Integrated winding module

Abstract

This invention provides an integrated winding module, including a first magnetic core assembly and winding elements. The first magnetic core assembly includes a first half-face magnetic core and a first resin-coated surface, with the first resin-coated surface covering the outer wall of the first half-face magnetic core. The first loop and the second loop are integrally molded into a robust integrated winding module using a plastic molding process at predetermined precise relative positions. Molding permanently fixes the spatial configuration of the winding and the spatial coordinates of the terminals, achieving "design-built-in" terminal coplanarity and batch consistency, fundamentally eliminating subsequent calibration processes. The winding elements are then assembled with the first and second magnetic core assemblies. Furthermore, the assembled first half-face magnetic core and the first loop are fully coated with the first and second resin-coated surfaces, forming a dense, uniform, and highly insulating protective layer.

Claims

1. An integrated winding module, comprising: A first magnetic core assembly (1) and a winding element (2), wherein the first magnetic core assembly (1) includes a first half-face magnetic core (101) and a first resin-coated surface (102); wherein the first resin-coated surface (102) covers the outer side wall of the first half-face magnetic core (101), the winding element (2) is mounted on the inner side wall of the first resin-coated surface (102), and a second magnetic core assembly (3) is mounted on one side of the outer side wall of the first half-face magnetic core (101); wherein the winding element (2) is integrally formed by molding process, and is assembled with the first magnetic core assembly (1) and the second magnetic core assembly (3) to form a complete integrated winding module; and wherein the second magnetic core assembly (3) is used to assemble with the first magnetic core assembly (1) and the winding element (2) to form a complete integrated winding module.

2. The integrated winding module as described in claim 1, wherein, The winding element (2) includes a first loop (201), a plastic (202), and a second loop (203); wherein, the outer side wall of the first loop (201) is slidably connected to the inner side wall of the first resin coating surface (102), the outer side wall of the plastic (202) is fixedly connected to the inner side wall of the first loop (201), and the outer side wall of the second loop (203) is fixedly connected to the inner side wall of the plastic (202).

3. The integrated winding module as described in claim 2, wherein, The first loop (201) and the second loop (203) are made of C1100H, and the electroplating requirements are Ni:150u"Min / / Sn:350u"Min. The plastic (202) is made of LCP-S471(BK).

4. The integrated winding module as described in claim 1, wherein, The second magnetic core assembly (3) includes a second half-face magnetic core (301) and a second resin-coated surface (302); wherein, one side of the outer wall of the second half-face magnetic core (301) is mounted on one side of the outer wall of the first half-face magnetic core (101), and the second resin-coated surface (302) covers the outer wall of the second half-face magnetic core (301).

5. The integrated winding module as described in claim 4, wherein, The first resin coating surface (102) and the second resin coating surface (302) are made of resin coating.

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