A large-current square common-mode inductor structure and its manufacturing method

Abstract

The present invention discloses a large-current square common-mode inductor structure and its manufacturing method, comprising: two groups of first magnetic cores arranged in parallel; two groups of second magnetic cores arranged in parallel, and the two groups of second magnetic cores are installed between the two groups of first magnetic cores to form a square structure with the first magnetic cores. Through the settings of the first card slot and the second card slot, the winding of each layer of the coil is staggered up and down, reducing the occurrence of magnetic leakage; the opposite end faces of the two second magnetic cores are both arc-shaped structures, maximizing the overlapping magnetic field between the two second magnetic cores and increasing the amount of electricity passing through the inductor per unit time; at the same time, after the two pins of the coil are clamped through the clamping linkage structure, they are fixed on the fixing block by welding, greatly improving the stability of the installation of the coil pins, thereby reducing the influence of the vibration of the common-mode inductor on the stability of the coil, and realizing a square common-mode inductor structure with anti-magnetic leakage, large current, good seismic performance and stable operation.

Description

Technical Field

[0001] The present invention relates to a large-current square common-mode inductor structure and a manufacturing method thereof. Background Art

[0002] A common-mode inductor, also called a common-mode choke coil, is often used in the switching power supply of a computer to filter common-mode electromagnetic interference signals. In the design of a circuit board, the common-mode inductor also plays the role of EMI filtering, which is used to suppress the electromagnetic waves generated by high-speed signal lines from radiating outward.

[0003] The existing common-mode inductor includes a magnetic core and a coil. The magnetic core is a square structure in the shape of a mouth formed by butting two U-shaped blocks. Chamfers are provided on the edges of the magnetic core, and an insulating layer is attached to the outer surface of the magnetic core. The coils are respectively wound around the middle parts of the two U-shaped blocks. However, this kind of common-mode inductor has weak anti-vibration and anti-shock capabilities, resulting in unstable situations often occurring during use and poor usability. Therefore, a large-current square common-mode inductor structure and a manufacturing method thereof are proposed to solve the above problems. Summary of the Invention

[0004] The purpose of the present invention is to provide a large-current square common-mode inductor structure and a manufacturing method thereof, which solve the problems of poor earthquake resistance and weak anti-shock ability of the common-mode inductor in the prior art, resulting in unstable use.

[0005] In order to achieve the above purpose, the present invention adopts the following technical solutions:

[0006] A large-current square common-mode inductor structure, comprising:

[0007] Two groups of first magnetic cores arranged in parallel;

[0008] Two groups of second magnetic cores arranged in parallel. The two groups of second magnetic cores are installed between the two groups of first magnetic cores to form a square structure with the first magnetic cores. The vertical cross-section of the second magnetic core is inclined with respect to the horizontal plane, and the opposite surfaces of the two second magnetic cores are arc-shaped structures;

[0009] A coil wound around the second magnetic core. The two ends of the coil form pins. The coil is wound around the second magnetic core in an up-and-down staggered manner, and the layer of the coil in contact with the second magnetic core is limited and clamped inside the second magnetic core;

[0010] A fixing member installed on the first magnetic core for fixing the four groups of pins. The pins are automatically clamped with the fixing member, and when the pins are welded, the welding liquid is guided into the clamping linkage structure inside the fixing member and into the clamping cavity where the clamping structure contacts the pins.

[0011] Preferably, annular first clamping grooves are equidistantly formed in the second magnetic core. A clamping ring is formed between two adjacent first clamping grooves. A second clamping groove is formed in the outer end face of the clamping ring, and the depth of the second clamping groove is smaller than that of the first clamping groove. When the coil is wound around the second magnetic core, the inner sides of the coil are respectively clamped in the first clamping groove and the second clamping groove.

[0012] Preferably, a first winding wire is clamped in the first clamping groove, a second winding wire is clamped in the second clamping groove, and two groups of third winding wires are wound and clamped between adjacent second winding wires. The first winding wire, the second winding wire, and the third winding wire are all winding structures for each turn of the coil.

[0013] Preferably, the fixing member includes two fixing blocks installed on each first magnetic core. A slot is formed in the top of the fixing block, and one end of the slot penetrates to the adjacent two side end faces of the fixing block for the pin to horizontally slide into the slot from the side end face of the fixing block.

[0014] Preferably, a movable pressing block is movably arranged up and down in the slot. The side end face of the movable pressing block is movably limited at the through hole on the side end face of the slot. The top of the movable pressing block is elastically connected to the inner side of the slot through a spring to form a clamping linkage structure composed of the movable pressing block and the spring. A leakage hole communicating with the slot is formed in the movable pressing block, and the bottom of the leakage hole penetrates to the pin clamping end face.

[0015] A manufacturing method of a large-current square common-mode inductor structure includes the following steps:

[0016] First step: Using a flat enameled wire winding, the coil is gradually wound from one end of the second magnetic core to the other end. When the coil is on the second magnetic core, it is first clamped in the first clamping groove to form a first winding wire, then wound around the first winding wire to form a third winding wire, then clamped in the second clamping groove to form a second winding wire, and finally, after being clamped between the third winding wire and the second winding wire, it is wound into the second first clamping groove and so on in sequence.

[0017] Second step: Take out the two pins of the coil. The pins horizontally slide into the slots of the fixing blocks from the outside. After the movable pressing block moves upward under the action of the extrusion force, it presses down on the pins under the reaction force of the spring.

[0018] Third step: Fix the pins by using a spot welding process. The welding liquid is sprayed into the slots from the top and respectively introduced between the top of the movable pressing block and the inner wall of the slot, and then introduced between the movable pressing block and the pins through the leakage holes.

[0019] Fourth step: Arrange the welding liquid flowing out of the fixing member, and the processing of the common-mode inductor is completed.

[0020] The present invention has at least the following beneficial effects:

[0021] 1. Through the settings of the first card slot and the second card slot, the winding of each layer of the coil is staggered up and down, reducing the occurrence of magnetic leakage; the opposite end faces of the two second magnetic cores are both arc-shaped structures, maximizing the overlapping magnetic field between the two second magnetic cores and increasing the power passing through the inductor per unit time; at the same time, after the two pins of the coil are clamped through the clamping linkage structure, they are fixed on the fixed block by welding, greatly improving the installation stability of the coil pins, thereby reducing the impact of the common mode inductor vibration on the coil stability, and realizing a square common mode inductor structure with anti-magnetic leakage, large current, good seismic performance and stable operation.

[0022] 2. Through the settings of the first card slot and the second card slot, the inner side of the coil is stuck in the first card slot and the second card slot, and the coil is wound from one side of the second magnetic core to the other side in turn. This setting greatly improves the winding stability between the coil and the second magnetic core and reduces the occurrence of the situation where the coil is scattered due to vibration. Brief Description of the Drawings

[0023] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following will briefly introduce the drawings required for the description of the embodiments. Obviously, the following drawings are some embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

[0024] Figure 1 It is a schematic structural diagram of the common mode inductor body;

[0025] Figure 2 It is a schematic structural diagram of the first magnetic core and the second magnetic core;

[0026] Figure 3 It is a schematic structural diagram of the second magnetic core;

[0027] Figure 4 It is a schematic vertical sectional view of the common mode inductor body;

[0028] Figure 5 It is an enlarged structural diagram at A;

[0029] Figure 6 It is an enlarged structural diagram at B;

[0030] Figure 7 It is a schematic cross-sectional top view of the fixing part.

[0031] In the figure: 1. First magnetic core; 2. Second magnetic core; 3. Fixing part; 4. Coil; 5. Pin; 6. First card slot; 7. Second card slot; 8. Clamping ring; 9. First winding; 10. Second winding; 11. Third winding; 12. Fixed block; 13. Slot; 14. Movable pressing block; 15. Leakage hole. Detailed Embodiments

[0032] In order to make the objectives, technical solutions and advantages of the present invention more clear and understandable, the present invention will be further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0033] Embodiment 1

[0034] Referring to Figures 1-7 , a large-current square common-mode inductor structure includes:

[0035] Two groups of first magnetic cores 1 arranged in parallel;

[0036] Two groups of second magnetic cores 2 arranged in parallel. The two groups of second magnetic cores 2 are installed between the two groups of first magnetic cores 1 to form a square structure with the first magnetic cores 1. The vertical cross-section of the second magnetic core 2 is inclined with respect to the horizontal plane, and the opposite faces of the two second magnetic cores 2 are arc-shaped structures; annular first card slots 6 are equidistantly arranged on the second magnetic core 2, and a clamping ring 8 is formed between two adjacent first card slots 6. A second card slot 7 is arranged on the outer end face of the clamping ring 8, and the depth of the second card slot 7 is less than the depth of the first card slot 6. When the coil 4 is wound around the second magnetic core 2, the inner sides of the coil 4 are respectively stuck in the first card slot 6 and the second card slot 7;

[0037] A coil 4 wound around the second magnetic core 2. Both ends of the coil 4 form pins 5. The coil 4 is wound around the second magnetic core 2 in a staggered manner up and down, and the layer of the coil 4 that fits with the second magnetic core 2 is limited and stuck in the second magnetic core 2; a first winding 9 is clamped in the first card slot 6, a second winding 10 is clamped in the second card slot 7, and two groups of third windings 11 are wound and clamped between adjacent second windings 10. The first winding 9, the second winding 10 and the third winding 11 are all winding structures for each turn of the coil 4;

[0038] A fixing member 3 installed on the first magnetic core 1 for fixing the four groups of pins 5. The pins 5 are automatically clamped with the fixing member 3. When the pins 5 are welded, the welding fluid is guided into the clamping linkage structure in the fixing member 3, and the welding fluid is guided into the clamping cavity where the clamping structure contacts the pins 5; the fixing member 3 includes two fixing blocks 12 installed on each first magnetic core 1. A slot 13 is opened at the top of the fixing block 12, and one end of the slot 13 penetrates to the adjacent two side end faces of the fixing block 12 for the pins 5 to horizontally slide into the slot 13 from the side end face of the fixing block 12. An active pressing block 14 is movably arranged up and down in the slot 13. The side end face of the active pressing block 14 is movably limited at the through hole on the side end face of the slot 13. The top of the active pressing block 14 is elastically connected to the inner side of the slot 13 through a spring to form a clamping linkage structure composed of the active pressing block 14 and the spring. A leakage hole 15 communicating with the slot 13 is opened in the active pressing block 14, and the bottom of the leakage hole 15 penetrates to the clamping end face of the pins 5;

[0039] In this embodiment, through the settings of the first card slot 6 and the second card slot 7, the coils 4 are staggered up and down after being wound, reducing the occurrence of magnetic leakage. At the same time, the second magnetic cores 2 are inclined, and the opposite end faces of the two second magnetic cores 2 are both arc-shaped structures, maximizing the overlapping magnetic field between the two second magnetic cores 2 and increasing the power passing through the inductor per unit time. At the same time, after the two pins 5 of the coil 4 are clamped through the clamping linkage structure, they are fixed on the fixed block 12 by welding, greatly improving the installation stability of the pins 5 of the coil 4, thereby reducing the influence of the common mode inductor vibration on the stability of the coil 4, and realizing a square common mode inductor structure with anti-magnetic leakage, large current, good seismic performance and stable operation.

[0040] Embodiment Two

[0041] Refer to Figures 1-7 , a manufacturing method of a large current square common mode inductor structure, comprising the following steps:

[0042] The first step: Using a flat enameled wire winding, the coil 4 is gradually wound from one end of the second magnetic core 2 to the other end. The coil 4 is first stuck in the first card slot 6 on the second magnetic core 2 to form the first winding 9, then wound around the first winding 9 to form the third winding 11, then stuck in the second card slot 7 to form the second winding 10, and finally, after being stuck in the third winding 11 and the second winding 10, it is wound into the second first card slot 6 and so on forward.

[0043] The second step, take out the two pins 5 of the coil 4, the pins 5 slide horizontally from the outside into the slot 13 of the fixed block 12. After the movable pressing block 14 moves up under the action of the extrusion force, it presses down on the pins 5 under the reaction force of the spring.

[0044] The third step, use spot welding technology to fix the pins 5, the welding liquid is sprayed from the top of the slot 13, and is respectively introduced between the top of the movable pressing block 14 and the inner wall of the slot 13, and is introduced between the movable pressing block 14 and the pins 5 through the leakage holes 15.

[0045] The fourth step, tidy up the welding liquid flowing out from the fixing part 3, and the processing of the common mode inductor is completed.

[0046] The above shows and describes the basic principles, main features and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited by the above embodiments. What is described in the above embodiments and the specification is only the principle of the present invention. Without departing from the spirit and scope of the present invention, the present invention will have various changes and improvements, and these changes and improvements all fall within the scope of the present invention claimed. The scope of protection required by the present invention is defined by the appended claims and their equivalents.

Claims

1. A large-current square common-mode inductor structure, characterized in that, Comprising: Two groups of first magnetic cores (1) arranged in parallel; Two groups of second magnetic cores (2) arranged in parallel, the two groups of second magnetic cores (2) are installed between the two groups of first magnetic cores (1) to form a square structure with the first magnetic cores (1), the vertical cross-section of the second magnetic core (2) is inclined with respect to the horizontal plane, and the opposite faces of the two second magnetic cores (2) are arc-shaped structures; A coil (4) wound around the second magnetic core (2), both ends of the coil (4) form pins (5), the coil (4) is wound around the second magnetic core (2) in a staggered manner up and down, and the layer of the coil (4) in contact with the second magnetic core (2) is limited and clamped within the second magnetic core (2); A fixing member (3) installed on the first magnetic core (1) for fixing the four groups of pins (5), the pins (5) are automatically clamped with the fixing member (3), and when the pins (5) are welded, the welding fluid is guided into the clamping linkage structure within the fixing member (3), and the welding fluid is guided into the clamping cavity where the clamping linkage structure contacts the pins (5); Annular first clamping grooves (6) are equidistantly formed on the second magnetic core (2), a clamping ring (8) is formed between two adjacent first clamping grooves (6), a second clamping groove (7) is formed on the outer end surface of the clamping ring (8), when the coil (4) is wound around the second magnetic core (2), the inner sides of the coil (4) are respectively clamped within the first clamping groove (6) and the second clamping groove (7); the depth of the second clamping groove (7) is less than the depth of the first clamping groove (6).

2. The structure of a large-current square common-mode inductor according to claim 1, wherein, A first winding wire (9) is clamped within the first clamping groove (6), a second winding wire (10) is clamped within the second clamping groove (7), and two groups of third winding wires (11) are wound and clamped between adjacent second winding wires (10), the first winding wire (9), the second winding wire (10) and the third winding wire (11) are all winding structures for each turn of the coil (4).

3. A large-current square common-mode inductor structure according to claim 2, characterized in that, The fixing member (3) includes two fixing blocks (12) installed on each first magnetic core (1), a slot (13) is formed at the top of the fixing block (12), and one end of the slot (13) penetrates to the adjacent two side end faces of the fixing block (12) for the pins (5) to horizontally slide into the slot (13) from the side end face of the fixing block (12).

4. A large-current square common-mode inductor structure according to claim 3, characterized in that, An active pressing block (14) is movably arranged up and down within the slot (13), the side end face of the active pressing block (14) is movably limited at the through hole on the side end face of the slot (13), the top of the active pressing block (14) is elastically connected to the inner side of the slot (13) through a spring to form a clamping linkage structure composed of the active pressing block (14) and the spring, a leakage hole (15) communicating with the slot (13) is formed within the active pressing block (14), and the bottom of the leakage hole (15) penetrates to the clamping end face of the pin (5).

5. A manufacturing method of a large-current square common-mode inductor structure, applied to the large-current square common-mode inductor structure described in claim 4, characterized in that, Comprising the following steps: The first step: Adopt a flat enameled wire winding. The coil (4) is gradually wound from one end to the other end of the second magnetic core (2). The coil (4) is on the second magnetic core (2). First, it is stuck in the first card slot (6) to form the first winding (9). Secondly, it is wound around the first winding (9) to form the third winding (11). Then, it is stuck in the second card slot (7) to form the second winding (10). Finally, after being stuck behind the third winding (11) and the second winding (10), it is wound into the second first card slot (6) and proceeds forward in sequence. The second step: Take out the two pins (5) of the coil (4). The pins (5) are horizontally slid into the slots (13) of the fixing block (12) from the outside. After the movable pressing block (14) moves upward under the action of the extrusion force, it presses down on the pins (5) under the reaction force of the spring. The third step: Fix the pins (5) by using the spot welding process. The welding liquid is sprayed in from the top of the slot (13) and is respectively introduced between the top of the movable pressing block (14) and the inner wall of the slot (13), and is introduced between the movable pressing block (14) and the pins (5) through the leakage holes (15). The fourth step: Arrange the welding liquid flowing out from the fixing part (3), and the common mode inductor processing is completed.

Images