Inductor and method of manufacturing the same

Abstract

The application discloses an inductor and a manufacturing method thereof. The inductor comprises a base, a magnetic core and at least two coils. The base has at least two winding through holes. The magnetic core has at least two winding columns arranged in parallel to each other. The magnetic core is fixedly installed on the base, and the at least two winding columns of the magnetic core after installation are arranged corresponding to the at least two winding through holes. The at least two coils are wound on the at least two winding columns respectively and form a wire package. The minimum distance between the center axis of each winding column and the edge of the corresponding winding through hole is greater than one half of the maximum distance of the outer contour of the wire package formed on the winding column. The application can realize automatic winding and wire arrangement, has high production efficiency and good heat dissipation performance.

Description

Technical Field

[0001] This invention relates to an inductor and its manufacturing method. Background Technology

[0002] As switching power supplies become increasingly thinner, higher in power density, and more automated, how to reduce labor costs, achieve automated production, high product efficiency, and good heat dissipation are issues that magnetic component design engineers must consider.

[0003] Currently available flat-wire vertical inductors offer advantages such as automatic winding and wire management (achieving automated production) due to the large space between the coil lead and the base, and the presence of lead grooves at the bottom of the base. They also exhibit good heat dissipation. However, this structure is relatively tall, making it unsuitable for applications with height restrictions.

[0004] Currently, there is a type of flat wire horizontal inductor 100, such as Figures 1A-1C As shown, it mainly includes a base 11, a magnetic core 12, and coils 13. The base 11 has two bases 111 and 112 adapted to be installed with the coils 13, and has wiring pins 113 and wire management spaces 114 and 115. The two coils 13 are wound on the two winding posts 121 and 122 of the magnetic core 12, respectively. However, although this structure is suitable for models with height restrictions, the magnetic core 12 needs to be separated from the base 11 during winding. The magnetic core 12 is placed on a winding machine to wind the coil (i.e., machine operation). After the magnetic core 12 is wound, it needs to be manually assembled with the base 11 by applying glue, and the starting and ending wires are manually wound onto the wiring pins for soldering (i.e., manual operation). In other words, this structure currently cannot automatically apply glue and automatically manage the wires, that is, it cannot fully realize automated production. Furthermore, because the base 11 is relatively large, when the magnetic core 12 with coil 13 is combined with the base 11, the bottom of the coil 13 will be covered by the base 11, resulting in poor heat dissipation performance.

[0005] Therefore, designing an inductor that can meet high requirements, be produced automatically, and has good heat dissipation has become an urgent problem to be solved. Summary of the Invention

[0006] The purpose of this invention is to provide an inductor and a method for manufacturing the same, which can overcome one or more defects of the prior art.

[0007] To achieve the above objectives, the present invention provides an inductor characterized in that it comprises: a base having at least two winding through holes; a magnetic core having at least two winding posts arranged parallel to each other, the magnetic core being fixedly mounted on the base, and the at least two winding posts of the mounted magnetic core being arranged corresponding to the at least two winding through holes; and at least two coils correspondingly wound on the at least two winding posts and forming a coil respectively; wherein the minimum distance between the central axis of each winding post and the edge of the corresponding winding through hole is greater than half of the maximum distance of the outer contour of the coil formed on the winding post.

[0008] In one embodiment of the present invention, a connecting post is provided between two adjacent winding through holes.

[0009] In one embodiment of the present invention, the base includes a first support base and a second support base disposed opposite to each other, and the connecting column is connected between the first support base and the second support base.

[0010] In one embodiment of the present invention, the first distance between the two ends of the first support base is less than or equal to the second distance between the two ends of the second support base.

[0011] In one embodiment of the present invention, the base further includes a plurality of wiring pins, the plurality of wiring pins including at least two first wiring pins disposed on the first support base and at least two second wiring pins disposed on the second support base.

[0012] In one embodiment of the present invention, the first terminal of each coil is correspondingly mounted on the first pin, and the second terminal is correspondingly mounted on the second pin; and / or, the first pitch between two adjacent first pins is smaller than the second pitch between two adjacent second pins.

[0013] In one embodiment of the present invention, the first support base has a first support surface and a first protrusion extending upward along the outer edge of the first support surface; the second support base has a second support surface and a second protrusion extending upward along the outer edge of the second support surface.

[0014] In one embodiment of the present invention, the magnetic core further includes a first magnetic end cap and a second magnetic end cap. The first magnetic end cap is connected to the first end of the at least two winding posts, and the second magnetic end cap is connected to the second end of the at least two winding posts. The first magnetic end cap is fixedly installed on the first support surface by adhesive or snap-fit ​​structure, and the second magnetic end cap is fixedly installed on the second support surface by adhesive or snap-fit ​​structure.

[0015] In one embodiment of the present invention, the outer contour of the coil is circular, and the side of the connecting post adjacent to the outer contour of the coil is inclined.

[0016] In one embodiment of the present invention, the magnetic core is horizontally fixed on the base, and the opposite left and right sides of each winding post are planes, and the opposite upper and lower sides of each winding post are arc surfaces that match the inner contour of the coil.

[0017] To achieve the above objectives, the present invention further provides a method for manufacturing an inductor, characterized in that it includes:

[0018] A base is provided having at least two winding through holes;

[0019] A magnetic core is provided having at least two winding posts arranged parallel to each other. The magnetic core is fixedly mounted on the base, wherein the at least two winding posts of the magnetic core after installation correspond to the at least two winding through holes.

[0020] At least two coils are provided, and a winding device is used to automatically wind the coils onto the at least two winding posts to form a coil, wherein the minimum distance between the central axis of each winding post and the edge of the corresponding winding through hole is greater than half the maximum distance of the outer contour of the coil formed on the winding post.

[0021] In one embodiment of the present invention, wherein:

[0022] The magnetic core is automatically glued and fixed to the base using a spot adhesive fixing device or an adhesive application fixing device; or the magnetic core is snapped and fixed to the base using a snap-fit ​​structure.

[0023] In another embodiment of the present invention, the method for manufacturing the inductor further includes:

[0024] A robotic arm is used to wind the terminals of the coil onto the terminals of the base;

[0025] The terminals are automatically soldered to the pins using a soldering device.

[0026] The inductor of this invention, after the base and magnetic core are combined, has sufficient winding space between them. After the magnetic core is wound, there is sufficient space between the coil ends and the base for wire management, thus enabling automated winding and wire management. Therefore, the inductor of this invention can be automatically assembled, has high production efficiency, low material costs, and a low unit price. Furthermore, the inductor of this invention has a large heat dissipation area and good heat dissipation performance.

[0027] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention. Attached Figure Description

[0028] The above and other features and advantages of the present invention will become more apparent from a detailed description of exemplary embodiments thereof with reference to the accompanying drawings.

[0029] Figure 1A This is a schematic diagram of the three-dimensional structure of an existing horizontal inductor;

[0030] Figure 1B for Figure 1A A schematic diagram of the base structure of a horizontal inductor;

[0031] Figure 1C for Figure 1A A schematic diagram of the magnetic core and coils assembled in a horizontal inductor.

[0032] Figure 2A This is a three-dimensional structural diagram of the inductor of the present invention;

[0033] Figure 2B for Figure 2A A schematic diagram of the structure of the inductor's base;

[0034] Figure 2C for Figure 2A A cross-sectional view of the longitudinal section of the inductor, showing the distance relationship between the winding coil and the base during automatic winding;

[0035] Figure 2D It shows Figure 2C The structure in which the inductor, after winding is completed, has the wire ends on both sides of the coil wound around the terminals by a wire management machine;

[0036] Figure 3A The structure of one of the steps in the method for manufacturing the inductor of the present invention is shown, wherein a base is provided;

[0037] Figure 3B The structure of one of the steps in the method of manufacturing an inductor according to the present invention is shown, wherein a magnetic core is provided and said magnetic core is automatically glued and fixed to the base using a spot adhesive fixing device;

[0038] Figure 3C The structure of one of the steps in the method of manufacturing an inductor according to the present invention is shown, wherein two coils are provided and the coils are automatically wound onto two winding posts of the magnetic core using a winding device;

[0039] Figure 4 A method for manufacturing the inductor of the present invention is shown. Detailed Implementation

[0040] Exemplary embodiments will now be described more fully with reference to the accompanying drawings. However, these exemplary embodiments can be implemented in many forms and should not be construed as limited to the embodiments set forth herein; rather, they are provided so that the invention will be thorough and complete, and the concept of the exemplary embodiments will be fully conveyed to those skilled in the art. The same reference numerals in the drawings denote the same or similar structures, and therefore their detailed description will be omitted.

[0041] In describing the elements / components / etc. described and / or illustrated herein, the terms “a,” “an,” “the,” “the,” and “at least one” are used to indicate the presence of one or more elements / components / etc. The terms “comprising,” “including,” and “having” are used to indicate an open-ended inclusion and to mean that additional elements / components / etc. may exist in addition to those listed. Relative terms, such as “upper” or “lower,” may be used in the embodiments to describe the relative relationship of one component of the icon to another component. It is understood that if the device of the icon is flipped so that it is upside down, the component described as being on the “upper” side will become the component on the “lower” side. Furthermore, the terms “first,” “second,” etc., in the claims are used only as illustrative marks and are not intended to limit the number of objects to which they apply.

[0042] like Figures 2A-2D As shown, the inductor 200 of a preferred embodiment of the present invention mainly includes a base 21, a magnetic core 22 and at least two coils 23.

[0043] The base 21, as Figure 2A and Figure 2B As shown, the system may include, for example, a first support base 211 and a second support base 212 disposed opposite to each other, and a connecting post 213 connecting the first support base 211 and the second support base 212. The base 21 has at least two winding through holes, including, but not limited to, winding through holes 214 and 215, with a connecting post 213 between adjacent winding through holes. In other words, the winding through holes 214 and 215 may be defined, for example, by the first support base 211, the second support base 212, and the connecting post 213. Figure 2BAs shown, the base 21 is generally "I"-shaped, with the left side of the winding through-hole 214 open and the right side of the winding through-hole 215 open. This not only provides more space for subsequent winding and wire management but also facilitates heat dissipation of the inductor coil. Preferably, the first support base 211 has a first support surface 2111 and a first protrusion 2112 extending upward along the outer edge of the first support surface 2111; the second support base 212 has a second support surface 2121 and a second protrusion 2122 extending upward along the outer edge of the second support surface 2121. The first protrusion 2112 and the second protrusion 2122 can not only be used to limit and fix the magnetic core 22 during the subsequent assembly and fixing process, but also to be used by devices such as robots to grip the base 21 during the production process, thereby protecting the magnetic core 22 assembled on the base 21 and preventing damage to the magnetic core 22 during gripping. Furthermore, the base 21 also includes a plurality of terminals, such as at least two first terminals 2113 and 2114 disposed on the first support base 211, and at least two second terminals 2123 and 2124 disposed on the second support base 212.

[0044] The magnetic core 22, as Figure 2A As shown, the magnetic core 22 is horizontally fixed to the base 21 and has at least two winding posts arranged parallel to each other, such as, but not limited to, winding posts 221 and 222. The magnetic core 22 is fixedly mounted on the base 21, and the at least two winding posts (e.g., winding posts 221 and 222) of the mounted magnetic core 22 are arranged corresponding to the at least two winding through holes (e.g., winding through holes 214 and 215). Specifically, winding post 221 is mounted above winding through hole 214, and winding post 222 is mounted above winding through hole 215. In this preferred embodiment, the magnetic core 22 further includes a first magnetic end cap 223 and a second magnetic end cap 224. The first magnetic end cap 223 is connected to the first end of the at least two winding posts (e.g., winding posts 221 and 222), and the second magnetic end cap 224 is connected to the second end of the at least two winding posts (e.g., winding posts 221 and 222). Furthermore, the first magnetic end cap 223 can be fixedly installed to the first support surface 2111 with adhesive, and the second magnetic end cap 224 can be fixedly installed to the second support surface 2121 with adhesive. It is worth noting that the adhesive can be glue, solid glue, or double-sided adhesive. In other embodiments, adhesive may not be used for fixing; instead, a snap-fit ​​structure can be provided to fix the magnetic core 22 to the base 21.

[0045] The at least two coils 23, such as Figure 2AAs shown, coils are wound around at least two winding posts to form coils, including but not limited to coils 231 formed on winding post 221 and coils 232 formed on winding post 222. The lower surface of coil 231 is exposed to the air through winding through hole 214, and the lower surface of coil 232 is exposed to the air through winding through hole 215, which can effectively improve heat dissipation. Furthermore, the first terminal of each coil 23 can be correspondingly mounted on the first terminal pins 2113 and 2114 on the first support base 211 (e.g., as wire exit), and the second terminal of each coil 23 can be correspondingly mounted on the second terminal pins 2123 and 2124 on the second support base 212 (e.g., as wire exit), in conjunction with reference to... Figure 2D As shown, the second terminal 2314 of the coil 23 forming the coil 231 is mounted on the second terminal 2124 of the base 21, for example, and the second terminal 2313 of the coil 23 forming the coil 232 is mounted on the second terminal 2123 of the base 21, for example.

[0046] In this invention, such as Figure 2A , Figure 2C As shown, the minimum distance L between the central axis I of each winding post (e.g., including winding posts 221, 222) and the edge of the corresponding winding through hole (e.g., including winding through holes 214, 215) is greater than half the maximum distance C of the outer contour of the coil (e.g., including coil 231, 232) formed on the winding post (i.e., L > C / 2). The edge of the winding through hole refers to the edge parallel to the central axis I, that is, the edge defined by the sides 2131 and 2132 of the connecting post 213, and not the edge defined by the side surfaces of the first support base 211 and the second support base 212, which is explained here first.

[0047] In this invention, preferably, as Figure 2A As shown, the outer contours of the coils 231 and 232 can be, for example, circular. The side of the connecting post 213 adjacent to the outer contours of the coils 231 and 232 can be, for example, a sloped surface, as shown in reference. Figure 2B , 2C As shown, the two sides 2131 and 2132 of the connecting post 213 are inclined surfaces. That is, the width of the upper surface of the connecting post 213 is smaller than the width of the lower surface, and the longitudinal cross-section of the connecting post 213 is approximately trapezoidal. This not only provides more space for winding and cable management but also improves the support strength of the connecting post 213. Furthermore, as... Figure 2BAs shown, the first distance D1 between the two ends of the first support base 211 can be less than or equal to the second distance D2 between the two ends of the second support base 212. Furthermore, the first pitch between two adjacent first pins (e.g., 2113 and 2114) can be less than the second pitch between two adjacent second pins (e.g., 2123 and 2124). This provides a mistake-proofing effect during manufacturing. Of course, it is understood that in other embodiments, the first distance D1 can also be equal to the second distance D2, and the first pitch can also be equal to the second pitch; these are not intended to limit the invention.

[0048] In this invention, preferably, in conjunction with reference to the reference Figure 2C Taking the winding post 222 as an example, the opposite left side 2221 and right side 2222 of each winding post 222 can be planes, and the opposite upper side 2223 and lower side 2224 of each winding post 222 are arc surfaces that match the inner contour of the coil 232.

[0049] like Figure 4 As shown, combined with Figures 3A-3C The inductor manufacturing method 400 of the present invention mainly includes:

[0050] Step 41, provide a base 21, such as Figure 3A As shown, it has at least two winding through holes 214 and 215;

[0051] Step 42: Provide a magnetic core 22 having at least two parallel winding posts 221, 222, and fix the magnetic core 22 onto the base 21, as follows. Figure 3B As shown, the at least two winding posts 221 and 222 of the installed magnetic core 22 are provided corresponding to the at least two winding through holes 214 and 215;

[0052] Step 43: Provide at least two coils 23, and use a winding device to automatically wind the coils 23 onto the at least two winding posts 221, 222 respectively to form coils 231, 232, as shown. Figure 3C As shown, the minimum distance L between the central axis of each winding post 221, 222 and the edge of the corresponding winding through hole 214, 215 is greater than half the maximum distance C of the outer contour of the coil 231, 232 formed on the winding post 221, 222 (i.e., L > C / 2, as shown). Figure 2C (As shown).

[0053] It is worth noting that in step 42, the magnetic core 22 can be automatically glued and fixed onto the base 21 using a dispensing device. Alternatively, an adhesive applicator can be used to automatically glue and fix the magnetic core 22 onto the base 21, where the adhesive applicator can automatically apply double-sided tape, etc. A snap-fit ​​structure can also be used to snap and fix the magnetic core 22 onto the base 21, thus eliminating the need for both the dispensing and applicator methods.

[0054] In this invention, the method for manufacturing the inductor may further include: using a robotic arm to wind the terminals of the coil 23 onto the pins of the base 21; and using a soldering device to automatically solder the terminals onto the pins.

[0055] In this invention, after the inductor is assembled with the base 21 and the magnetic core 22 (e.g., by automatic glue dispensing), since L > C / 2, there is sufficient winding space between the base 21 and the magnetic core 22, allowing for automated winding using a winding machine. Furthermore, after the magnetic core 22 is wound, there is sufficient space for wire management between the coil 23's wire end and the base 21, enabling automated wire management. Therefore, the inductor of this invention can achieve automated glue dispensing assembly, winding, wire management, and welding processes throughout the entire manufacturing process, resulting in high production efficiency, low material costs, and low unit product price. Moreover, the inductor of this invention has a large heat dissipation area and good heat dissipation performance.

[0056] Exemplary embodiments of the present invention have been specifically illustrated and described above. It should be understood that the present invention is not limited to the disclosed embodiments; rather, the present invention is intended to cover various modifications and equivalent arrangements contained within the spirit and scope of the appended claims.

Claims

1. An inductor, characterized in that, include: A base having at least two winding through holes; A magnetic core having at least two winding posts arranged in parallel to each other, the magnetic core being fixedly mounted on the base, and the at least two winding posts of the magnetic core after installation being arranged corresponding to the at least two winding through holes; as well as At least two coils are wound around the at least two winding posts and each forms a coil; The minimum distance between the central axis of each winding post and the edge of the corresponding winding through hole is greater than half the maximum distance of the outer contour of the coil formed on the winding post.

2. The inductor according to claim 1, characterized in that, A connecting post is provided between two adjacent winding through holes.

3. The inductor according to claim 2, characterized in that, The base includes a first support base and a second support base arranged opposite to each other, and the connecting column is connected between the first support base and the second support base.

4. The inductor according to claim 3, characterized in that, The first distance between the two ends of the first support base is less than or equal to the second distance between the two ends of the second support base.

5. The inductor according to claim 3, characterized in that, The base also includes a plurality of wiring pins, including at least two first wiring pins disposed on the first support base and at least two second wiring pins disposed on the second support base.

6. The inductor according to claim 5, characterized in that, The first terminal of each coil is correspondingly mounted on the first pin, and the second terminal is correspondingly mounted on the second pin; and / or, the first pitch between two adjacent first pins is smaller than the second pitch between two adjacent second pins.

7. The inductor according to claim 3, characterized in that, The first support base has a first support surface and a first protrusion extending upward along the outer edge of the first support surface; the second support base has a second support surface and a second protrusion extending upward along the outer edge of the second support surface.

8. The inductor according to claim 7, characterized in that, The magnetic core further includes a first magnetic end cap and a second magnetic end cap. The first magnetic end cap is connected to the first end of the at least two winding posts, and the second magnetic end cap is connected to the second end of the at least two winding posts. The first magnetic end cap is fixedly installed on the first support surface by adhesive or snap-fit ​​structure, and the second magnetic end cap is fixedly installed on the second support surface by adhesive or snap-fit ​​structure.

9. The inductor according to any one of claims 2 to 8, characterized in that, The outer contour of the coil is circular, and the side of the connecting post adjacent to the outer contour of the coil is inclined.

10. The inductor according to claim 9, characterized in that, The magnetic core is horizontally fixed on the base, and the opposite left and right sides of each winding post are flat, while the opposite upper and lower sides of each winding post are arc surfaces that match the inner contour of the coil.

11. A method for manufacturing an inductor, characterized in that, include: A base is provided having at least two winding through holes; A magnetic core is provided having at least two winding posts arranged parallel to each other. The magnetic core is fixedly mounted on the base, wherein the at least two winding posts of the magnetic core after installation correspond to the at least two winding through holes. At least two coils are provided, and a winding device is used to automatically wind the coils onto the at least two winding posts to form a coil, wherein the minimum distance between the central axis of each winding post and the edge of the corresponding winding through hole is greater than half the maximum distance of the outer contour of the coil formed on the winding post.

12. The method for manufacturing an inductor according to claim 11, characterized in that, in: The magnetic core is automatically glued and fixed to the base using a spot adhesive fixing device or an adhesive application fixing device; or the magnetic core is snapped and fixed to the base using a snap-fit ​​structure.

13. The method for manufacturing an inductor according to claim 11, characterized in that, Also includes: A robotic arm is used to wind the terminals of the coil onto the terminals of the base; The terminals are automatically soldered to the pins using a soldering device.

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