Magnetic induction coil module

Abstract

The present invention provides a magnetic induction coil module, comprising: a coil module consisting of a first group of coils and a second group of coils, wherein the first group of coils is coated with a first isolation layer, and the second group of coils is a flat coil having an open first loop body, so as to form two ends that do not contact each other, wherein one end has a first conductive portion protruding outward from the first loop body, and the other end has a connecting end, which extends outward as a whole to form an open second loop body, and the end of the second loop body has a protruding second conductive portion, wherein a turning portion is included on the connecting end, and the turning portion makes the second loop body and the first loop body face each other in the same direction, and the second group of coils are positioned on the first isolation layer in a clamping manner, thereby improving assembly efficiency and reducing product defect rate.

Description

Technical Field

[0001] The present invention relates to a coil module, in particular to a magnetic induction coil module for an inductor or a transformer. Background Art

[0002] For example, the structure of a magnetic induction coil module such as a transformer includes at least two sets of independent coils, namely the so-called "primary coil" and the "secondary coil". After the current is passed through, the voltage value is converted according to the turn ratio of the two sets of coils based on the principle of electromagnetic induction.

[0003] In actual applications, the transformer is usually constructed on an independent insulating base. The insulating base is pre-arranged with multiple conductive pins or contact pins connected to the coil to form a transformer assembly. These conductive pins or contact pins are welded to the external circuit to make the transformer assembly conductive to the external circuit. At the same time, the insulating base is used as a signal isolation to avoid interference.

[0004] In order to meet the miniaturization requirements of consumer electronic products, the design of these transformers is becoming increasingly thinner and lighter, which is an inevitable trend. In the known prior art, there is a coil group made by using the circuit printing technology of the printed circuit board (PCB) to produce a flat (or flat) transformer (Planar transformer). For example, the Chinese patent specification No. CN201138608 discloses a transformer assembly with a conductive coil pattern printed on the PCB. The patent No. CN201138608 uses PCB to make a primary coil and a secondary coil, and a layer of insulating paint is applied on the surface of the two sets of coils to isolate them, and they are assembled with a magnetic core to form a flat transformer.

[0005] Although the prior art No. CN201138608 can make the transformer thinner, it still has many defects in the manufacturing and assembly process as follows:

[0006] 1. It should be noted that the process of using PCB printing technology to manufacture conductive coil patterns to form the primary and secondary coils of the transformer is complex, has low current resistance, and is costly, making it difficult for the resulting products to have price competitiveness in the market.

[0007] 2. Applying insulating paint on the surface of the two sets of coils to isolate them from each other is difficult to meet the safety regulations for transformer manufacturing and is likely to cause damage to the transformer during operation; especially for AC-DC transformers connected to the mains, due to the large voltage difference at the AC power supply end, the primary coil and the secondary coil must be isolated with a certain safety distance according to regulations.

[0008] 3. The prior art in No. CN201138608 Figure 7 In the transformer disclosed in FIG8 , when a 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 reserved assembly holes on each set of coils, so the alignment of these coil assembly holes must be very precise, otherwise it will cause assembly difficulties or cause the problem of too large a gap between the coil and the magnetic core. In particular, as shown in FIG8 of the case, the two sets of secondary coils 4A, 6A made of PCB also need to accurately connect the coil patterns to each other through the conductive pins (pins) shown on the left before providing connection with the external circuit, which is the main factor that makes it difficult to introduce automation and mass production based on this design.

[0009] Another prior art related to the present invention known to the inventor is a planar transformer disclosed in U.S. Patent Publication No. 2013 / 0278371, which sequentially inserts a plurality of prefabricated planar coils (including primary and secondary coils) onto the magnetic core of the transformer, and provides a base having a plurality of conductive pins, which is connected to the plurality of coils and an external circuit by welding technology, wherein the base can serve as an isolation protection between the magnetic core and the external circuit.

[0010] Obviously, the flat metal coil used in the prior art No. 2013 / 0278371 can be directly formed by die casting or stamping in advance, and the manufacturing cost is much lower than the previously disclosed coil made of PCB and is more suitable for mass production. In addition, the thickness of the metal layer can withstand a larger current than the PCB printed conductive coil. However, the following defects still exist in the transformer manufacturing process and the assembly process:

[0011] 1. There is a lack of isolation design for safe spacing between the flat coils. As mentioned above, even if a layer of insulating paint is applied on the surface of each group of coils as isolation, it is difficult to meet the transformer safety regulations, especially for transformers connected to the mains. Due to the large voltage difference at the power supply end, the transformer is easily damaged during operation.

[0012] 2. Each set of coils is an independent unit and component. When assembled with the magnetic core, the central magnetic column of the magnetic core must pass through the assembly holes reserved on each set of coils in sequence. Therefore, the alignment of these coil assembly holes must be very precise, which not only increases the difficulty of assembly and makes it easy to fail, but also wastes working hours and is difficult to introduce automated processes, which is not conducive to large-scale production operations.

[0013] 3. The multiple conductive pins are pre-fixed on an independent base. The wire ends of each coil, whether primary or secondary, must be connected to each conductive pin one by one for conduction. If the number of coils required is large (this is related to the turns ratio of the primary and secondary coils), it will inevitably affect the production effect. Obviously, the more connections are made, the easier it is to make mistakes, such as blind connection or wrong connection, which will increase the failure rate. Summary of the invention

[0014] In order to solve the above problems, the present invention provides a more novel "magnetic induction coil module", which is not only easier to manufacture and assemble than the previous technology, but also more convenient to use as an inductor, transformer or other magnetic induction coil module, and can reduce the defective rate of the end product, which is the main purpose of the present invention.

[0015] To achieve the purpose of the invention, the magnetic induction coil module disclosed in the present invention includes: a first group of coils, which have a first isolation layer on the outside; a second group of coils, which have an open first loop body, the first loop body has two ends that do not contact each other, one of which has a first conductive portion protruding outward from the first loop body, and the other end has a connecting end, which also extends outward as a whole to form an open second loop body, and the end of the second loop body has a protruding second conductive portion, wherein a turning portion is included on the connecting end, and the turning portion makes the second loop body and the first loop body face each other in the same direction, and the second group of coils are positioned on the first isolation layer in a clamping manner to form a coil module.

[0016] Optionally, the first isolation layer is molded with insulating material over the outside of the first group of coils.

[0017] Optionally, the first isolation layer is formed of an insulating material to form a mold frame for the first group of coils to be sleeved and covered.

[0018] Optionally, the first group of coils and the first isolation layer also have a common adapting hole, and the adapting hole corresponds to the loop holes of the first loop body and the second loop body.

[0019] Optionally, a positioning groove adapted to the contours of the first loop body and the second loop body is disposed on the first isolation layer at the periphery of the adapting hole.

[0020] Optionally, the first group of coils is formed by a conductive pattern arranged in an insulating substrate, and a plurality of contact portions are arranged on one side thereof, which are connected with the conductive pattern and exposed outside the first isolation layer.

[0021] Optionally, a carrier is disposed at one end of the first isolation layer to provide the first conductive portion and the second conductive portion of the second group of coils to be arranged on two opposite sides of the carrier.

[0022] Optionally, the first isolation layer establishes a boss between the connection end of the second group of coils and the first conductive portion and the second conductive portion for isolation.

[0023] Optionally, the outside of the coil module is further covered with a second isolation layer, and the first conductive portion and the second conductive portion are exposed.

[0024] Optionally, the invention may further include: 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, a plurality of the first loop bodies having a first protruding conductive portion, and a plurality of connection ends, the plurality of connection ends extending outward in the same direction and as a whole to form a plurality of continuous open second loop bodies, a second conductive portion protruding from the ends of the plurality of continuous second loop bodies, wherein each of the plurality of connection ends includes a turning portion, the turning portion enables the plurality of the second loop bodies to be opposite to the plurality of the first loop bodies in the same direction, and the second group of coils are positioned on the first isolation layer in a clamping manner to form a coil module.

[0025] The present invention has the following advantages: 1. The second set of coils can be made of die-cast or stamped conductive materials to reduce production costs. The first loop body and the second loop body are integrally connected to form the second set of coils, which simplifies the assembly process of using multiple independent coils in the prior art and the trouble of precise alignment. In particular, when connecting to an external circuit, only the first conductive part and the second conductive part need to be connected at two contact points, which reduces the chance of blind connection and more effectively improves the reliability of the terminal product.

[0026] 2. 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 adaptation hole to facilitate their alignment and assembly, and a boss is established between the connecting end and the first loop body and the second loop body for isolation.

[0027] 3. Another implementation method can be derived from the structure of the second group of coils, that is, the second group of coils is also a flat coil, which has a plurality of continuous open first loop bodies, which have a protruding first conductive end, and a plurality of connecting ends, the plurality of connecting ends integrally extend outward to form a plurality of continuous open second loop bodies, the ends of the plurality of continuous second loop bodies have a protruding second conductive end, wherein each of the plurality of connecting ends includes a turning portion, and the plurality of turning portions provide the plurality of second loop bodies to be opposite to the plurality of first loop bodies 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 coil module. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 It is an exploded view of the present invention;

[0029] Figure 2 It is a structural diagram of the second set of coils of the present invention when unfolded;

[0030] Figure 3 It is an assembled external view of the present invention;

[0031] Figure 4 It is an assembled external view of the present invention from another perspective;

[0032] Figure 5 It is the Figure 3 cross-sectional view of the present invention in the A - A' direction;

[0033] Figure 6 It is an external view of another embodiment of the present invention;

[0034] Figure 7 It is a structural diagram of another embodiment of the second set of coils of the present invention when unfolded.

[0035] In the figure:

[0036] 1 The first set of coils; 10 Conductive pattern; 11 Insulating substrate; 12 Contact part; 13 Adaptation hole; 2, 2a The second set of coils; 20, 20a The first loop body; 200, 200a The first conduction part; 201 Loop hole; 21, 21a The second loop body; 210, 210a The second conduction part; 211 Loop hole; 22, 22a Connection end; 220, 220a Turning part; 3 The first isolation layer; 30 Positioning groove

[0037] 31 Boss; 32 Carrier; 4 The second isolation layer; 5 Magnetic core; 6 Coil module. Detailed implementation mode

[0038] The present invention is a coil module, which can be applied to magnetic induction components such as inductors or transformers.

[0039] Please refer to Figure 1 to Figure 5 simultaneously. The present invention includes a first set of coils 1 and a second set of coils 2. Among them, the outside of the first set of coils 1 has a first isolation layer 3, and the second set of coils 2 is positioned on the first isolation layer 3 in a sandwiching manner to form a coil module as shown in Figure 3 and Figure 4 the figure.

[0040] In the preferred embodiment disclosed by the present invention, as shown in Figure 1 and Figure 5As disclosed, the first set of coils 1 is a first set of coils 1 made by deploying a conductive pattern 10 on an insulating substrate 11, for example, by using a printed circuit board (hereinafter referred to as PCB) manufacturing technology to deploy the conductive pattern 10 in the PCB; or, the conductive pattern 10 is directly laid on the insulating substrate 11 to form the first set of coils 1, but not limited thereto. In addition, a plurality of contact portions 12 may be pre-deployed on one side of the insulating substrate 11 to communicate with the conductive pattern 10, so as to provide circuit conduction with the outside; and an adapter hole 13 may be pre-set in the first set of coils 1, which may be used as a magnetic core configuration with a transformer.

[0041] The second group of coils 2 is a conductive material, and is made into a flat coil by die casting, stamping, or other methods. It has an open first loop body 20. The first loop body 20 has two non-contacting ends, one of which has a first conductive portion 200 protruding outward from the first loop body 20, and the other end is a connecting end 22. The connecting end 22 extends outward as a whole to form an open second loop body 21. The end of the second loop body 21 has a protruding second conductive portion 210. Preferably, the shapes of the first loop body 20 and the second loop body 21 are symmetrical to each other; wherein, the connecting end 22 also includes a turning portion 220, and the turning portion 220 provides the second loop body 21 and the first loop body 20 to face each other in the same direction.

[0042] The first isolation layer 3 is provided to insulate and isolate the first coil 1 from the outside by covering the outside of the first coil 1, and the plurality of contact portions 12 are exposed to be connected to the external circuit. The covering method can be through direct injection molding of the insulating material outside the first coil 1, or the insulating material is used to pre-form a mold frame for the first coil 1 to be inserted therein; preferably, the first isolation layer 3 is provided with a positioning groove 30 that matches the contour of the first loop body 20 and the second loop body 21 on the periphery of the adapting hole 13 to facilitate their alignment and assembly, and a boss 31 is established between the connecting end 22 and the first conductive portion 200 and the second conductive portion 210 for isolation. In addition, the first isolation layer 3 is provided with a carrier 32 at the opposite end away from the contact portion 12, and the carrier 32 can provide the first conductive portion 200 and the second conductive portion 210 of the second coil 2.

[0043] During assembly, the first loop body 20 is placed on one side of the first isolation layer 3 covering the outside of the first coil 1. By forming the turning portion 220, the second loop body 21 is bent toward the first loop body 20 and faces the first loop body 20 in the same direction, so that the first coil 1 is sandwiched between the first loop body 20 and the second loop body 21 to form a Figure 3 and Figure 4The coil module shown; at the same time, the loop holes 201 and 211 of the first loop body 20 and the second loop body 21 naturally correspond to the adapter holes 13 of the first group of coils 1, as the magnetic core configuration of the transformer. Preferably, the first loop body 20 and the second loop body 21 are filled in the positioning groove 30 on the first isolation layer 3 to enhance the positioning effect, and the first conductive part 200 and the second conductive part 210 are arranged on two opposite sides of the carrier 32 to provide conductive pin insertion with the external circuit, or soldering by SMT surface adhesion. As for the connection end 22 and the turning part 220, they are straddled on the carrier 32 to make the positioning of the second group of coils 2 more compact and stable. Please refer to Figure 4 As shown, the first conductive portion 200 and the second conductive portion 210 can also be bent vertically toward the first loop body 20 in the same direction and welded to the external circuit plug hole.

[0044] Please refer to Figure 6 As shown, please refer to Figure 6 As shown, after the assembly of the coil module is completed, a second isolation layer 4 can be coated on the outside of the coil module with an insulating material through injection molding, and the contact portion 12 of the first group of coils 1 and the first and second conductive portions 200 and 210 of the second group of coils 2 are exposed to provide connection with external circuits.

[0045] Finally, please refer to Figure 7 2 is another preferred embodiment of the second coil of the present invention. The second coil 2a is also a flat coil made of a conductive material through molding, stamping, or other methods. It has a plurality of continuous open first loop bodies 20a. The plurality of first loop bodies 20a have a protruding first conductive portion 200a and a plurality of connecting ends 22a. The plurality of connecting ends 22a extend outward in the same direction and integrally to form a plurality of continuous open second loop bodies 21a. The plurality of continuous second loop bodies 21a have a second conductive portion 210a protruding at the end. 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 each of the plurality of connecting ends 22a includes a turning portion 220a. The plurality of turning portions 220a provide the plurality of second loop bodies 21a and the plurality of first loop bodies 20a to be opposite in the same direction. In this way, the number of turns of the second coil 2a can be increased to meet the requirements of the configured magnetic induction coil module.

[0046] Compared with the prior art, it can be found that the advantages of the magnetic induction coil module disclosed in the present invention include:

[0047] 1. The second set of coils 2 is made of die-cast or stamped conductive material. Compared with the prior art transformer in which both the primary and secondary coils use PCB, it can obviously reduce production costs and is easy to implement.

[0048] Second, the first loop body 20 and the second loop body 21 are integrally connected to form the second set of coils 2, which simplifies the assembly process of using multiple independent coils in the previous technology and the trouble of precise alignment; in particular, when connecting to an external circuit, it only needs to connect to the two contacts of the first conductive part 200 and the second conductive part 210 provided, which reduces the chance of blind connection and improves reliability.

[0049] 3. The second set of coils 2 is positioned on the first isolation layer 3 in a manner similar to a clamping method to form a coil module, which is more conducive to the subsequent processing operation of covering the second isolation layer 4 on the outside; in particular, a positioning groove 30 adapted to the contours of the first loop body 20 and the second loop body 21 is pre-established on the first isolation layer 3 for filling, which further enhances the positioning effect of the two during assembly.

[0050] Fourth, when the coil module of the present invention is used as a transformer, the magnetic core of the transformer only needs to be aligned with the matching holes 13 of the first set of coils to complete the assembly, thus simplifying the manufacturing process and reducing the failure rate.

[0051] The above-mentioned embodiments are only preferred embodiments for fully illustrating the present invention, and the protection scope of the present invention is not limited thereto. Equivalent substitutions or changes made by technicians in the technical field on the basis of the present invention, such as defining the position, quantity, form of the primary coil or secondary coil of the coil module, or the molding method of the first group and the second group of coils, are all within the protection scope of the present invention. The protection scope of the present invention shall be subject to the claims.

Claims

1. A magnetic induction coil module, It is characterized in that include: A first group of coils, with a first isolation layer outside thereof; A second group of coils has an open first loop body, the first loop body has two ends that do not contact each other, one of which has a first conductive portion protruding outward from the first loop body, and the other end has a connecting end, which also extends outward as a whole to form an open second loop body, and the end of the second loop body has a protruding second conductive portion, wherein a turning portion is included on the connecting end, and the turning portion makes the second loop body and the first loop body face each other in the same direction, and the second group of coils are positioned on the first isolation layer in a clamping manner to form a coil module.

2. The magnetic induction coil module according to claim 1, It is characterized in that The first isolation layer is molded by covering the outside of the first group of coils with insulating material.

3. The magnetic induction coil module according to claim 1, It is characterized in that The first isolation layer is formed of an insulating material to form a mold frame for the first group of coils to be sleeved and covered.

4. The magnetic induction coil module according to claim 1, It is characterized in that The first group of coils and the first isolation layer outside thereof also have a matching hole in common, and the matching hole corresponds to the holes of the first loop body and the second loop body.

5. The magnetic induction coil module according to claim 4, It is characterized in that A positioning groove matching the contours of the first loop body and the second loop body is disposed on the first isolation layer at the periphery of the matching hole.

6. The magnetic induction coil module according to claim 1, It is characterized in that The first group of coils is formed by a conductive pattern arranged in an insulating substrate, and a plurality of contact portions are arranged on one side thereof to communicate with the conductive pattern and to be exposed outside the first isolation layer.

7. The magnetic induction coil module according to claim 1, It is characterized in that A carrier is disposed at one end of the first isolation layer to provide the first conductive portion and the second conductive portion of the second coil group to be disposed on two opposite sides of the carrier.

8. The magnetic induction coil module according to claim 1, It is characterized in that The first isolation layer has a boss established between the connection end of the second coil group and the first conductive part and the second conductive part for isolation.

9. The magnetic induction coil module according to any one of claims 1 to 8, It is characterized in that The coil module is also coated with a second isolation layer on the outside, and the first conductive part and the second conductive part are exposed.

10. A magnetic induction coil module, It is characterized in that include: A first group of coils has a first isolation layer on the outside; a second group of coils has a plurality of continuous open first loop bodies, the plurality of first loop bodies have a first conductive portion protruding outward, and a plurality of connection ends, the plurality of connection ends are in the same direction and extend outward as a whole to form a plurality of continuous open second loop bodies, the ends of the plurality of continuous second loop bodies protrude a second conductive portion, wherein each of the plurality of connection ends includes a turning portion, the turning portion makes the plurality of second loop bodies and the plurality of first loop bodies face each other in the same direction, and the second group of coils are positioned on the first isolation layer in a sandwiching manner to form a coil module.

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