub-step S1131 is performed. As shown in FIG. 11 , part of the insulating layer of the wires located in the two accommodating grooves 1111 is physically removed, so that each of the two wires 3A and 3B is exposed. The conductive layer 33 is exposed. The above-mentioned physical method may be laser peeling or cutting peeling, which means that the insulating layers 34 of the two wires 3A and 3B can be removed by physical methods.

A soldering sub-step S1132 is performed, and the exposed conductive layers 33 of the two wires 3A and 3B are respectively electrically connected to the conductive layers 2 of the two adjacent coupling stages 1112 by soldering, That is, the magnetic core structure 100 shown in FIG. 9 .

It should be noted that the wires 3A and 3B in this embodiment are high heat-resistant enameled wires, that is, the insulating layer cannot be directly removed by high temperature, but must be removed by physical means, but the present invention is not limited to this. For example, the two wires 3A and 3B can also be other enameled wires whose insulating layers cannot be removed by high temperature.

[Third Embodiment]

As shown in FIG. 12 to FIG. 15 , which is the third embodiment of the present invention, this embodiment is similar to the above-mentioned first embodiment, and the similarities between the two embodiments will not be repeated. The difference between the above-mentioned first embodiment is that the preparation step S101 of this embodiment is different from that of the first embodiment, and the manufacturing method of the magnetic core structure further includes implementing steps S115 and S117 .

In the preparation step S101, the magnetic core 1' of this embodiment is different from the magnetic core 1 of the first embodiment. Specifically, as shown in FIG. 13 , each of the protruding portions 111 in this embodiment further includes a tangent groove 1113 , and the tangent groove 1113 is disposed along the width direction D2 at any two adjacent ones of the Between the coupling stages 1112, and the tangent grooves 1113 communicate with the accommodating grooves 1111, which means that any of the tangent grooves 1113 and the accommodating grooves 1111 corresponding to their positions will form a "cross" shape together.

After the conducting step S113, a tangential step S115 is further performed. As shown in FIG. 14, the two wires (and the conductive material located on the tangent grooves 1113) are physically cut along the two tangent grooves 1113. ), so that two of the wires form four sub-wires S3. Accordingly, the magnetic core structure 100 forms four sets of windings, that is, the two sub-conductors S3 located between the first side pillar 12 and the two outer protrusions 111 are two of the sub-conductors S3 windings, and the two sub-conductors S3 located between the two outer protrusions 111 and the second side pillars 13 are the other two windings. In a preferred case, the aforementioned physical method can be the same as the physical method of the second embodiment, and the laser cutting method is particularly preferred.

After the line-cutting step S115, a short-circuiting step S117 is further performed. As shown in FIG. 15, two short-circuit lines 4 are used to electrically couple the first setting stage 121 and the second setting table on the same side respectively. The conductive layer 2 of the stage 131 . That is to say, on both sides of the magnetic core 1 along the width direction D2, one of the conductive layers 2 of the first setting stage 121 uses one of the short-circuit lines 4 to connect with all the conductive layers 2 on the same side. The conductive layer 2 of the second setting stage 131 is short-circuited, and the other conductive layer 2 of the first setting stage 121 uses another short-circuit line 4 to be the same as the second setting on the other side. The conductive layer 2 of the stage 131 is short-circuited, so that when the magnetic core structure 100 is used as a transformer, the center tap is located at the positions of the two protruding portions 111 . Of course, personnel can also omit the tangent step in due course according to production requirements.

The above-mentioned first to third embodiments are descriptions of the manufacturing method of the magnetic core structure 100 . The following describes a magnetic core structure 100 manufactured by the above-mentioned manufacturing method of the magnetic core structure 100 , but the present invention is not limited thereto. . That is to say, the magnetic core structure 100 of this embodiment can also be fabricated by other fabrication methods.

[Fourth Embodiment]

Referring back to FIG. 1 to FIG. 9 , the fourth embodiment provides a magnetic core structure 100 . The magnetic core structure 100 includes a magnetic core 1 , a plurality of conductive layers 2 and two conductive layers disposed on the magnetic core 1 . 3 wires. The magnetic core 1 in this embodiment includes a winding column 11 , a first side column 12 and a second side column 13 connecting two ends of the winding column 11 . Next, the components of the magnetic core 1 and their connection relationships will be described below.

Referring back to FIG. 5 , in this embodiment, the winding column 11 has a body portion 112 and two protruding portions 111 connected to the body portion 112 . Specifically, each of the protruding portions 111 is formed by two sides of the body portion 112 facing outward along the width direction D2, and the height of each of the protruding portions 111 along the height direction D3 higher than the height of the body portion 112 .

It is worth noting that each of the protruding portions 111 includes an accommodating groove 1111 and two coupling platforms 1112 located on both sides of the accommodating groove 1111 . In detail, in this embodiment, each of the accommodating grooves 1111 is generally disposed along the extending direction D1, and the two ports of each of the accommodating grooves 1111 face the first side post 12 and the first side post 12 respectively. The second side column 13 is connected to the outer side of the outer convex portion 111 corresponding to its position, but the present invention is not limited thereto. For example, each of the accommodating grooves 1111 may be inclined relative to the extending direction D1 as shown in FIG. 4 .

The first side post 12 and the second side post 13 are connected to both ends of the main body portion 112 , and the first side post 12 has two first setting platforms 121 spaced apart from each other, and the first side post 12 The two side pillars 13 have two second installation platforms 131 arranged at a distance from each other. Ideally, the top surfaces of the two first setting platforms 121 , the top surfaces of the two second setting platforms 131 , and the top surfaces of the two convex portions 111 are coplanar with each other, which means that The heights along the height direction D3 are all the same (as shown in FIG. 2 ).

A plurality of the conductive layers 2 are disposed on the two first setting platforms 121 , the two second setting platforms 131 , and the two protruding portions 111 . Generally speaking, the plurality of the conductive layers 2 can be formed by planar printing and electroplating, so the plurality of the conductive layers 2 are also coplanar with each other (as shown in FIG. 5 ), but the present invention is not limited thereto.

Two of the wires 3 are wound on the body portion 112 , and both ends of the two wires 3 are fixed by welding and electrically coupled to the conductive layers 2 of the two first setting platforms 121 . and the two conductive layers 2 of the second setting stage 131 . Wherein, when two of the wires 3 are disposed on the winding post 11, parts of the two wires 3 will be located in the two accommodating grooves 1111, and the two wires 3 use The tension generated during winding makes the two wires 3 abut against the inner edges of the two accommodating grooves 1111 to limit the position.

[Fifth Embodiment]

As shown in FIG. 13 and FIG. 15 , it is a fifth embodiment of the present invention. This embodiment is similar to the above-mentioned fourth embodiment, and the similarities between the two embodiments will not be repeated. The difference between the above-mentioned fourth embodiment is mainly that: the total number of wires of the magnetic core structure 100 in this embodiment is four, and is further defined as two first wires 3A and two second wires 3B. In addition, the two outer protrusions 111 are also different in this embodiment.

Specifically, as shown in FIG. 13 , each of the protruding portions 111 includes four coupling stages 1112 , a tangential groove 1113 , and an accommodating groove 1111 . Specifically, in each of the protruding portions 111 , the four coupling stages 1112 are spaced apart from each other, and the accommodating grooves 1111 are arranged between the four coupling stages 1112 along the extending direction D1 and the tangent grooves 1113 are disposed between the four coupling platforms 1112 along the width direction D2 and communicate with the accommodating grooves 1111 , that is, the accommodating grooves 1111 and the tangent grooves 1113 Together they form a "cross" shape. Of course, the two accommodating grooves 1111 may also be arranged obliquely with respect to the extending direction D1.

The conductive layers on the two first setting platforms 121 and the two second setting platforms 131 are further defined as a first conductive layer 2A, and the conductive layers arranged on the plurality of coupling platforms 1112 are further defined as a first conductive layer 2A. The layer is defined as a second conductive layer 2B. It can also be understood that a plurality of the first conductive layers 2A are arranged on two of the first installation stages 121 and two of the second installation stages 131 , and a plurality of the second conductive layers 2B are arranged on a plurality of the second installation stages 131 . on the coupling stage 1112.

The two first wires 3 are respectively wound around the main body portion 112 between the first side posts 12 and the two protruding portions 111 , and parts of the two first wires 3 are respectively located at In the two accommodating grooves 1111 , two ends of one of the first wires 3 are respectively electrically coupled to the first conductive layer 2A of the first setting stage 121 located on the same side and adjacent to each other. and two of the second conductive layers 2B, the two ends of the other first wire 3 are respectively electrically coupled to the first conductive layers of the first setting stage 121 located on the same other side and adjacent to each other layer 2A and two of the second conductive layers 2B.

The two second wires 3 are respectively wound around the main body portion 112 and located between the second side posts 13 and the two protruding portions 111 , and the parts of the two second wires 3 are respectively located at In the two accommodating grooves 1111 , two ends of one of the second wires 3 are respectively electrically coupled to the first conductive layer 2A of the second setting stage 131 located on the same side and adjacent to each other. and on the two second conductive layers 2B, the two ends of the other second wire 3 are respectively electrically coupled to the first set stage 121 on the same other side and adjacent to each other. On the conductive layer 2A and the two second conductive layers 2B. It should be noted that the “same side” and “the same other side” mentioned above are the two sides of the magnetic core 1 along the width direction D2.

[Technical effects of the embodiments of the present invention]

To sum up, the magnetic core structure and the manufacturing method thereof disclosed in the embodiments of the present invention can pass through “the accommodating grooves of the two outer protrusions” and “the parts of the two wires are located in the two The design of "inside the accommodating groove" enables the magnetic core structure to prevent the two wires from being scattered or loosened in the case of two welding steps. Accordingly, the magnetic core structure can improve the manufacturing efficiency.

The contents disclosed above are only preferred feasible embodiments of the present invention, and are not intended to limit the scope of the present invention. Therefore, any equivalent technical changes made by using the contents of the description and drawings of the present invention are included in the application of the present invention. within the scope of the patent.

100: Magnetic Structure 1, 1': magnetic core 11: Winding column 111: Outer convex part 1111: accommodating slot 1112: Coupling table 1113: tangent groove 112: body part 12: First jamb 121: The first setting station 13: Second jamb 131: Second setting station 2: Conductive layer 2A: The first conductive layer 2B: Second Conductive Layer 3A, 3B: wire 31: First End 32: Second End 33: Exposed conductive layer 34: Insulation layer S3: Subwire 4: Short circuit 5: Solder 6: Conductive material D1: extension direction D2: Width direction D3: Height direction S1131～S1132: Sub-steps S101～S117: Steps

FIG. 1 is a flow block diagram of a manufacturing method according to a first embodiment of the present invention.

FIG. 2 is a schematic perspective view of the first embodiment of the present invention when a planar electroplating step is performed.

3 is a schematic top view of the magnetic core according to the first embodiment of the present invention when a conductive layer is plated.

FIG. 4 is a schematic top view of the magnetic core of another aspect of the first embodiment of the present invention when a conductive layer is plated.

FIG. 5 is a schematic perspective view of the first embodiment of the present invention when the first welding step is performed.

6 is a schematic perspective view of the first embodiment of the present invention when the first winding step is performed.

7 is a schematic perspective view of the first embodiment of the present invention when the second winding step is performed.

FIG. 8 is a schematic perspective view of the second welding step according to the first embodiment of the present invention.

FIG. 9 is a schematic perspective view of the first embodiment of the present invention when the conducting step is performed.

FIG. 10 is a schematic block diagram of a flow chart of a turn-on step according to the second embodiment of the present invention.

11 is a schematic perspective view of the second embodiment of the present invention when the peeling sub-step is performed.

FIG. 12 is a schematic block flow diagram of a manufacturing method according to a third embodiment of the present invention.

13 is a schematic perspective view of the magnetic core according to the third embodiment of the present invention when the conductive layer is plated.

FIG. 14 is a schematic perspective view of the third embodiment of the present invention when the thread tangent step is performed.

FIG. 15 is a schematic perspective view of the third embodiment of the present invention when the short-circuiting step is performed.

S101~S113: Steps

Claims (10)

A manufacturing method of a magnetic core structure is applicable to a magnetic core structure, the magnetic core structure includes a magnetic core, the magnetic core has a winding column and a first side column connecting both ends of the winding column and a second side column; the winding column has an extension direction and a width direction perpendicular to the extension direction, and the winding column includes a main body part and two outer convex parts connected to the main body part, Each of the protruding portions includes an accommodating groove and two coupling platforms located on both sides of the accommodating groove; the first side post and the second side post each have two spaced apart from each other Setting the stage, the manufacturing method includes the following steps: Carrying out a plane electroplating step: using plane electroplating to print on the two setting stages of the first side post, the two setting stages of the second side post, and the two outer protrusions A conductive layer is formed on the coupling stage; Implementing a first welding step: fixing a first end of two wires to the conductive layers on the two setting tables of the first side post by welding; Implementing a first winding step: winding a part of the body portion along the extending direction with a second end of the two wires, and passing through the two accommodating grooves respectively; Implementing a second winding step: using the second ends of the two wires to wind another part of the main body along the extending direction; A second welding step is performed: the second ends of the two wires are respectively fixed to the conductive layers on the two setting stages of the second side post by welding; and A conducting step is performed: using a conductive material to be disposed between any one of the wires and the conductive layers on the adjacent two coupling stages, so that the two wires are electrically coupled to their phases respectively. the conductive layers on two adjacent coupling stages. The method for manufacturing a magnetic core structure according to claim 1, wherein the two wires are direct-welded enameled wires; in the conducting step, a high-temperature conductive material is used to set any one of the wires and its adjacent ones between the conductive layers on the two coupling stages. The method for manufacturing a magnetic core structure according to claim 1, wherein the conducting step further comprises: Carrying out a peeling sub-step: physically removing part of the insulating layer of the wires located in the two accommodating grooves, so that each of the two wires exposes a bare conductive layer; and A soldering sub-step is performed: the exposed conductive layers of the two wires are electrically connected to the conductive layers of the two adjacent coupling stages respectively by soldering. The method for manufacturing a magnetic core structure according to any one of claims 1 to 3, wherein each of the protruding portions further includes a tangential groove, and the tangential groove is disposed along the width direction of its adjacent grooves. between any two of the coupling stages and communicate with the accommodating groove; after the conducting step is performed, the manufacturing method further includes: Carrying out the tangent step: physically cutting the two wires along the two tangent grooves, so that the two wires form four sub-wires. The manufacturing method of the magnetic core structure according to claim 4, wherein, after the tangent step, the manufacturing method further comprises: A short-circuiting step is performed: using two short-circuit lines to electrically couple the conductive layers of the two setting stages located on the same side respectively. The method for manufacturing a magnetic core structure according to claim 4, wherein, in the peeling sub-step and the tangent step, the physical method is laser removal. A magnetic core structure comprising: A magnetic core, containing: a winding column with an extension direction, the winding column includes a main body part and two outer convex parts connected to the main body part, each of the outer convex parts includes an accommodating groove; and A first side post and a second side post are respectively connected to two ends of the main body along the extending direction, the first side post has two first setting platforms spaced apart from each other, the second side post is the column has two second setting stations spaced apart from each other; a plurality of conductive layers, disposed on the two first setting platforms, the two second setting platforms, and the two outer protrusions; and Two wires are wound on the body part, the parts of the two wires are respectively located in the two accommodating grooves, and the two ends of one of the wires are electrically coupled to all the wires on the same side respectively. The conductive layers on the first setting table and the second setting table, and the two ends of the other wire are respectively electrically coupled to the first setting table and the second setting on the same other side the conductive layer on the stage. The magnetic core structure according to claim 7, wherein the plurality of conductive layers are coplanar with each other, and the two accommodating grooves are arranged obliquely with respect to the extending direction. A magnetic core structure comprising: A magnetic core, containing: A winding column has an extension direction, the winding column includes a main body part and two outer convex parts connected to the main body part, each of the outer convex parts has four coupling platforms, a tangent groove, and an accommodating slot, the four coupling stages are arranged at intervals from each other, and the accommodating slot and the tangent slot communicate with each other and are arranged between the four coupling stages; A first side post and a second side post are respectively connected to two ends of the main body along the extending direction, the first side post has two first setting platforms spaced apart from each other, the second side post is the column has two second setting stations spaced apart from each other; A plurality of first conductive layers are arranged on two of the first setting stages and two of the second setting stages; a plurality of second conductive layers, disposed on the four coupling stages of the two outer protrusions; Two first wires are respectively wound around the body portion and located between the first side pillars and the two outer protrusions, and parts of the two first wires are respectively located in the two receptacles In the slot, two ends of one of the first wires are respectively electrically coupled to the first conductive layer and the two second conductive layers of the first setting stage located on the same side and adjacent to each other, Two ends of the other one of the first wires are respectively electrically coupled to the first conductive layer and the two second conductive layers of the first setting stage located on the same other side and adjacent to each other; and Two second wires are respectively wound around the body portion and located between the second side pillars and the two outer protrusions, and parts of the two second wires are respectively located in the two receptacles In the slot, two ends of one of the second wires are respectively electrically coupled to the first conductive layer and the two second conductive layers of the second setting stage located on the same side and adjacent to each other, Two ends of the other second conducting wire are respectively electrically coupled to the first conductive layer and the two second conductive layers of the first setting stage located on the same other side and adjacent to each other. The magnetic core structure according to claim 9, wherein the plurality of first conductive layers and the plurality of second conductive layers are coplanar with each other, and the two accommodating grooves are skewed with respect to the extending direction configuration.

Images