A coil assembly, coil and magnetic induction element

Abstract

The application discloses a coil assembly, comprising a first coil, a second coil and a third coil, the first coil comprising a first body and a first main extension and a first auxiliary extension extending outward from two ends of the first body; the second coil comprising a second main body and a second auxiliary body, one end of the second main body and the second auxiliary body being connected to each other, the other end of the second main body and the second auxiliary body respectively having a second main extension and a second auxiliary extension extending outward; the third coil comprising a third body and a third main extension and a third auxiliary extension extending outward from two ends of the third body. The coil assembly of the application can realize the conduction between the coils by subsequent bending, and the bending and connecting parts are all located outside the injection molding part, so that the coil crossing structure in the traditional structure is not needed, and problems such as short circuit between the coils caused by material pressure during the injection molding process can be effectively avoided.

Description

Technical Field

[0001] This invention relates to the field of magnetic induction element technology, and more specifically to a coil assembly suitable for a magnetic induction element having at least two turns of coil in a set of coils, a coil prepared from the coil assembly, and a magnetic induction element including the coil. Background Technology

[0002] With social development and technological advancements, more and more electronic and electrical products are entering people's daily lives. These products include many magnetic induction components, such as transformers. In recent years, with the increasing demand for thinner and lighter electronic and electrical products, the design and use of magnetic induction components have become particularly important.

[0003] The architecture of magnetic induction components such as transformers includes at least two independent coils, namely the "primary coil" and the "secondary coil". After current is passed through, the voltage value is converted according to the principle of electromagnetic induction and the turns ratio of the two coils.

[0004] Existing magnetic induction components such as transformers use stamped metal sheets as coils. When there are two or more independent coils, the inner coil needs to extend the connector to the outside, which makes manufacturing difficult. In addition, if the coil is wrapped by injection molding, the inside of the coil is prone to contact, causing a short circuit. Summary of the Invention

[0005] In view of this, in order to overcome the shortcomings of the prior art, the object of the present invention is to provide a coil assembly that can avoid problems such as short circuits caused by having multiple turns of coil.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] A coil assembly includes a first coil, a second coil, and a third coil, wherein the second coil is located within the space formed by the first coil and the third coil; the first coil includes a first body and a first main extension and a first secondary extension extending outward from both ends of the first body; the second coil includes a second main body and a second copy body, one end of the second main body and the second copy body being connected to each other, and the other ends of the second main body and the second copy body respectively having a second main extension and a second secondary extension extending outward; the third coil includes a third body and a third main extension and a third secondary extension extending outward from both ends of the third body.

[0008] Without considering manufacturing processes, the first, second, and third coils are completely independent in their original state. The second main body and the second replica of the second coil are smaller than the first and third bodies, respectively, so that the second main body is located within the first body, and the second replica is located within the third body. The extension of the second coil is located between the extensions of the first and third coils. By providing extensions between the first and third bodies, and between the second main body and the second replica, subsequent connections and conduction between the coils can be achieved through bending, while avoiding short circuits caused by the coils needing to bypass themselves.

[0009] According to some preferred embodiments of the present invention, a connector is provided between the second main body and the second replica body, the connector being disposed between the second main extension and the second auxiliary extension. The connector is used to electrically connect the second main body and the second replica body, enabling conduction, and to isolate the second main extension and the second auxiliary extension.

[0010] According to some preferred embodiments of the present invention, the second main body is located within the first main body, and the second copy body is located within the third main body. That is, the size of the second main body is smaller than the size of the first main body, and the size of the second copy body is smaller than the size of the third main body. In some embodiments, the second main body and the second copy body are the same size, and the first main body and the third main body are the same size. More preferably, the second main body and the second copy body are axially symmetrically arranged, the first main body and the third main body are axially symmetrically arranged, and the two axes of symmetry coincide.

[0011] According to some preferred embodiments of the invention, the second main extension is located between the connector and the first main extension; the first auxiliary extension is located between the connector and the third auxiliary extension; and the second auxiliary extension is located between the connector and the first auxiliary extension. The extensions serve two purposes: firstly, to enable current conduction; and secondly, to achieve connection and conduction between coils on the same side of the final coil structure.

[0012] According to some preferred embodiments of the present invention, the first main extension includes a first connecting portion and a first bending portion that are perpendicular to each other, the first bending portion being used to connect with the second secondary extension after bending. That is, the first bending portion is used to realize the conduction between the first coil and the second coil.

[0013] According to some preferred embodiments of the present invention, the third main extension includes a third connecting portion and a third bending portion that are perpendicular to each other, the third bending portion being used to connect with the first secondary extension after bending. That is, the third bending portion is used to realize the conduction between the first coil and the third coil.

[0014] In some embodiments, the second main extension of the second coil is bent to form a second bent portion, i.e., a first pin, and the third secondary extension of the third coil is bent to form a second pin.

[0015] According to some preferred embodiments of the present invention, the coil assembly is located in the same plane in its original state (without bending), and the first, second, and third coils are separated or detachably connected. Subsequent bending is required to bend certain portions onto different planes to create a planar difference, thereby achieving connection and conductivity. Furthermore, the bending and connecting portions are located outside the subsequently molded part, preventing short circuits between coils due to material pressure during the injection molding process. Without considering the manufacturing process, the first, second, and third coils are separated and completely independent in their original state. Under certain process conditions, due to process limitations, it may be necessary to add connectors between the first, second, and third coils to allow for detachable connection. These connectors are then removed during subsequent manufacturing, thereby separating the first, second, and third coils.

[0016] The present invention also provides a coil prepared from the coil assembly described above.

[0017] The present invention also provides a magnetic induction element, including a magnetic core, a coil module, a circuit board and a connection terminal, wherein the coil module includes a coil as described above.

[0018] According to some preferred embodiments of the invention, the coil module includes a first coil module and a second coil module electrically connected by the coil, wherein the body of the coil is embedded in the first coil module and the second coil module.

[0019] Due to the implementation of the above technical solutions, the present invention has the following advantages compared with the prior art: The coil assembly of the present invention is designed with a first coil, a second coil and a third coil that are initially separated from each other, and each has its own structure. By setting multiple extensions, the current flow direction is ensured to be correct, so that the conduction between the coils can be achieved by bending. Moreover, the bending and connecting parts are all located outside the injection molded part, eliminating the need for coils to be strung together in the traditional structure. This can effectively avoid problems such as short circuits between coils caused by material pressure during the injection molding process. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a front view of the coil assembly in a preferred embodiment of the present invention;

[0022] Figure 2 This is a front view of the coil assembly after the first bend in a preferred embodiment of the present invention;

[0023] Figure 3 This is a perspective view of the coil assembly after the first bending in a preferred embodiment of the present invention;

[0024] Figure 4 This is a front view of the coil assembly after the second bending in a preferred embodiment of the present invention;

[0025] Figure 5 This is a perspective view of the coil assembly after a second bending in a preferred embodiment of the present invention;

[0026] Figure 6 This is a perspective view of the coil assembly after injection molding in a preferred embodiment of the present invention;

[0027] Figure 7 This is a perspective view of the coil assembly during its third bend in a preferred embodiment of the present invention;

[0028] Figure 8 This is a perspective view of the coil module in the magnetic induction element of the embodiment;

[0029] Figure 9 This is a perspective view of the magnetic induction element in a preferred embodiment of the present invention;

[0030] Figure 10 A perspective view of the coil in the magnetic induction element of the embodiment;

[0031] In the attached diagram: coil assembly-1, first body-21, first connecting part-221, first bending part-222, first secondary extension-23, first connecting end-231, second main body-31, second replica body-32, connecting body-33, second main extension-34, first pin-341, second secondary extension-35, second connecting end-351, third body-41, third connecting part-421, third bending part-422, third secondary extension-43, second pin-431, magnetic core-5, coil module-6, first coil module-61, second coil module-62, circuit board-7, connecting terminal-8, coil-9, magnetic induction element-10. Detailed Implementation

[0032] To enable those skilled in the art to better understand the technical solutions of the present invention, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0033] like Figure 9 As shown, the magnetic induction element 10 in this embodiment includes a magnetic core 5, a coil module 6, a circuit board 7, and a connecting terminal 8. The coil module 6 includes a first coil module 61 and a second coil module 62. The circuit board 7 is located between the first coil module 61 and the second coil module 62. The connecting terminal 8 is disposed on the circuit board 7 and passes through the first coil module 61. The body portion of the coil 9 is embedded in the first coil module 61 and the second coil module 62, such as... Figure 10 As shown, the first coil module 61 and the second coil module 62 are electrically connected through the coil 9.

[0034] In this embodiment, the coil is formed by bending and connecting the coil assembly 1 with the following structure.

[0035] like Figure 1-8 As shown, the coil assembly 1 in this embodiment includes a first coil, a second coil, and a third coil, which are located in the same plane in their original state (without bending) and are either separate or detachably connected. The first coil includes a first body 21 and a first main extension and a first secondary extension 23 extending outward from both ends of the first body 21. The second coil includes a second main body 31 and a second copy body 32, with one end of the second main body 31 and the second copy body 32 connected to each other via a connector 33. The other ends of the second main body 31 and the second copy body 32 respectively have a second main extension 34 and a second secondary extension 35 extending outward from both ends. The third coil includes a third body 41 and a third main extension and a third secondary extension 43 extending outward from both ends of the third body 41.

[0036] A connector 33 is disposed between the second main extension 34 and the second auxiliary extension 35. The connector 33 electrically connects the second main body 31 and the second replica body 32, enabling conductivity, and isolates the second main extension 34 and the second auxiliary extension 35 on both sides of the connector 33. The second main body 31 is located within the first body 21, and the second replica body 32 is located within the third body 41. That is, the size of the second main body 31 is smaller than the size of the first body 21, and the size of the second replica body 32 is smaller than the size of the third body 41. In this embodiment, the second main body 31 and the second replica body 32 are the same size, and the first body 21 and the third body 41 are the same size. More preferably, the second main body 31 and the second replica body 32 are axially symmetrically arranged, and the first body 21 and the third body 41 are axially symmetrically arranged, with the two axes of symmetry coinciding.

[0037] The second main extension 34 is located between the connector 33 and the first main extension; the first auxiliary extension 23 is located between the connector 33 and the third auxiliary extension 43; and the second auxiliary extension 35 is located between the connector 33 and the first auxiliary extension 23. The extensions serve two purposes: firstly, to enable current conduction; and secondly, to achieve connection and conduction between coils on the same side of the final coil structure.

[0038] To achieve conduction through bending, the first main extension in this embodiment includes a first connecting portion 221 and a first bending portion 222 that are perpendicular to each other. The first bending portion 222 is used to connect with the second auxiliary extension 35 after bending. That is, the first bending portion 222 is used to achieve conduction between the first coil and the second coil. The third main extension includes a third connecting portion 421 and a third bending portion 422 that are perpendicular to each other. The third bending portion 422 is used to connect with the first auxiliary extension 23 after bending. That is, the third bending portion 422 is used to achieve conduction between the first coil and the third coil. The second main extension 34 of the second coil is bent to form the second bending portion, i.e., the first pin 341, and the third auxiliary extension 43 of the third coil is bent to form the second pin 431.

[0039] like Figure 1 As shown, in this embodiment, when not bent, the first connecting portion 221, the third connecting portion 421, the second main extension portion 34, the connecting body 33, the second auxiliary extension portion 35, the first auxiliary extension portion 23, and the third auxiliary extension portion 43 in the coil assembly 1 are parallel to each other, and the first connecting portion 221 and the third connecting portion 421 are located in the same extension direction, while the remaining portions are located in different extension directions. Simultaneously, the first connecting portion 221 and the first bent portion 222 are arranged perpendicularly to each other and constitute the first main extension portion, and the third connecting portion 421 and the third bent portion 422 are arranged perpendicularly to each other and constitute the third main extension portion.

[0040] For subsequent bending to connect or form pins, and to ensure the correct direction of current flow, such as Figure 1 As shown, in this embodiment, the first main extension and the third main extension are located on both sides of the axis of symmetry (the axis of symmetry between the bodies). The second main extension 34 extends from one end of the second main body 31 toward the second copy body 32 and beyond the axis of symmetry, and beyond the position of the third bending portion 422. That is, the distance between the end of the second main extension 34 and the second copy body 32 is less than the distance between the third bending portion 422 and the second copy body 32, so as to better bend and form the first pin 341. The second auxiliary extension 35 extends from one end of the second copy body 32 toward the second main body 31 and beyond the axis of symmetry, and reaches the extension position of the first bending portion 222, so as to connect with the bent first bending portion 222. The first auxiliary extension 23 extends from one end of the first body 21 toward the second copy body 32 and beyond the axis of symmetry, and reaches the extension position of the third bending portion 422, so as to connect with the bent third bending portion 422. The third extension 43 extends from one end of the third body 41 toward the first body 21 and beyond the axis of symmetry, and beyond the position of the first bend 222, so as to bend more effectively to form the second pin 431.

[0041] Without considering the manufacturing process, in this embodiment, the first, second, and third coils are separated from each other and completely independent in their original state, with the second coil located within the space formed by the first and third coils. Under certain manufacturing conditions, due to process limitations, it may be necessary to add connectors between the first, second, and third coils to allow for a detachable connection. In subsequent manufacturing processes, these connectors are removed, thereby separating the first, second, and third coils from each other.

[0042] The second main body 31 and the second replica body 32 of the second coil are smaller than the first body 21 and the third body 41, respectively, so that the second main body 31 is located inside the first body 21, and the second replica body 32 is located inside the third body 41. The extension of the second coil is located between the extensions of the first coil and the third coil. By setting extensions between the first body 21 and the third body 41, and between the second main body 31 and the second replica body 32, subsequent bending is required to bend some parts onto different planes to form a plane difference, thereby connecting and conducting, and ensuring the correct direction of current flow. Moreover, the bending and connecting parts are all located outside the injection molded part, avoiding short circuits between coils due to material injection pressure during the injection molding process.

[0043] The following is a brief description of the fabrication process from coil assembly 1 to magnetic induction element 10 in this embodiment:

[0044] Punching: punching out shapes such as... Figure 1The coil assembly 1 shown forms three independent coils, a first coil, a second coil, and a third coil, located on the same plane.

[0045] First bend: The coil assembly 1 is bent for the first time, causing the second main extension 34 to bend downwards (90° vertically) to form the first pin 341, preventing interference with subsequent bends. Simultaneously, the ends of the first secondary extension 23 and the second secondary extension 35 are bent downwards to form the first connecting end 231 and the second connecting end 351, respectively, to connect with the bent first bend 222 and the third bend 422. The first connecting end 231 and the second connecting end 351 do not need to be bent vertically; they only need to be bent to a point where they are not on the same horizontal plane as the coil body, for subsequent connection with the bends, preventing short circuits caused by contact with other parts. Figure 2 and 3 As shown.

[0046] Second bend: The first bend 222 and the third bend 422 are bent downwards by 180° to connect and conduct with the second connecting end 351 of the second extension 35 and the first connecting end 231 of the first extension 23, respectively. Welding can be performed if necessary to strengthen the connection. Figure 4 and 5 As shown.

[0047] Injection molding: The coil assembly 1, after the second bending, is fixed and injection molded to form a first coil module 61 and a second coil module 62. The two coil modules are connected and conductive through the extension of the coil. At this time, the two coil modules 6 are still located on the same horizontal plane. Figure 6 As shown.

[0048] The third bending: the two coil modules 6 are bent from 90° to 180°, ultimately causing the second coil module 62 to be superimposed on top of the first coil module 61; finally, the third extension 43 is bent to form the second pin 431. Figure 7 and 8 As shown in Figure 10.

[0049] Assembly: The coil module 6 is assembled with the magnetic core 5, PCB circuit board 7, connecting terminals 8, etc., to finally form the magnetic induction element 10. For example... Figure 9 As shown.

[0050] The coil assembly 1 structure in this embodiment can achieve bending connection after stamping. Under the premise of ensuring the correct current flow direction, the traditional cross-connection point is moved to the outside of the coil body by means of structural design in a three-dimensional way, so as to avoid the occurrence of short circuit and other problems.

[0051] The above embodiments are only for illustrating the technical concept and features of the present invention. Their purpose is to enable those skilled in the art to understand the content of the present invention and implement it accordingly. They should not be used to limit the scope of protection of the present invention. All equivalent changes or modifications made in accordance with the spirit and essence of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A coil assembly, characterized by, The coil assembly comprises a first coil, a second coil and a third coil, the second coil is located in a space formed by the first coil and the third coil; the first coil comprises a first body and a first main extension and a first auxiliary extension extending outward from two ends of the first body; the second coil comprises a second main body and a second auxiliary body, one end of the second main body and the second auxiliary body are connected with each other, the other end of the second main body and the second auxiliary body respectively has a second main extension and a second auxiliary extension extending outward; the third coil comprises a third body and a third main extension and a third auxiliary extension extending outward from two ends of the third body; the first main extension comprises a first connecting portion and a first bending portion, the first bending portion is used for connecting with the second auxiliary extension after being bent.

2. The coil assembly of claim 1, wherein, A connecting body is arranged between the second main body and the second auxiliary body, and the connecting body is arranged between the second main extension and the second auxiliary extension.

3. The coil assembly of claim 1, wherein, The second main body is located in the first body, and the second auxiliary body is located in the third body.

4. The coil assembly of claim 2, wherein, The second main extension is located between the connecting body and the first main extension, the first auxiliary extension is located between the connecting body and the third auxiliary extension, and the second auxiliary extension is located between the connecting body and the first auxiliary extension.

5. The coil assembly of claim 1, wherein, The third main extension comprises a third connecting portion and a third bending portion, and the third bending portion is used for connecting with the first auxiliary extension after being bent.

6. The coil assembly of claim 1, wherein, The coil assembly is located in the same plane when not being bent, and the first coil, the second coil and the third coil are separated or detachably connected with each other.

7. A coil, characterized by The coil assembly is prepared by any one of claims 1-6.

8. A magnetic induction element, characterized by The coil assembly comprises a magnetic core, a coil module, a circuit board and a connecting terminal, the coil module comprises the coil according to claim 7.

9. The magnetic induction element of claim 8, wherein, The coil module comprises a first coil module and a second coil module electrically connected by the coil, and the first coil module and the second coil module are embedded with the body of the coil.

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