Inductor, manufacturing method thereof and electronic equipment

Abstract

The invention provides an inductor, a manufacturing method thereof and electronic equipment. The inductor comprises a magnetic core and an inductance coil. The inductance coil comprises the coil part and the welding foot parts which are arranged in pairs, and the coil part and the welding foot parts are of an integrated structure so as to ensure that the whole inductance coil is free of any additional welding spot connection, so that the structural stability and the electrical reliability of the inductor are remarkably improved. The coil part is a main place for generating an inductive effect, is wound on the outer side of the magnetic core along the spiral line direction, and extends along the axis direction of the magnetic core. And the welding foot parts arranged in pairs are respectively arranged at the two ends of the coil part. And the welding foot part is used as an input and output port of an electric signal so as to be conveniently connected with an external circuit. According to the structure of the coil part, a micro-sized conductive metal tube is adopted as a base material, an insulating groove is formed in the tube wall of the micro-sized conductive metal tube through a precise cutting or etching process, and the conductive metal tube wall is isolated into a similar structure formed by winding a coil through the insulating effect of the insulating groove.

Description

Technical Field

[0001] The present application belongs to the technical field of inductors, and more specifically, relates to an inductor and a manufacturing method thereof, and an electronic device. Background Art

[0002] With the development of the electronic information industry, consumer electronics require miniaturization of inductors and transformers to meet consumers' demand for compact and portable products. Therefore, inductors and transformers with small size and high reliability are widely used in mobile communications, computers, automotive electronics and other fields, becoming the mainstream direction of the electronic components market.

[0003] Traditionally, the coil of the inductor is mainly made of enameled copper wire. Although this process is mature, the contact area of ​​the coil pins wound with enameled copper wire is limited, making it difficult to ensure stability and reliability during welding. Especially in the automated assembly process, the small contact area is prone to poor welding due to operational errors or environmental factors. On the other hand, if an additional welding method is used to connect the coil to the terminal electrode in order to enhance the connection reliability, it not only increases the complexity of production, but may also reduce the overall reliability of the inductor due to welding stress or heat. When the coil of the inductor is wound with a flat coil, it is difficult to achieve a small-sized coil due to the shape of the wire. Summary of the invention

[0004] The purpose of the embodiments of the present application is to provide an inductor and a manufacturing method thereof, and an electronic device, so as to solve the technical problem in the prior art that the inductor is difficult to miniaturize.

[0005] To achieve the above purpose, the technical solution adopted in this application is:

[0006] An inductor is provided, comprising:

[0007] Magnetic core;

[0008] The inductor coil includes a coil portion and a pair of welding legs, wherein the coil portion and the welding legs are an integrated structure, the coil portion is wound around the outside of the magnetic core along a spiral line direction and extends along the axial direction of the magnetic core, and the pair of welding legs are respectively arranged at both ends of the coil portion.

[0009] As a further improvement of the above technical solution:

[0010] Optionally, the surface of the coil portion is provided with an insulating heat-resistant coating.

[0011] Optionally, the number of turns of the coil portion is at least one.

[0012] Optionally, the width dimension of each turn of the coil portion is greater than the thickness dimension of each turn of the coil portion.

[0013] Optionally, the welding foot portion is arched, and two ends of the welding foot portion are connecting contacts.

[0014] Optionally, the inductor further includes a shell, the magnetic core and the inductor coil are both arranged in the shell, and the connecting contact extends to the outside of the shell.

[0015] The present application also provides an electronic device, comprising the above-mentioned inductor.

[0016] The present application also provides a method for manufacturing an inductor, comprising the following steps:

[0017] Obtain a conductive metal tube;

[0018] Cutting welding foot forming grooves at both ends of the conductive metal tube, and cutting a spiral groove in the middle section of the conductive metal tube;

[0019] The two ends of the conductive metal tube are shaped into welding foot portions along the shape of the welding foot forming grooves, and the middle section of the conductive metal tube is a coil portion, so as to form an inductor coil with an integrated structure;

[0020] Spraying an insulating heat-resistant coating on the outer surface of the coil portion;

[0021] The inductor coil is assembled onto the magnetic core and encapsulated in a shell.

[0022] The inductor and the manufacturing method thereof, and the electronic device provided by the present application have the following beneficial effects:

[0023] The inductor of the present application includes a magnetic core and an inductor coil. The magnetic core serves as the basic support structure of the inductor and provides the necessary magnetic field environment for the inductor coil. The inductor coil includes a coil portion and a welding leg portion arranged in pairs. The coil portion and the welding leg portion are an integrated structure to ensure that the inductor coil as a whole has no additional solder joint connection, thereby significantly improving the structural stability and electrical reliability of the inductor. The coil portion is the main place where the inductance effect is generated. It is wound on the outside of the magnetic core along the spiral line direction and extends along the axial direction of the magnetic core. The welding leg portions arranged in pairs are respectively arranged at both ends of the coil portion. The welding leg portions serve as input and output ports of electrical signals to facilitate connection with external circuits. The structure of the coil portion abandons the use of traditional enameled copper wire winding or flat coils, and instead uses a small-sized conductive metal tube as the basic material. On the tube wall of this small-sized conductive metal tube, an insulating groove is formed by precision cutting or etching process, and the insulating effect of the insulating groove isolates the conductive metal tube wall into a structure similar to that formed by coil winding. Since a micro-sized conductive metal tube is easier to obtain than a micro-sized coil, it is also easier to process a corresponding micro-sized coil portion on this basis, thereby making it easier to achieve miniaturization of the inductor.

[0024] The present application also provides an electronic device, which includes the above-mentioned inductor and therefore also has the advantages of the above-mentioned inductor. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0026] Figure 1 A schematic diagram of the three-dimensional structure of the inductor coil of the first inductor provided in the present application;

[0027] Figure 2 A schematic diagram of the main structure of the first inductor provided in this application;

[0028] Figure 3 A schematic diagram of the main structure of the inductor coil of the first inductor provided in the present application;

[0029] Figure 4 A schematic diagram of the three-dimensional structure of the inductor coil of the second inductor provided in the present application;

[0030] Figure 5 A schematic diagram of the top view of the inductor coil of the second inductor provided in the present application.

[0031] Among them, the reference numerals in the figure are:

[0032] 1. Magnetic core; 2. Inductor coil;

[0033] 21. Welding foot part; 22. Coil part;

[0034] 3. Shell. DETAILED DESCRIPTION

[0035] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present invention, and should not be construed as limiting the present invention.

[0036] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as limiting the present invention.

[0037] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, the meaning of "plurality" is two or more, unless otherwise clearly and specifically defined.

[0038] In the present invention, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be an indirect connection through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0039] In the present invention, unless otherwise clearly specified and limited, a first feature being "above" or "below" a second feature may include that the first and second features are in direct contact, or may include that the first and second features are not in direct contact but are in contact through another feature between them. Moreover, a first feature being "above", "above" and "above" a second feature includes that the first feature is directly above and obliquely above the second feature, or simply indicates that the first feature is higher in level than the second feature. A first feature being "below", "below" and "below" a second feature includes that the first feature is directly below and obliquely below the second feature, or simply indicates that the first feature is lower in level than the second feature.

[0040] In addition, the technical solutions between the various embodiments can be combined with each other, but it must be based on the fact that ordinary technicians in the field can implement it. When the combination of technical solutions is contradictory or cannot be implemented, it should be deemed that such combination of technical solutions does not exist and is not within the scope of the present invention.

[0041] In the following description, suffixes such as "module", "component", "assembly" or "unit" are used only to facilitate the description of the present invention and have no specific meanings. Therefore, they can be used in combination.

[0042] The present invention will be further described in detail below through specific implementation modes in conjunction with the accompanying drawings.

[0043] like Figure 1 and Figure 2 As shown, the present application provides an inductor, comprising a magnetic core 1 and an inductor coil 2 .

[0044] Among them, the magnetic core 1 serves as the basic supporting structure of the inductor and provides the necessary magnetic field environment for the inductor coil 2. The inductor coil 2 includes a coil portion 22 and a pair of welding legs 21. The coil portion 22 and the welding legs 21 are an integrated structure to ensure that the inductor coil 2 as a whole has no additional welding point connection, thereby significantly improving the structural stability and electrical reliability of the inductor. The coil portion 22 is the main place where the inductance effect is generated. It is wound along the spiral line direction on the outside of the magnetic core 1 and extends along the axial direction of the magnetic core 1. The welding legs 21 arranged in pairs are respectively arranged at both ends of the coil portion 22. The welding legs 21 serve as input and output ports for electrical signals to facilitate connection with external circuits.

[0045] The structure of the coil part 22 abandons the use of traditional enameled copper wire winding or flat coils, and instead uses a micro-sized conductive metal tube as the basic material. On the tube wall of this micro-sized conductive metal tube, an insulating groove is formed through a precision cutting or etching process. Through the insulating effect of the insulating groove, the conductive metal tube wall is isolated into a structure similar to that formed by winding the coil. Since a micro-sized conductive metal tube is easier to obtain than a micro-sized coil, it is also easier to process a corresponding micro-sized coil part 22 on this basis, thereby making it easier to miniaturize the inductor.

[0046] In a specific embodiment of the present application, the surface of the coil portion 22 is provided with an insulating heat-resistant coating. The insulating heat-resistant coating, as an important protective layer of the coil portion 22, needs to withstand a high temperature environment of at least 180°C, thereby ensuring that the inductor can maintain stable electrical performance under extreme temperature conditions. In addition to its excellent heat resistance, the insulating heat-resistant coating also achieves effective insulation between each turn of the coil, ensuring reliable electrical isolation between adjacent coil turns, and effectively avoiding the risk of short circuits caused by direct contact between coils.

[0047] like Figure 4 and Figure 5As shown, in a specific embodiment of the present application, the number of turns of the coil portion 22 is at least one. When current flows through the coil portion 22, since the number of turns of the coil portion 22 is at least one, a closed magnetic circuit can be formed, so that the magnetic field is enhanced and accumulated inside the coil. This accumulation effect of the magnetic field not only increases the inductance value of the inductor, but also enables it to more effectively store and release magnetic field energy, thereby playing a role in stabilizing current, filtering or storing energy in the circuit. Figures 1 to 3 As shown, the number of turns of the coil portion 22 may be multiple.

[0048] In a specific embodiment of the present application, the width of each turn of the coil portion 22 is greater than the thickness of each turn of the coil portion 22. This configuration enables each turn of the coil to present a flat wire shape, and the coil portion 22 can also form a structural feature similar to a flat coil, thereby making full use of space, improving the filling factor of the coil, and achieving a higher inductance value within the same volume. At the same time, the shape of the flat coil also helps to reduce the resistance of the coil, improve the current transmission efficiency, thereby reducing energy loss and improving the overall performance of the inductor.

[0049] like Figure 1 and Figure 4 As shown, in a specific embodiment of the present application, the solder leg portion 21 is arched, and the coil portion 22 is connected to the arch top position, thereby effectively raising the height of the coil portion 22 so as to form a certain height difference with the connection contact. The two ends of the solder leg portion 21 are arched feet, which serve as connection contacts and are connected to the external circuit.

[0050] like Figure 2 As shown, in a specific embodiment of the present application, the inductor also includes a shell 3. The magnetic core 1 and the inductor coil 2 are both arranged in the shell 3, which not only effectively isolates the potential interference of the external environment to the internal structure of the inductor, but also improves the overall anti-interference ability and durability of the inductor through the physical barrier of the shell. At the same time, in order to ensure the smooth connection between the inductor and the external circuit, the connection contacts extend to the outside of the shell 3. The shell 3 and the magnetic core 1 can be an integrated structure, that is, the shell 3 and the magnetic core 1 are manufactured as a whole. This structure not only simplifies the assembly process, but also improves the overall strength and stability of the inductor. The shell 3 and the magnetic core 1 can also be a split structure, that is, the shell 3 and the magnetic core 1 are two independent components, which are assembled by specific connection means (such as threaded connection, snap connection, etc.). This structure provides greater flexibility and maintainability, which is convenient for the inspection or replacement of the inductor.

[0051] The present application also provides an electronic device, which may be a transformer, a frequency converter, etc. These electronic devices all require the use of an inductor. Since the electronic device includes the inductor in the above embodiment, it also has the advantages of the inductor in the above embodiment.

[0052] The present application also provides a method for manufacturing an inductor, comprising the following steps:

[0053] First, select a conductive metal tube that meets the design requirements. Its diameter must accurately match the expected specifications of the inductor coil to ensure the accuracy and consistency of the inductor performance.

[0054] Next, precision machining techniques such as laser cutting or precision etching are used to accurately cut weld leg forming grooves at both ends of the conductive metal tube. The weld leg forming grooves are used to provide a geometric profile for the subsequent formation of the weld leg portion 21. At the same time, a spiral groove is cut in the middle section of the conductive metal tube to create conditions for the formation of the coil portion 22.

[0055] Subsequently, the two ends of the conductive metal tube are shaped to form a welding leg portion 21 along the shape of the welding leg forming groove, and the middle section of the conductive metal tube naturally forms a coil portion 22. Since the welding leg portion 21 and the coil portion 22 are an integrated structure, the inductor coil 2 as a whole has no additional welding point connection, which significantly improves the structural stability and electrical reliability of the inductor.

[0056] In order to enhance the insulation and heat resistance of the inductor coil, a layer of insulating heat-resistant coating is evenly sprayed on the outer surface of the coil portion 22 to ensure that the inductor coil can maintain good electrical insulation and heat resistance during long-term operation, thereby improving the overall reliability and service life of the inductor.

[0057] Finally, the inductor coil 2 is assembled onto the magnetic core 1 and packaged together with the magnetic core 1 in the shell 3 through a packaging process, which not only ensures the compactness and stability of the internal structure of the inductor, but also further improves the anti-interference ability and environmental adaptability of the inductor through the protective effect of the shell 3.

[0058] The above description is only a preferred embodiment of the present application and is not intended to limit the present application. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present application should be included in the protection scope of the present application.

Claims

1. An inductor, characterized in that: include: Magnetic core (1); The inductor coil (2) comprises a coil portion (22) and a pair of welding legs (21), wherein the coil portion (22) and the welding legs (21) are an integrated structure, the coil portion (22) is wound along a spiral line direction on the outside of the magnetic core (1) and extends along the axial direction of the magnetic core (1), and the pair of welding legs (21) are respectively arranged at two ends of the coil portion (22).

2. The inductor according to claim 1, wherein: The surface of the coil part (22) is provided with an insulating heat-resistant coating.

3. The inductor according to claim 1, wherein: The number of turns of the coil part (22) is at least one turn.

4. The inductor according to claim 1, wherein: The width dimension of each coil turn of the coil portion (22) is greater than the thickness dimension of each coil turn of the coil portion (22).

5. The inductor according to claim 1, wherein: The welding foot portion (21) is arched, and two ends of the welding foot portion (21) are connection contacts.

6. The inductor according to claim 5, wherein: It also comprises a shell (3), wherein the magnetic core (1) and the inductor coil (2) are both arranged in the shell (3), and the connecting contacts extend to the outside of the shell (3).

7. An electronic device, characterized in that: Comprising the inductor according to any one of claims 1 to 6.

8. A method for manufacturing an inductor, characterized in that: The steps include: Obtain a conductive metal tube; Cutting welding foot forming grooves at both ends of the conductive metal tube, and cutting a spiral groove in the middle section of the conductive metal tube; The two ends of the conductive metal tube are shaped along the shape of the weld foot forming groove to form a weld foot portion (21), and the middle section of the conductive metal tube is a coil portion (22), so as to form an inductor coil (2) of an integrated structure; spraying an insulating heat-resistant coating on the outer surface of the coil portion (22); The inductor coil (2) is assembled onto the magnetic core (1) and encapsulated in a housing (3).

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