TWM593055U - Magnetic induction element - Google Patents

Abstract

A magnetic induction component includes a magnetic core, a coil module composed of a first set of coils and a second set of coils, the first set of coils is coated with a first isolation layer, the second set of coils is A flat coil having an open first loop body, which forms two non-contacting ends, one of which has a first conducting portion protruding toward the body of the first loop, and the other end It has a connecting end that extends integrally outwards to form an open second loop body. The terminal of the second loop body has a convex second conducting portion, wherein a twist is included on the connecting end The turning part makes the second loop body and the first loop body opposite in the same direction, so that the second group of coils is positioned on the first isolation layer in a clamping manner, thereby improving assembly efficiency, and Reduce the defect rate of the product.

Description

Magnetic induction element

This creation is a kind of magnetic induction components such as inductors and transformers.

For example, the architecture of magnetic induction components such as transformers includes at least two sets of independent coils, so-called "primary coils" and "secondary coils". After passing current, according to the principle of electromagnetic induction, the coils of the two sets of coils ( Turn) ratio to convert the voltage value.

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 connect to the external circuit through these conductive pins or contact pins, so that the transformer assembly is connected to the external circuit, and the insulating base is used as signal isolation to avoid dryness. Disturb.

In order to meet the demand for miniaturization of consumer electronic products, the thinner and thinner the design of these transformers is an inevitable trend. Among the known prior art, there are coil printing assemblies that use printed circuit board (PCB) circuit printing technology to produce A flat (or flat) transformer, such as disclosed in Chinese Patent Publication No. CN201138608, discloses a transformer assembly printed with a conductive coil pattern on a PCB. This '608 patent uses PCB to make the primary coil and the secondary coil, and coats the surface of the two sets of coils with a layer of insulating varnish to isolate it, and it becomes a flat transformer by assembling with the core.

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

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

2. Applying insulating paint on the surface of the two groups of coils to isolate 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 for AC-DC transformers connected to the commercial power supply. The voltage difference is large, and the primary coil and the secondary coil must have a certain safety separation between the specifications.

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

Another creator knows the prior art related to this creation, which is a planar transformer disclosed in US Publication No. 2013/0278371, which consists of a plurality of pre-made flat coils (including primary and secondary coils) Put on the magnetic core of the transformer in order, and provide a base with a plurality of conductive pins (pins) established, and use welding technology to connect the coils and external circuits, wherein the base can be As the isolation protection of magnetic core and external circuit.

Obviously, the flat metal coil used in the prior art No. '371 can be directly formed by molding or stamping in advance, and the manufacturing cost is much lower than that of the coil made of PCB and it is more suitable. Mass production, and the thickness of the metal layer also withstands greater current than PCB printed conductive coils; however, there are still some procedures in the transformer manufacturing process and assembly process The following defects:

1. There is a lack of safe separation between the flat coils. As mentioned above, even if a layer of insulating paint is coated on the surface of each group of coils as isolation, it is difficult to meet the safety requirements of the transformer, especially the AC used to connect to the mains. -DC transformers, due to the large voltage difference at the power supply end, are prone to damage to the transformer during operation.

2. Each group of coils is an independent unit and component. When assembling with the magnetic core, the central magnetic pole of the core must pass through the assembly holes reserved on each group of coils in sequence. The alignment must be very accurate, which not only makes the assembly more difficult and easy to fail, but also wastes man-hours, and it is more difficult to introduce automated processes and is not conducive to large-scale production operations.

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

In order to improve the defects of the previous technology, this creation provides a more novel "magnetic induction element", compared with the previous technology, not only is more conducive to manufacturing, assembly, when used as an inductor, transformer or other magnetic induction element application It is more convenient and can reduce the defect rate of the end product, which is the main purpose of this creation.

For the purpose of creation, the magnetic induction element disclosed in this creation includes a magnetic core and a coil module composed of a first set of coils and a second set of coils, the first set of coils is coated with a first isolation layer , The second group of coils is a flat coil, which has an open first loop body, so that two non-contacting ends are formed, one end of which has a first projecting toward the body of the first loop A conducting part, the other end has a connecting end, the connecting end integrally extends outward to form an open second loop body, the terminal of the second loop body has a convex second conducting part, wherein, The connecting end further includes a turning part, which makes the second loop body and the first loop body face in the same direction, so that the second group of coils is positioned on the first isolation by clamping On the floor.

In this creation, the second group of coils can be manufactured using 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 a second group of coils. The prior art uses multiple independent coils in the assembly process, and the trouble of accurate positioning; in particular, when connecting to an external circuit, only the first conduction part and the first The two contacts of the two conducting parts are connected, which reduces the chance of blind connection and also improves the reliability of the terminal product 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 fitting hole to facilitate its alignment and assembly. A protrusion is established between the connecting end, the first loop body and the second loop body as isolation.

Furthermore, another embodiment can be derived from the architecture of the second group of coils, that is, the second group 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, and 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, 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 group of coils can be increased to correspond to and meet the requirements of the configured magnetic induction device.

As for the detailed structure and other detailed features of this creation, please explain with the implementation mode and the drawings described later.

2‧‧‧The first set of coils

10‧‧‧ conductive pattern

11‧‧‧Insulated substrate

12‧‧‧Contact

13‧‧‧Adaptive hole

2,2a‧‧‧coil of the second group

20,20a‧‧‧The first loop body

200,200a‧‧‧First Conducting Department

201‧‧‧ circle hole

21,21a‧‧‧Second loop body

210,210a‧‧‧Second Conducting Department

211‧‧‧ circle hole

22,22a‧‧‧connector

220,220a‧‧‧Turning Department

3‧‧‧The first isolation layer

30‧‧‧Locating slot

31‧‧‧Boss

32‧‧‧ stage

4‧‧‧Second isolation layer

5‧‧‧ magnetic core

6‧‧‧coil module

Figure 1 is a three-dimensional appearance of this creation.

Figure 2 is an exploded view of this creation.

FIG. 3 is an exploded perspective view of the first set of coils and the second set of coils in this creation.

FIG. 4 is a developed structural diagram of the second group of coils in this creation.

FIG. 5 is a combined appearance view of the first group of coils and the second group of coils in this creation.

FIG. 6 is another perspective view of the combination of the first set of coils and the second set of coils in this creation.

Fig. 7 is a cross-sectional view taken along the line A-A' of Fig. 5 of the present creation.

FIG. 8 is an external view of the coil module of this creation.

FIG. 9 is an expanded structural view of another embodiment of the second group of coils of this creation.

This creation is used as a magnetic induction element such as an inductor or a transformer.

Please refer to FIG. 1 and FIG. 2, the creation includes a magnetic core (5) and a coil module (6), the coil module (6) is sleeved on the magnetic core (5), and the coil module The group (6) generates magnetic induction with the magnetic core (5) after being energized.

Please also refer to FIG. 3 to FIG. 8 at the same time, the coil module (6) includes a first group of coils (1) and a second group of coils (2), wherein the first group of coils (1) has A first isolation layer (3), the second group of coils (2) are positioned on the first isolation layer (3) in a clamping manner.

In the preferred embodiment disclosed in this creation, as disclosed in FIGS. 3 and 7, the first set of coils (1) is a conductive pattern (10) on an insulating substrate (11), for example, by printing Circuit board (hereinafter referred to as PCB) manufacturing technology, the conductive pattern (10) is deployed in the first group of coils (1) made in the PCB; or, the conductive pattern (10) is directly laid on The first group of coils (1) is formed on the insulating substrate (11), but not limited to this. In addition, a plurality of contact portions (12) and a conductive pattern (10) can be pre-deployed on one side of the insulating substrate (11) to provide electrical conduction to the external circuit; and, the first group of coils (1) An adaptation hole (13) is preset in the socket for placing the first group of coils (1) on the magnetic core (5).

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

The first isolation layer (3) provides insulation and isolation of the first group of coils (1) from the outside by covering the first group of coils (1), and exposes the plurality of contact portions (12) The external circuit is connected. The cladding method can be directly injection molded outside the first group of coils (1) through an insulating material, or a formwork is pre-formed with the insulating material to provide the first group of coils (1) to be sleeved therein; as preferred, The first isolation layer (3) is provided with a positioning groove (30) which is adapted to the contours of the first loop body (20) and the second loop body (21) on the periphery of the adapting hole (13) To facilitate alignment and assembly, a boss (31) is established between the connecting end (22), the first conducting portion (200), and the second conducting portion (210) as isolation. In addition, the first isolation layer (3) is provided with a carrier (32) at the opposite end away from the contact part (12), and the carrier (32) can provide the first conducting part of the second group of coils (2) (200), and the second conducting portion (210) are arranged.

When assembling, the first loop body (20) is placed on the side of the first isolation layer (3) covered by the first group of coils (1). By forming the turning part (220), the second The loop body (21) is bent toward the first loop body (20) and is opposite to the same direction, so that the first group of coils (1) is sandwiched between the first loop body (20) and the Between the second loop body (21); meanwhile, the first loop body (20) The fitting holes (13) of the first group of coils (1) correspond to the loop holes (201, 211) of the second loop body (21) for covering the magnetic core (5). Preferably, the first loop body (20) and the second loop body (21) are filled into the positioning groove (30) on the first isolation layer (3) to enhance the positioning effect, and the The first conducting part (200) and the second conducting part (210) are arranged on two opposite sides of the stage (32) to provide conductive pin insertion with an external circuit, or soldering by SMT (surface adhesion), As for the connecting end (22) and the turning part (220), it is spanned on the carrier (32) to make the positioning of the second group of coils (2) more compact and stable. Please refer to FIG. 6, the first conducting part (200) and the second conducting part (210) can also be vertically bent toward the first loop body (20) in the same direction and welded to the external circuit jack.

Please refer to FIG. 8, after the assembly of the first group of coils (1) and the second group of coils (2) is completed, the first group of coils (1) and the second group of coils (2) are reassembled. A second isolation layer (4) is coated with insulating material through injection, and the contact portion (12) of the first group of coils (1) and the first and second conducting parts of the second group of coils (2) (200,210) exposed, providing connection to the outside line.

Finally, please refer to FIG. 9, which is another preferred embodiment of the second group of coils in this creation. The second group of coils (2a) is also made of a conductive material by die casting, stamping, or other methods The formed flat coil has a plurality of continuous open first loop bodies (20a), the plurality of first loop bodies (20a) has a convex first conducting portion (200a), and a plurality of connections end (22a), the connecting ends (22a) extend in the same direction and integrally to form a plurality of continuous open second loop bodies (21a), and the end of the continuous second loop bodies (21a) protrudes outward The 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 among these connection ends ( 22a) each includes a turning portion (220a), the turning portions (220a) provide the plurality of second loop bodies (21a) and the plurality of first loop bodies (20a) facing in the same direction In this way, the number of turns of the second group of coils (2a) can be increased to correspond to the requirements of the configured magnetic induction device.

Compared with the prior art, it can be found that the advantages of the magnetic sensing element disclosed in this creation include:

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

2. The first loop body (20) and the second loop body (21) are integrally connected to form a second group of coils (2), which reduces the assembly process and the need for multiple independent coils in the prior art. The trouble of precise alignment; especially when connecting to an external circuit, it only needs to be connected to the two contacts of the first conducting part (200) and the second conducting part (210), which reduces the possibility of blind connection. Increased reliability.

3. The second group of coils (2) is positioned on the first isolation layer (3) in a similar manner to become a coil module (6), which is more conducive to subsequent covering of the second isolation layer (4) Processing operations; in particular, a positioning groove (30) is formed on the first isolation layer (3) in advance to match the contours of the first loop body (20) and the second loop body (21) The filling is provided to further strengthen the positioning effect of the two during assembly.

4. When the coil module (6) of this creation is used as a transformer, the magnetic core (5) of the transformer only needs to assemble the adapter hole (13) in the first group of coils to complete the assembly, which reduces the manufacturing process and reduces the failure rate.

The above description is only a series of one of the preferred embodiments of this creation, and is not used to limit the substance of this creation. Any equivalent replacement and simple modification made by this art by the skilled person using this creation, such as defining the coil mode The position, number, and form of the primary coil or secondary coil of the group, or the forming method of the first group and the second group of coils should still be covered by the scope of the patent application described later.

1‧‧‧ first coil

11‧‧‧PCB

12‧‧‧Contact

13‧‧‧Adaptive hole

2‧‧‧The second set of coils

20‧‧‧The first loop body

200‧‧‧First Conducting Department

21‧‧‧The second loop body

210‧‧‧Second Conducting Department

22‧‧‧Connector

220‧‧‧Transition Department

3‧‧‧The first isolation layer

30‧‧‧Locating slot

31‧‧‧Boss

32‧‧‧ stage

Claims (10)

A magnetic induction element includes: a first group of coils having a first isolation layer on the outside; a second group of coils having an open first loop body, the first loop body having two non-contacts , One end of which has a first conducting portion that protrudes toward the body of the first loop body, and the other end has a connecting end that extends integrally outward to form an open second loop body, The terminal of the second loop body has a convex second conducting portion, wherein the connecting end includes a turning portion, the turning portion makes the second loop body and the first loop body opposite in the same direction The second group of coils is positioned on the first isolation layer in a clamping manner to form a coil module; and a magnetic core is sleeved in the coil module to form a magnetic induction element. The magnetic induction element according to claim 1, wherein the first isolation layer is overmolded with an insulating material outside the first group of coils. The magnetic induction device according to claim 1, wherein the first isolation layer is formed by insulating material to form a mold base to provide the first set of coils to be covered. The magnetic induction element according to claim 1, wherein the first group of coils and the first isolation layer have an adaptation hole corresponding to the first and second loop bodies and the loop holes provide the core Nesting. The magnetic induction element according to claim 4, wherein a positioning groove adapted to the contours of the first loop body and the second loop body is disposed on each of the first isolation layers around the fitting hole. The magnetic induction element according to claim 1, wherein the first group of coils is formed by arranging a conductive pattern in an insulating substrate, and a plurality of contact portions are arranged on one side to communicate with the conductive pattern and exposed to the first Outside an isolation layer. The magnetic induction element according to claim 1, wherein the first isolation layer is provided with a stage at one end, and the first conducting portion and the second conducting portion providing the second group of coils are arranged on two opposite sides of the stage . The magnetic induction element according to claim 1, wherein the first isolation layer establishes a boss between the connection end of the second group of coils and the first conducting portion and the second conducting portion as isolation. The magnetic induction element according to any one of claims 1 to 8, wherein the outside of the first group of coils and the second group of coils is further coated with a second isolation layer and exposes the first and second conducting parts. A magnetic induction element includes: a first group of coils having a first isolation layer on the outside; a second group of coils having a plurality of continuous open first loop bodies, the plurality of first loop bodies having A convex first conducting portion and a plurality of connecting ends, the connecting ends extend in the same direction and integrally to form a plurality of A continuous open second loop body, the terminals of the continuous second loop bodies protrude a second conducting portion, wherein each of the connecting ends includes a turning portion, the turning portion makes the second The loop body is opposite to the first loop bodies in the same direction, and the second group of coils is positioned on the first isolation layer in a clamping manner to form a coil module; and, a magnetic core is sleeved A magnetic induction element is formed in the coil module.

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