Magnetic core structure and method of making the same

Abstract

A magnetic core structure and a manufacturing method thereof are disclosed. The magnetic core structure includes a magnetic core, a plurality of conductive layers and two wires. The magnetic core has a winding column, a first side column and a second side column connecting two ends of the winding column. The winding column includes two outer protrusions with a receiving slot. The first side column has two first setting platforms, and the second side column has two second setting platforms. The plurality of conductive layers are disposed on the two first setting platforms and the two second setting platforms. The two wires are wound on the winding column, and parts of the two wires are respectively located in the two receiving slots. One wire is electrically coupled to the conductive layers on the first setting platform and the second setting platform of the same side, and the other wire is electrically coupled to the conductive layers on the first setting platform and the second setting platform of the other side. Thus, the magnetic core structure can improve the manufacturing efficiency.

Description

TECHNICAL FIELD

[0001] The present application relates to a magnetic core structure, and more particularly to a magnetic core structure and a manufacturing method thereof capable of greatly improving manufacturing efficiency. BACKGROUND

[0002] The existing magnetic core structure includes a primary coil, a secondary coil, and a magnetic core. The magnetic core has a middle column, an intermediate step connecting both sides of the middle column, and a first step and a second step connecting both ends of the middle column. In the manufacturing process, the primary coil and the secondary coil are first individually spot-welded at both ends of the first step, then wound to the intermediate step for the second spot-welding, and finally wound to both ends of the second step for the third spot-welding, thereby completing the manufacturing of the existing magnetic core structure.

[0003] However, due to the elastic recovery force of the material of the primary coil and the secondary coil, the second spot-welding step and its order cannot be omitted. For example, when the second spot-welding step is omitted in the manufacturing process, the primary coil and the secondary coil will spread apart at the part located at the intermediate step due to the lack of fixation (spot-welding), thereby causing the primary coil and the secondary coil to fail to smoothly perform the third spot-welding. Furthermore, even if the third spot-welding is completed, the primary coil and the secondary coil will have the problem of loosening or spreading apart because the winding path on the magnetic core is too long.

[0004] Therefore, the present inventor believes that the above-mentioned defects can be improved, and after careful research and application of scientific principles, finally proposes the present application which is reasonably designed and effectively improves the above-mentioned defects. SUMMARY

[0005] The technical problem to be solved by the present application is to provide a magnetic core structure and a manufacturing method thereof to overcome the deficiencies of the prior art.

[0006] The present application discloses a manufacturing method of a magnetic core structure, which is suitable for a magnetic core structure. The magnetic core structure includes a magnetic core. The magnetic core has a winding column, a first side column and a second side column connected to both ends of the winding column. The winding column has an extension direction and a width direction perpendicular to the extension direction. The winding column includes a body part and two outer protruding parts connected to the body part. Each outer protruding part includes a receiving groove and two coupling platforms located on both sides of the receiving groove. The first side column and the second side column each have two setting platforms arranged at a distance from each other. The manufacturing method includes the following steps: performing a planar electroplating step: using planar electroplating to print a conductive layer on the two setting platforms of the first side column, the two setting platforms of the second side column, and the two coupling platforms of the two outer protruding parts; performing a first soldering step: using soldering to fix a first end of two wires to the conductive layer on the two setting platforms of the first side column; performing a first winding step: using a second end of the two wires to wind a part of the body part along the extension direction and through the two receiving grooves; performing a second winding step: using the second end of the two wires to wind another part of the body part along the extension direction; performing a second soldering step: using soldering to fix the second end of the two wires to the conductive layer on the two setting platforms of the second side column; and performing a conduction step: using conductive material to set between the conductive layer on any one of the wires and its adjacent two coupling platforms, so that the two wires are respectively electrically coupled to the conductive layer on their adjacent two coupling platforms.

[0007] Preferably, the two wires are straight soldering type enameled wires. In the conduction step, high-temperature conductive material is used to set between the conductive layer on any one of the wires and its adjacent two coupling platforms.

[0008] Preferably, the conduction step further includes: performing a peeling sub-step: using a physical method to remove part of the insulating layer of the wires in the two receiving grooves, so that the two wires each expose a bare conductive layer; and performing a soldering sub-step: using soldering to electrically connect the bare conductive layer of the two wires to the conductive layer of their adjacent two coupling platforms, respectively.

[0009] Preferably, each outer protruding part further includes a cutting groove. The cutting groove is arranged between any two adjacent coupling platforms along the width direction and is connected to the receiving groove. After the conduction step is performed, the manufacturing method further includes: performing a cutting step: using a physical method to cut the two wires along the two cutting grooves, so that the two wires form four sub-wires.

[0010] Preferably, after the cutting step, the manufacturing method further comprises: performing a short-circuiting step, in which two short-circuiting wires are respectively electrically coupled to the conductive layers on the same side of the two setting platforms.

[0011] Preferably, in the peeling step and the cutting step, the physical method is laser removal.

[0012] The embodiments of the present application also disclose a magnetic core structure, which comprises: a magnetic core, including: a winding column having an extension direction, the winding column including a body part and two outer convex parts connected to the body part, each of the outer convex parts including a receiving groove; and a first side column and a second side column respectively connected to two ends of the body part along the extension direction, the first side column having two first setting platforms arranged at intervals from each other, and the second side column having two second setting platforms arranged at intervals from each other; a plurality of conductive layers arranged on the two first setting platforms, the two second setting platforms and the two outer convex parts; and two wires wound on the body part, parts of the two wires respectively located in the two receiving grooves, wherein two ends of one of the wires are respectively electrically coupled to the conductive layers on the same side of the first setting platform and the second setting platform, and two ends of the other wire are respectively electrically coupled to the conductive layers on the same side of the first setting platform and the second setting platform.

[0013] Preferably, the plurality of conductive layers are coplanar with each other, and the two receiving grooves are arranged at an angle with respect to the extension direction.

[0014] The magnetic core structure includes a magnetic core including a winding column having an extension direction, the winding column including a body portion and two outer protruding portions connected to the body portion, each of the outer protruding portions having four coupling platforms, a tangent slot, and a receiving slot, the four coupling platforms being arranged at intervals from each other, and the receiving slot and the tangent slot being communicated with each other and arranged between the four coupling platforms; a first side column and a second side column connected to two ends of the body portion along the extension direction, the first side column having two first arrangement platforms arranged at intervals from each other, and the second side column having two second arrangement platforms arranged at intervals from each other; a plurality of first conductive layers arranged on the two first arrangement platforms and the two second arrangement platforms; a plurality of second conductive layers arranged on the four coupling platforms of the two outer protruding portions; two first wires wound on the body portion between the first side column and the two outer protruding portions, parts of the two first wires being located in the two receiving slots respectively, and two ends of one of the first wires being electrically connected to the first conductive layers and the two second conductive layers of the first arrangement platforms located on the same side and adjacent to each other respectively, and two ends of the other of the first wires being electrically connected to the first conductive layers and the two second conductive layers of the first arrangement platforms located on the other side and adjacent to each other respectively; and two second wires wound on the body portion between the second side column and the two outer protruding portions, parts of the two second wires being located in the two receiving slots respectively, and two ends of one of the second wires being electrically connected to the first conductive layers and the two second conductive layers of the second arrangement platforms located on the same side and adjacent to each other respectively, and two ends of the other of the second wires being electrically connected to the first conductive layers and the two second conductive layers of the second arrangement platforms located on the other side and adjacent to each other respectively.

[0015] Preferably, the plurality of first conductive layers and the plurality of second conductive layers are coplanar with each other, and the two receiving slots are arranged at an angle with respect to the extension direction.

[0016] In summary, the magnetic core structure and the manufacturing method thereof can make the two wires not spread or loosen in the case of two welding steps, so that the manufacturing efficiency of the magnetic core structure is improved.

[0017] For further understanding of the features and technical contents of the present application, please refer to the following detailed description of the present application and the attached drawings, but these descriptions and drawings are only used to illustrate the present application, and do not limit the protection scope of the present application. BRIEF DESCRIPTION OF DRAWINGS

[0018] Figure 1 Flowchart of the manufacturing method of the first embodiment of the present application.

[0019] Figure 2 Schematic diagram of the plane plating step of the first embodiment of the present application.

[0020] Figure 3 Schematic diagram of the plane plating step of the first embodiment of the present application.

[0021] Figure 4 Schematic diagram of the plane plating step of the first embodiment of the present application.

[0022] Figure 5 Schematic diagram of the plane plating step of the first embodiment of the present application.

[0023] Figure 6 Schematic diagram of the plane plating step of the first embodiment of the present application.

[0024] Figure 7 Schematic diagram of the plane plating step of the first embodiment of the present application.

[0025] Figure 8 Schematic diagram of the plane plating step of the first embodiment of the present application.

[0026] Figure 9 Schematic diagram of the plane plating step of the first embodiment of the present application.

[0027] Figure 10 Schematic diagram of the plane plating step of the first embodiment of the present application.

[0028] Figure 11 Schematic diagram of the plane plating step of the first embodiment of the present application.

[0029] Figure 12 Schematic diagram of the plane plating step of the first embodiment of the present application.

[0030] Figure 13 Schematic diagram of the plane plating step of the first embodiment of the present application.

[0031] Figure 14 Schematic diagram of the plane plating step of the first embodiment of the present application.

[0032] Figure 15 Schematic diagram of the plane plating step of the first embodiment of the present application. DETAILED DESCRIPTION

[0033] The following detailed description is presented in terms of a particular embodiment so as to provide a thorough understanding of the present application. The present application, however, can be practiced in a variety of embodiments and / or applications without departing from the scope or spirit of the application. Details of the present application can be modified in different particulars by those skilled in the art without departing from the spirit and scope of the present application. Furthermore, the present application is not to be limited by the following description, but is only limited by the scope of the appended claims.

[0034] It should be understood that although the terms "first", "second", "third" and the like can be used herein to describe various components, these components should not be limited by these terms. These terms are generally only used to distinguish one component from another. Additionally, the term "or" as used herein should be understood to mean either one of the associated listed items, or any combination of the associated listed items. Further, the term "electrically coupled" as used herein means one of "indirectly electrically connected" and "directly electrically connected".

[0035] First Embodiment

[0036] Referring to Figures 1 to 9 the drawings, the present embodiment provides a method for manufacturing a magnetic core structure 100 including steps S101 to S113, but in actual applications, one of the steps S101 to S113 can be omitted or replaced by a reasonable variation according to the designer's needs.

[0037] A preparation step S101 is implemented, as shown in Figure 2 and Figure 3 , a magnetic core 1 is provided. For the convenience of subsequent description, the magnetic core 1 has (or is defined as) an extension direction D1 and a width direction D2 perpendicular to the extension direction D1, and the extension direction D1 is the left-right direction of the magnetic core 1 in Figure 3 , and the width direction D2 is the up-down direction of the magnetic core 1 in Figure 3 , but the present application is not limited thereto.

[0038] Further, the magnetic core 1 in the present embodiment is a substantially "W"-shaped magnetic conductive member, and has a winding column 11, and a first side column 12 and a second side column 13 connecting both ends of the winding column 11. The winding column 11 includes a body portion 112 and two outer protruding portions 111 connecting the body portion 112, the body portion 112 connects the first side column 12 and the second side column 13 at both ends along the extension direction D1, and the two outer protruding portions 111 are arranged at both sides of the body portion 112 along the width direction D2 and between the first side column 12 and the second side column 13. Each of the outer protruding portions 111 includes a receiving groove 1111 and two coupling platforms 1112 arranged at both sides of the receiving groove 1111.

[0039] Further, each of the receiving grooves 1111 is substantially arranged along the extension direction D1, and both ends of any one of the receiving grooves 1111 face the first side column 12 and the second side column 13, respectively. That is, each of the receiving grooves 1111 communicates with the outside of the outer protruding portion 111 corresponding to the position of the receiving groove 1111, but the present application is not limited thereto. For example, the two receiving grooves 1111 can be arranged obliquely with respect to the extension direction D1, and the two ends are not simultaneously arranged on an imaginary line (such as the line shown in Figure 4

[0040] In addition, the first side column 12 and the second side column 13 each have two arrangement platforms arranged at a distance from each other, and each of the arrangement platforms of the first side column 12 is further defined as a first arrangement platform 121, and each of the arrangement platforms of the second side column 13 is defined as a second arrangement platform 131. The top surfaces of the two first arrangement platforms 121 and the two second arrangement platforms 131 are coplanar, that is, the height of the top surface of any one of the first arrangement platforms 121 is the same as the height of the top surface of any one of the second arrangement platforms 131, and the heights of the top surfaces of the two first arrangement platforms 121 or the two second arrangement platforms 131 are also the same as each other. It should be noted that the aforementioned height is measured in a height direction D3 perpendicular to the extension direction D1 and the width direction D2, that is, the up-down direction of the magnetic core 1 in Figure 2

[0041] A planar electroplating step S103 is performed, and referring again to Figure 2 , a conductive layer 2 is formed on the two first arrangement platforms 121 of the first side column 12, the two second arrangement platforms 131 of the second side column 13, and the two coupling platforms 1112 of the two outer protruding portions 111 by planar electroplating printing.

[0042] ​​Generally, the aforementioned planar electroplating printing is a single printing process, meaning that the conductive layer 2 is formed simultaneously on the two first mounting platforms 121, the two second mounting platforms 131, and the two coupling platforms 1112 of the two external protrusions 111. For example, one side of the magnetic core 1 is immersed in an electroplating solution, allowing the top surfaces of the two first mounting platforms 121, the two second mounting platforms 131, and the two coupling platforms 1112 of the two external protrusions 111 to be electroplated simultaneously, thereby forming multiple conductive layers 2 on the magnetic core 1. However, the present invention is not limited to this.

[0043] Perform a first welding step S105, such as Figure 5 As shown, the first ends 31 of the two wires 3A and 3B are respectively fixed to the conductive layer 2 on the two first mounting platforms 121 (of the first side post 12) by welding. In practice, the aforementioned welding method can be spot welding, gas welding, resistance welding, etc., that is, as long as the first ends 31 of the two wires 3A and 3B are fixed by solder 5 and electrically coupled to the two first mounting platforms 121, it is not limited to any particular welding method.

[0044] Perform the first winding step S107, as follows: Figure 6 As shown, a portion of the body portion 112 is wound around the second ends 32 of the two wires 3A and 3B along the extending direction D1, and passes through the two receiving grooves 1111 respectively. Specifically, the second ends 32 of the two wires 3A and 3B are first wound (or rolled) several times around the body portion 112 between the first side post 12 and the two protrusions 111, and then the two second ends 32 pass through the two receiving grooves 1111 respectively. Thus, portions of the two wires 3A and 3B are accommodated and confined within the two receiving grooves 1111, and the two second ends 32 are located between the two protrusions 111 and the second side post 13 via the ports of the two receiving grooves 1111.

[0045] Perform the second winding step S109, as follows: Figure 7 As shown, the second ends 32 of the two wires 3A and 3B are wound around another part of the body portion 112 along the extending direction D1. That is, the two wires 3A and 3B are wound around the body portion 112 several times and are located between the two protruding portions 111 and the second side post 13.

[0046] It is worth noting that the two wires 3A, 3B are partially located in the two accommodating grooves 1111, so that when the second winding step S109 is completed, the two wires 3A, 3B can be tightly pressed against the inner edges of the two accommodating grooves 1111 by the tension generated during winding. Thus, the two wires 3A, 3B can be fixed on the two outer protrusions 111, and again, the magnetic core 1 is most effective in the manner of Figure 4 .

[0047] A second soldering step S111 is implemented, as shown in Figure 8 , the second ends 32 of the two wires 3A, 3B are fixed to the conductive layers 2 on the two second setting platforms 131 of the second side column 13 by soldering. In practice, the soldering method used in the second soldering step S111 is the same as that used in the first soldering step S105, which is convenient for production line maintenance, but of course it can be different.

[0048] A conduction step S113 is implemented, as shown in Figure 9 , the conductive layers 2 between any one of the wires 3A, 3B and its adjacent two coupling platforms 1112 are provided with conductive materials, so that the two wires 3A, 3B are electrically coupled to the conductive layers 2 on their adjacent two coupling platforms 1112, respectively. Thus, the magnetic core structure 100 forms two windings, and when used as a transformer, the center tap is located at the first side column 12 and the second side column 13.

[0049] Further, the two wires 3A, 3B in this embodiment are straight soldering type enameled wires, so in the conduction step S113, the person only needs to use high-temperature conductive materials 6 between any one of the wires and its adjacent two coupling platforms 1112, so that the high temperature of the conductive materials 6 can directly melt the insulating layer of the two wires 3A, 3B and electrically couple each wire 3A, 3B to the conductive layers 2 on its adjacent two coupling platforms 1112.

[0050] It is worth noting that the conduction step S113 can be omitted in practice according to the situation, that is, the two wires 3A, 3B are only electrically coupled to the plurality of conductive layers 2 on the first side column 12 and the second side column 13. In addition, the conduction step S113 is different from the soldering method used in the first soldering step S105 and the second soldering step S111, and the conduction step S113 is a soldering method, but the present application is not limited thereto.

[0051] It should also be noted that, in this field, welding is the most time-consuming process, especially since the T-shaped magnetic core structure 100 requires at least three welding steps. Therefore, saving any welding step can significantly improve manufacturing efficiency. As can be seen from steps S101 to S113 of this embodiment, the manufacturing process of the magnetic core structure 100 only requires two welding steps, namely, performing only the first welding step S105 and the second welding step S111, to fix the two wires 3A and 3B to the T-shaped magnetic core 1. In other words, any manufacturing method that involves welding on the T-shaped magnetic core more than twice is not the manufacturing method referred to in this invention.

[0052] Second Embodiment

[0053] like Figure 10 and Figure 11 As shown, this is the second embodiment of the present invention. This embodiment is similar to the first embodiment described above. The similarities between the two embodiments will not be repeated. The main difference between this embodiment and the first embodiment described above is that the conduction step S113 further includes a peeling step S1131 and a soldering step S1132.

[0054] Perform a peeling step S1131, such as Figure 11 As shown, a portion of the insulation layer of the wires located in the two receiving grooves 1111 is removed by physical means, exposing a bare conductive layer 33 in each of the two wires 3A and 3B. The physical method can be laser peeling, cutting peeling, or other methods that physically remove the insulation layer 34 of the two wires 3A and 3B.

[0055] A soldering step S1132 is performed, in which the exposed conductive layers 33 of the two conductors 3A and 3B are electrically connected to the conductive layers 2 of their adjacent coupling stations 1112 by soldering. Figure 9 The magnetic core structure 100 is shown.

[0056] It should be noted that the conductors 3A and 3B in this embodiment are high-heat-resistant enameled wires, meaning that their insulation layer cannot be directly removed by high temperatures and must be removed by physical means. However, the present invention is not limited to this. For example, the two conductors 3A and 3B could also be other enameled wires whose insulation layer cannot be removed by high temperatures.

[0057] Third Embodiment

[0058] like Figures 12 to 15As shown, it is a third embodiment of the present application, which is similar to the first embodiment described above, and the same parts of the two embodiments will not be described again. The difference between the two embodiments is that the preparation step S101 of the present embodiment is different from the first embodiment, and the manufacturing method of the magnetic core structure further comprises steps S115 and S117.

[0059] In the preparation step S101, the magnetic core 1' of the present embodiment is different from the magnetic core 1 of the first embodiment. Specifically, as shown in Figure 13 As shown, each of the outer protrusions 111 of the present embodiment further comprises a cutting slot 1113, which is arranged between any two adjacent coupling platforms 1112 along the width direction D2, and the cutting slot 1113 communicates with the accommodation slot 1111, that is, any cutting slot 1113 and the accommodation slot 1111 corresponding to its position form a cross shape.

[0060] After the conduction step S113, a cutting step S115 is further implemented, as shown in Figure 14 As shown, two wires (and conductive materials located on the cutting slot 1113) are cut along the two cutting slots 1113 by a physical method, so that the two wires form four sub-wires S3. Thus, the magnetic core structure 100 forms four groups of windings, that is, two sub-wires S3 located between the first side column 12 and the two outer protrusions 111 are two of the windings, and the other two sub-wires S3 located between the two outer protrusions 111 and the second side column 13 are the other two windings. In the preferred case, the aforementioned physical method can be the same as the physical method of the second embodiment, and the laser cutting method is particularly preferred.

[0061] After the cutting step S115, a short circuit step S117 is further implemented, as shown in Figure 15 As shown, two short circuit lines 4 are respectively electrically coupled to the conductive layer 2 of the first setting platform 121 and the second setting platform 131 on the same side. That is, among the two sides of the magnetic core 1 along the width direction D2, one of the conductive layers 2 of the first setting platform 121 is short-circuited with the conductive layer 2 of the second setting platform 131 on the same side by one of the short circuit lines 4, and the other conductive layer 2 of the first setting platform 121 is short-circuited with the conductive layer 2 of the second setting platform 131 on the same side by the other short circuit line 4, so that the center tap of the magnetic core structure 100 when used as a transformer is located at the position of the two outer protrusions 111. Of course, the cutting step can also be omitted according to the manufacturing needs.

[0062] The first to third embodiments above are for the manufacturing method of the magnetic core structure 100, and the following will introduce a magnetic core structure 100 manufactured by the manufacturing method of the magnetic core structure 100 above, but the present application is not limited thereto. That is, the magnetic core structure 100 of the present embodiment can also be manufactured by other manufacturing methods.

[0063] Fourth embodiment

[0064] Referring again to Figures 1 to 9 Fig. 4, the fourth embodiment provides a magnetic core structure 100, which comprises a magnetic core 1, and a plurality of conductive layers 2 and two conductive wires 3 disposed on the magnetic core 1. The magnetic core 1 in the present embodiment comprises a winding column 11, a first side column 12 and a second side column 13 connected to both ends of the winding column 11. The following will introduce each component of the magnetic core 1 and its connection relationship.

[0065] Referring again to Figure 5 Fig. 4, the winding column 11 in the present embodiment has a body portion 112 and two outer protrusions 111 connected to the body portion 112. Specifically, each outer protrusion 111 is formed outward along the width direction D2 from both sides of the body portion 112, and the height of each outer protrusion 111 along the height direction D3 is higher than the height of the body portion 112.

[0066] It is worth noting that each outer protrusion 111 has a receiving groove 1111 and two coupling platforms 1112 located on both sides of the receiving groove 1111. In detail, each receiving groove 1111 in the present embodiment is arranged substantially along the extension direction D1, and both ends of each receiving groove 1111 are respectively directed to the first side column 12 and the second side column 13, thereby communicating the outside of the corresponding outer protrusion 111, but the present application is not limited thereto. For example, each receiving groove 1111 can be arranged obliquely relative to the extension direction D1 as shown in Figure 4 Fig. 5.

[0067] The first side column 12 and the second side column 13 are connected to both ends of the body portion 112, and the first side column 12 has two first setting platforms 121 arranged at intervals, and the second side column 13 has two second setting platforms 131 arranged at intervals. In an ideal case, the top surfaces of the two first setting platforms 121, the top surfaces of the two second setting platforms 131, and the top surfaces of the two outer protrusions 111 are coplanar, that is, the heights along the height direction D3 are the same as shown in Figure 2 Fig. 6.

[0068] The plurality of conductive layers 2 are disposed on the two first setting platforms 121, the two second setting platforms 131, and the two outer protrusions 111. Generally, the plurality of conductive layers 2 can be formed by a planar printed plating method, so the plurality of conductive layers 2 are coplanar with each other (as shown in Figure 5 The present application is not limited thereto.

[0069] The two conductive wires 3 are wound on the body portion 112, and the two ends of the two conductive wires 3 are fixed and electrically coupled to the conductive layers 2 of the two first setting platforms 121 and the conductive layers 2 of the two second setting platforms 131 by welding. When the two conductive wires 3 are disposed on the winding column 11, parts of the two conductive wires 3 are located in the two accommodating grooves 1111, and the two conductive wires 3 are limited by the inner edges of the two accommodating grooves 1111 by the tension generated by winding.

[0070] Fifth embodiment

[0071] As shown in Figure 13 and Figure 15 This is a fifth embodiment of the present application, which is similar to the fourth embodiment described above. The same parts of the two embodiments will not be described again, and the differences between the two embodiments are mainly that the total number of conductive wires in the magnetic core structure 100 in this embodiment is four, which are further defined as two first conductive wires 3A and two second conductive wires 3B. In addition, the two outer protrusions 111 in this embodiment are also different.

[0072] Specifically, as shown in Figure 13 Each of the outer protrusions 111 includes four coupling platforms 1112, a cutting groove 1113, and an accommodating groove 1111. Specifically, in each of the outer protrusions 111, the four coupling platforms 1112 are spaced apart from each other, the accommodating groove 1111 is disposed between the four coupling platforms 1112 along the extension direction D1, and the cutting groove 1113 is disposed between the four coupling platforms 1112 along the width direction D2 and communicates with the accommodating groove 1111, that is, the accommodating groove 1111 and the cutting groove 1113 together form a cross shape. Of course, the two accommodating grooves 1111 can also be skewed with respect to the extension direction D1.

[0073] The conductive layers on the two first setting platforms 121 and the two second setting platforms 131 are further defined as a first conductive layer 2A, and the conductive layers on the plurality of coupling platforms 1112 are defined as a second conductive layer 2B. It can also be understood that the plurality of first conductive layers 2A are arranged on the two first setting platforms 121 and the two second setting platforms 131, and the plurality of second conductive layers 2B are arranged on the plurality of coupling platforms 1112.

[0074] The two first wires 3 are wound on the body part 112 between the first side column 12 and the two outer protrusions 111, and parts of the two first wires 3 are arranged in the two accommodating grooves 1111. The two ends of one of the first wires 3 are electrically connected to the first conductive layer 2A and the two second conductive layers 2B of the first setting platform 121 on the same side and adjacent to each other, and the two ends of the other first wire 3 are electrically connected to the first conductive layer 2A and the two second conductive layers 2B of the first setting platform 121 on the other side and adjacent to each other.

[0075] The two second wires 3 are wound on the body part 112 between the second side column 13 and the two outer protrusions 111, and parts of the two second wires 3 are arranged in the two accommodating grooves 1111. The two ends of one of the second wires 3 are electrically connected to the first conductive layer 2A and the two second conductive layers 2B of the second setting platform 131 on the same side and adjacent to each other, and the two ends of the other second wire 3 are electrically connected to the first conductive layer 2A and the two second conductive layers 2B of the first setting platform 121 on the other side and adjacent to each other. It should be noted that the "same side" and "the other side" are the two sides of the magnetic core 1 along the width direction D2.

[0076] Technical effects of the embodiment of the present application

[0077] In summary, the magnetic core structure and the manufacturing method thereof disclosed in the embodiment of the present application can make the two wires not spread or loosen in the case of two welding steps, so as to improve the manufacturing efficiency of the magnetic core structure.

[0078] The above description is only the preferred and feasible embodiment of the present application, and is not intended to limit the protection scope of the present application. Any equivalent changes and modifications made within the scope of the patent application of the present application shall be within the protection scope of the claims of the present application.

Claims

1. A method for manufacturing a magnetic core structure, the magnetic core structure comprising a magnetic core having a winding column, a first side column and a second side column connected to two ends of the winding column, the winding column having an extending direction and a width direction perpendicular to the extending direction, and the winding column comprising a body portion and two outer protruding portions connected to the body portion, each of the outer protruding portions comprising a receiving slot and two coupling platforms located on two sides of the receiving slot, the first side column and the second side column each having two setting platforms arranged apart from each other, and each of the outer protruding portions further comprising a cutting slot arranged along the width direction between any two adjacent coupling platforms and connected to the receiving slot, the method comprising the following steps: performing a planar plating step to form a conductive layer on the two setting platforms of the first side column, the two setting platforms of the second side column, and the two coupling platforms of the two outer protruding portions by planar plating printing; performing a first soldering step to fix a first end of each of two conductive wires to the conductive layer on the two setting platforms of the first side column by soldering; performing a first winding step to wind a first portion of the body portion along the extending direction by a second end of each of the two conductive wires and through the two receiving slots, respectively; performing a second winding step to wind a second portion of the body portion along the extending direction by the second end of each of the two conductive wires; performing a second soldering step to fix the second end of each of the two conductive wires to the conductive layer on the two setting platforms of the second side column by soldering; and performing a conducting step to electrically connect the conductive layer on each of the two conductive wires to the conductive layer on two adjacent coupling platforms of the two conductive wires by a conductive material arranged between the conductive layer on each of the two conductive wires and the conductive layer on the two adjacent coupling platforms of the two conductive wires. performing a cutting step to cut the two conductive wires along the two cutting slots by a physical method to form four sub-conductive wires from the two conductive wires. The two conductive wires are straight soldering type enameled wires, and in the conducting step, a high-temperature conductive material is arranged between the conductive layer on each of the two conductive wires and the conductive layer on the two adjacent coupling platforms of the two conductive wires.

2. The method of manufacturing a magnetic core structure according to claim 1, wherein The conducting step further comprises:

3. The method of producing a magnetic core structure according to claim 1, wherein performing a peeling sub-step to remove a portion of an insulating layer of each of the two conductive wires in the two receiving slots by a physical method to expose a bare conductive layer of each of the two conductive wires; and performing a soldering sub-step to electrically connect the bare conductive layer of each of the two conductive wires to the conductive layer on two adjacent coupling platforms of the two conductive wires by soldering. After the cutting step, the method further comprises:

4. The method of producing a magnetic core structure according to claim 1, wherein performing a short circuiting step to electrically connect the conductive layer on two setting platforms located on the same side by two short circuit wires, respectively. In the peeling sub-step and the cutting step, the physical method is laser removal.

5. The method of producing a magnetic core structure according to claim 3, wherein The magnetic core structure comprises:

6. A magnetic core structure, characterized by a magnetic core comprising: ​ A winding post has an extending direction, the winding post includes a body portion and two outer protrusions connected to the body portion, each of the outer protrusions includes a receiving slot and a cutting slot, the receiving slot and the cutting slot are communicated with each other; and A first side post and a second side post are connected to two ends of the body portion along the extending direction, the first side post has two first setting platforms arranged at intervals with each other, and the second side post has two second setting platforms arranged at intervals with each other; A plurality of conductive layers are arranged on the two first setting platforms, the two second setting platforms, and the two outer protrusions; and Two wires are wound on the body portion, parts of the two wires are located in the two receiving slots respectively, two ends of one of the wires are electrically connected to the conductive layers on the first setting platforms and the second setting platforms on the same side respectively, and two ends of the other wire are electrically connected to the conductive layers on the first setting platforms and the second setting platforms on the other side respectively.

7. The magnetic core structure of claim 6, wherein, The plurality of conductive layers are coplanar with each other, and the two receiving slots are arranged at an angle with respect to the extending direction.

8. A magnetic core structure, characterized by The magnetic core structure includes: A magnetic core includes: A winding post has an extending direction, the winding post includes a body portion and two outer protrusions connected to the body portion, each of the outer protrusions has four coupling platforms, a cutting slot, and a receiving slot, the four coupling platforms are arranged at intervals with each other, and the receiving slot and the cutting slot are communicated with each other and arranged between the four coupling platforms; A first side post and a second side post are connected to two ends of the body portion along the extending direction, the first side post has two first setting platforms arranged at intervals with each other, and the second side post has two second setting platforms arranged at intervals with each other; A plurality of first conductive layers are arranged on the two first setting platforms and the two second setting platforms; A plurality of second conductive layers are arranged on the four coupling platforms of the two outer protrusions; Two first wires are wound on the body portion between the first side post and the two outer protrusions respectively, parts of the two first wires are located in the two receiving slots respectively, two ends of one of the first wires are electrically connected to the first conductive layers and the two second conductive layers of the first setting platforms on the same side and adjacent to each other respectively, and two ends of the other first wire are electrically connected to the first conductive layers and the two second conductive layers of the first setting platforms on the other side and adjacent to each other respectively; and Two second wires are wound on the body portion between the second side post and the two outer protrusions respectively, parts of the two second wires are located in the two receiving slots respectively, two ends of one of the second wires are electrically connected to the first conductive layers and the two second conductive layers of the second setting platforms on the same side and adjacent to each other respectively, and two ends of the other second wire are electrically connected to the first conductive layers and the two second conductive layers of the second setting platforms on the other side and adjacent to each other respectively.

9. The magnetic core structure of claim 8, wherein, The first conductive layers and the second conductive layers are coplanar with each other, and the two accommodating grooves are arranged obliquely relative to the extension direction.

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