A flat wire vertically wound inductor with firm welding and a packaging method thereof

Abstract

The application discloses a kind of welding firm flat wire vertical winding inductor, including frame and annular magnetic core, flat coil is wound on magnetic core along its circumferential direction, it is characterized by: the lower part of magnetic core is connected and fixed with the bottom of frame by support, the bottom of frame is provided with two groups of terminal, the two ends of flat coil are welded with two groups of terminal respectively, annular piece is fixed on the top of frame and is located directly above magnetic core, vertical locking bolt is arranged in annular piece, locking hole is formed in the top of magnetic core and is located directly below locking bolt, the lower end of locking bolt extends into locking hole, the upper end of locking bolt is welded and fixed with annular piece.The inductor, by designing additional support, the lower part of magnetic core is connected and fixed with frame by support, and the top of magnetic core is locked by locking bolt, the magnetic core and frame can be more stable and reliable, firmly fixed together, so that the inductor is not prone to magnetic core loosening or misplacement.

Description

Technical Field

[0001] This invention relates to the field of electronic and electrical technology, and more specifically, to a welded, flat wire vertically wound inductor and its packaging method. Background Technology

[0002] An inductor is a component that converts electrical energy into magnetic energy and stores it. It generally consists of a frame, windings, and a magnetic core. With the continuous development of electronic technology, various types and forms of inductors have appeared on the market, and the flat wire vertical wound inductor is one of them.

[0003] Currently, the magnetic core of flat-wire vertically wound inductors is generally toroidal. This toroidal structure makes it difficult to directly connect and fix the core to the frame. Instead, the core is indirectly positioned and stabilized by connecting the flat coil wound around it to the frame or circuit board. This fixing method is relatively ineffective at stabilizing the core. When the inductor is subjected to vibration or impact, the core and frame often shift relative to each other, causing tension at the connection points of the flat coils. This can lead to loosening or misalignment of the core, and needs improvement. Summary of the Invention

[0004] To address the shortcomings of existing technologies, the present invention aims to provide a welded flat wire vertically wound inductor and its packaging method, which can improve the stability and robustness of the connection between the magnetic core and the frame.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] A welded, firmly wound flat wire inductor includes a frame and an annular magnetic core. The magnetic core stands inside the frame, and a flat coil is wound around the magnetic core circumferentially. The lower part of the magnetic core is connected and fixed to the bottom of the frame via a bracket. Two sets of terminals are provided at the bottom of the frame, extending downward to the outside of the frame. The two ends of the flat coil are welded to the two sets of terminals respectively. An annular component is fixed at the top of the frame and directly above the magnetic core. A vertical locking bolt is installed inside the annular component. A locking hole is opened at the top of the magnetic core and directly below the locking bolt. The lower end of the locking bolt extends into the locking hole, and the upper end of the locking bolt is welded and fixed to the annular component.

[0007] As a preferred embodiment: a mounting groove is provided at the inner bottom of the frame along the front-to-back direction, the cross-sectional shape of the mounting groove is "convex", the bracket extends downward to below the magnetic core, the lower cross-sectional shape of the bracket is also "convex", and the bracket is snapped into the mounting groove.

[0008] As a preferred embodiment: two sets of transverse support plates are symmetrically arranged on both sides of the middle part of the frame. The outer ends of the support plates are connected and fixed to the frame. The inner ends of the support plates extend into the inner side of the magnetic core. A positioning post is fixed to the inner end of the support plate. The positioning post is arranged in the front-back direction. The inner side of the magnetic core is symmetrically provided with recesses. The positioning post passes through the recesses and abuts against the magnetic core.

[0009] As a preferred embodiment, the connection between the outer end of the support plate and the frame is provided with reinforcing ribs.

[0010] As a preferred embodiment, the system further includes a base plate and adjusting bolts. The base plate is located below the frame. Two sets of side pins are provided on the sides of the base plate, and two sets of bottom pins are provided at the bottom of the base plate. First connecting blocks are symmetrically arranged on both sides of the lower part of the frame, and second connecting blocks are symmetrically arranged on both sides of the base plate. The second connecting blocks are located directly below the first connecting blocks. The adjusting bolts pass through the first connecting blocks and are threaded into them. The lower end of the adjusting bolts is rotatably connected to the second connecting blocks. A vertical support plate is fixed to the top of the base plate. The support plate is elastic and located around the terminal block. A hemispherical contact protrusion is provided on the side of the terminal block facing the support plate. An arc-shaped recessed first contact piece and a second contact piece are provided on the side of the support plate facing the contact protrusion. The first contact piece is located above the second contact piece. The first contact piece is connected and conductive to the side pins, and the second contact piece is connected and conductive to the bottom pins. Both the first and second contact pieces are used to contact the contact protrusions.

[0011] As a preferred embodiment: an elastic pad is fixed to the side of the support piece facing the terminal block, and the first contact piece and the second contact piece are fixed to the elastic pad.

[0012] A method for packaging a firmly welded flat wire vertically wound inductor, applicable to the inductor, includes the following steps:

[0013] S1. Adjust the angle of the magnetic core so that the locking hole on the magnetic core faces directly upward. Sleeve the bracket and fix it to the lower part of the magnetic core, and wind the flat coil on the magnetic core.

[0014] S2. Insert the magnetic core into the frame so that the lower part of the bracket is inserted into the mounting groove at the bottom of the frame.

[0015] S3. Press down to insert the lower end of the locking bolt at the top of the frame into the locking hole at the top of the magnetic core, and weld the upper end of the locking bolt to the annular part at the top of the frame.

[0016] S4. Weld the two ends of the flat coil to the two sets of terminals on the frame respectively.

[0017] As a preferred option: Before performing step S2, align the two sets of recesses on the inner side of the magnetic core with the two sets of positioning posts in the middle of the frame, and while inserting the lower part of the bracket into the mounting groove, make the positioning posts pass through the recesses.

[0018] As a preferred option, the method also includes a pin selection step, which involves adjusting the base plate by turning the adjusting bolts to connect the flat coil to the corresponding pins based on the installation conditions the inductor will face.

[0019] Compared with the prior art, the advantages of the present invention are:

[0020] This inductor utilizes an additional support bracket to connect and secure the lower part of the magnetic core to the frame, while a locking bolt secures the top of the core. This design effectively stabilizes and positions the core in both the front-to-back and vertical directions, and the wider bracket effectively suppresses lateral torsional sway of the core. The combination of the bracket and locking bolt ensures a more stable, reliable, and secure connection between the core and the frame. The inductor's welding and encapsulation are completed simply by soldering the two ends of the flat coil to two sets of terminals and the upper end of the locking bolt to the ring-shaped component. This minimizes solder joints and ensures high structural stability and overall strength after welding and encapsulation, reducing the likelihood of core loosening or misalignment. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall structure of the inductor in Embodiment 1;

[0022] Figure 2 This is a schematic diagram of the overall structure of the inductor in Embodiment 2;

[0023] Figure 3 for Figure 2 Enlarged view of part A in the image.

[0024] Explanation of reference numerals in the attached drawings: 1. Magnetic core; 2. Frame; 3. Flat coil; 4. Bracket; 5. Mounting groove; 6. Ring-shaped part; 7. Through hole; 8. Locking bolt; 9. Locking hole; 10. Support plate; 11. Reinforcing rib; 12. Positioning post; 13. Base plate; 14. Terminal block; 15. Side pin; 16. Bottom pin; 17. First connecting block; 18. Second connecting block; 19. Adjusting bolt; 20. Support piece; 21. Elastic pad; 22. First contact piece; 23. Second contact piece; 24. Contact protrusion; 25. Wire hole; 26. First wire; 27. Second wire; 28. Receiving cavity. Detailed Implementation

[0025] Example 1:

[0026] Reference Figure 1A welded, firmly wound flat wire inductor includes a frame 2 and an annular magnetic core 1. The magnetic core 1 stands inside the frame 2. A flat coil 3 is wound around the magnetic core 1 along its circumference. A mounting groove 5 is provided at the inner bottom of the frame 2 along the front-to-back direction (the front-to-back direction is the thickness direction of the magnetic core 1). The cross-sectional shape of the mounting groove 5 is "convex". A bracket 4 is installed and fixed at the lower part of the magnetic core 1. The bracket 4 extends downward to the bottom of the magnetic core 1. The lower cross-sectional shape of the bracket 4 is also "convex", that is, the lower shape and size of the bracket 4 are adapted to the mounting groove 5.

[0027] The lower part of the bracket 4 is inserted and clamped in the mounting groove 5. The large contact friction between the bracket 4 and the mounting groove 5 can ensure that the lower part of the bracket 4 will not be relatively displaced from the mounting groove 5 when the inductor is subjected to vibration or impact.

[0028] Two sets of terminals 14 are provided at the bottom of the frame 2. The terminals 14 extend downward to the outside of the frame 2. The two ends of the flat coil 3 are respectively soldered to the two sets of terminals 14. The terminals 14 are used to connect the flat coil 3 to the external circuit, thereby connecting the inductor into the circuit.

[0029] A ring-shaped component 6 is fixed at the top of the frame 2 and directly above the magnetic core 1. The ring-shaped component 6 is made of a weldable material. A through hole 7 is provided inside the ring-shaped component 6. A vertical locking bolt 8 is installed in the through hole 7. The locking bolt 8 can move up and down in the through hole 7. The upper end of the locking bolt 8 is made of a weldable material. The main body of the locking bolt 8 is made of a non-magnetic material. A locking hole 9 is provided at the top of the magnetic core 1 and directly below the locking bolt 8. The lower end of the locking bolt 8 extends into the locking hole 9. The upper end of the locking bolt 8 is welded and fixed to the ring-shaped component 6.

[0030] This inductor, through the design of an additional bracket 4, connects and fixes the lower part of the magnetic core 1 to the frame 2, and locks the top of the magnetic core 1 with a locking bolt 8. This effectively stabilizes and positions the magnetic core 1 in both the front-to-back and vertical directions, and the relatively wide bracket 4 effectively suppresses lateral torsion of the magnetic core 1. Through the cooperation of the bracket 4 and the locking bolt 8, the magnetic core 1 and the frame 2 can be stably and reliably fixed together. The inductor can be completed by simply welding the two ends of the flat coil 3 to the two sets of terminals 14 and welding the upper end of the locking bolt 8 to the ring part 6. The number of solder joints is small, which ensures that the inductor has high structural stability and overall strength after welding and packaging, and it is not easy for the magnetic core 1 to loosen or misalign.

[0031] In this embodiment, two sets of transverse support plates 10 are symmetrically arranged on both sides of the middle part of the frame 2. The outer end of the support plate 10 is connected and fixed to the frame 2, and the inner end of the support plate 10 extends into the inner side of the magnetic core 1. A positioning post 12 is fixed at the inner end of the support plate 10. The positioning post 12 is arranged in the front-back direction. A recess is symmetrically arranged on the inner side of the magnetic core 1. The positioning post 12 passes through the recess and abuts against the magnetic core 1.

[0032] The support plate 10 and the positioning post 12 can stabilize and strengthen the middle part of the magnetic core 1, prevent the magnetic core 1 from lateral torsion when subjected to large external forces, and further improve the structural stability and robustness of the inductor.

[0033] In this embodiment, a reinforcing rib 11 is also provided at the connection between the outer end of the support plate 10 and the frame 2 to enhance the structural strength and load-bearing performance of the support plate 10.

[0034] Example 2:

[0035] Reference Figure 2 and Figure 3 In this embodiment, a base plate 13 is added based on the first embodiment. The base plate 13 is located below the frame 2. Two sets of side pins 15 are provided on the side of the base plate 13, and two sets of bottom pins 16 are provided at the bottom of the base plate 13. First connecting blocks 17 are symmetrically arranged on both sides of the lower part of the frame 2, and second connecting blocks 18 are symmetrically arranged on both sides of the base plate 13. The second connecting blocks 18 are located directly below the first connecting blocks 17.

[0036] The inductor in this embodiment also includes an adjusting bolt 19, which passes through the first connecting block 17 and is threaded into the first connecting block 17 (i.e., the first connecting block 17 has a threaded hole inside). The lower end of the adjusting bolt 19 is rotatably connected to the second connecting block 18. Turning the adjusting bolt 19 in the forward direction can drive the base plate 13 to rise, and turning the adjusting bolt 19 in the reverse direction can drive the base plate 13 to fall.

[0037] A vertical support plate 20 is fixed on the top of the base plate 13. The support plate 20 is elastic and is located around the terminal 14. A hemispherical contact bump 24 is provided on the side of the terminal 14 facing the support plate 20. A first contact plate 22 and a second contact plate 23 with an arc-shaped recess are provided on the side of the support plate 20 facing the contact bump 24. The first contact plate 22 is located above the second contact plate 23. Both the first contact plate 22 and the second contact plate 23 are made of conductive material. The first contact plate 22 is connected to the side pin 15 through the first wire 26, and the second contact plate 23 is connected to the bottom pin 16 through the second wire 27. Both the first contact plate 22 and the second contact plate 23 are used to contact the contact bump 24.

[0038] By turning the adjusting bolt 19 in the forward direction to drive the base plate 13 to rise, the support piece 20, the first contact piece 22, and the second contact piece 23 can be driven to rise synchronously, so that the contact protrusion 24 on the side of the contact terminal slides from the first contact piece 22 into the second contact piece 23, thereby connecting the flat coil 3 with the bottom pin 16. By turning the adjusting bolt 19 in the reverse direction to drive the base plate 13 to fall, the support piece 20, the first contact piece 22, and the second contact piece 23 can be driven to fall synchronously, so that the contact protrusion 24 on the side of the contact terminal slides from the second contact piece 23 into the first contact piece 22, thereby connecting the flat coil 3 with the side pin 15.

[0039] Thus, when mounting the inductor onto a circuit board or connecting it to a circuit, the side pin 15 or the bottom pin 16 can be freely selected depending on the mounting conditions, making the installation and wiring of the inductor more flexible and versatile, suitable for different mounting conditions. During packaging, the flat coil 3 can be connected to the corresponding pin to conduction according to the application scenario and mounting conditions of the inductor.

[0040] In addition, an elastic pad 21 is fixed to the side of the support piece 20 facing the terminal 14, and the first contact piece 22 and the second contact piece 23 are fixed to the elastic pad 21. The elastic pad 21 can increase the movement space and elasticity of the first contact piece 22 and the second contact piece 23, so that the contact protrusion can better contact and separate from the contact piece.

[0041] In this embodiment, a recessed receiving cavity 28 is also provided on the bottom surface of the frame 2. The receiving cavity 28 is used for the support piece 20, the first contact piece 22, and the second contact piece 23 to enter, and the wiring terminal 14 is located inside the receiving cavity 28. Adding the receiving cavity 28 makes the structure of the inductor in this embodiment more compact and reduces the space occupied.

[0042] Example 3:

[0043] A method for packaging a firmly welded flat wire vertically wound inductor, applicable to the inductor in Embodiment 2, includes the following steps:

[0044] S1. Adjust the angle of the magnetic core so that the locking hole on the magnetic core faces directly upward. Sleeve the bracket and fix it to the lower part of the magnetic core, and wind the flat coil on the magnetic core.

[0045] S2. Insert the magnetic core into the frame so that the lower part of the bracket is inserted into the mounting groove at the bottom of the frame.

[0046] S3. Press down to insert the lower end of the locking bolt at the top of the frame into the locking hole at the top of the magnetic core, and weld the upper end of the locking bolt to the annular part at the top of the frame.

[0047] S4. Weld the two ends of the flat coil to the two sets of terminals on the frame respectively.

[0048] In this embodiment, before performing step S2, the two sets of recesses on the inner side of the magnetic core are aligned with the two sets of positioning posts in the middle of the frame. While inserting the lower part of the bracket into the mounting groove, the positioning posts pass through the recesses.

[0049] This embodiment also includes a pin selection step, which involves driving the base plate to move by turning the adjusting bolt according to the installation conditions that the inductor will face, thereby connecting the flat coil to the corresponding pin for conduction.

[0050] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A welded, firmly wound flat wire inductor, comprising a frame and a toroidal magnetic core, the magnetic core standing inside the frame, with a flat coil wound around the magnetic core along its circumference, characterized in that: The lower part of the magnetic core is connected and fixed to the bottom of the frame via a bracket. The bottom of the frame is provided with two sets of terminals, which extend downward to the outside of the frame. The two ends of the flat coil are respectively welded to the two sets of terminals. An annular piece is fixed at the top of the frame and directly above the magnetic core. A vertical locking bolt is installed inside the annular piece. A locking hole is opened at the top of the magnetic core and directly below the locking bolt. The lower end of the locking bolt extends into the locking hole, and the upper end of the locking bolt is welded and fixed to the annular piece. The frame has a mounting groove at its inner bottom along the front-to-back direction. The mounting groove has a convex cross-sectional shape. The bracket extends downward to below the magnetic core. The lower part of the bracket also has a convex cross-sectional shape. The bracket is engaged in the mounting groove. Two sets of transverse support plates are symmetrically arranged on both sides of the middle part of the frame. The outer ends of the support plates are connected and fixed to the frame. The inner ends of the support plates extend into the inner side of the magnetic core. A positioning post is fixed to the inner end of the support plate. The positioning post is arranged in the front-back direction. The inner side of the magnetic core is symmetrically provided with recesses. The positioning post passes through the recesses and abuts against the magnetic core. It also includes a base plate and adjusting bolts. The base plate is located below the frame. The base plate has two sets of side pins on its sides and two sets of bottom pins on its bottom. First connecting blocks are symmetrically arranged on both sides of the lower part of the frame, and second connecting blocks are symmetrically arranged on both sides of the base plate. The second connecting blocks are located directly below the first connecting blocks. The adjusting bolts pass through the first connecting blocks and are threaded into them. The lower end of the adjusting bolts is rotatably connected to the second connecting blocks. A vertical support plate is fixed to the top of the base plate. The support plate is elastic and located around the terminal block. A hemispherical contact protrusion is provided on the side of the terminal block facing the support plate. An arc-shaped recessed first contact plate and a second contact plate are provided on the side of the support plate facing the contact protrusion. The first contact plate is located above the second contact plate. The first contact plate is connected and conductive to the side pins, and the second contact plate is connected and conductive to the bottom pins. Both the first and second contact plates are used to contact the contact protrusions.

2. The welded, firmly wound flat wire inductor according to claim 1, characterized in that: The outer end of the support plate is provided with reinforcing ribs at the connection between it and the frame.

3. The welded, firmly wound flat wire inductor according to claim 1, characterized in that: An elastic pad is fixed to the side of the support piece facing the terminal block, and the first contact piece and the second contact piece are fixed to the elastic pad.

4. A method for packaging a firmly welded flat wire vertically wound inductor, applied to the inductor of claim 1, characterized in that, Includes the following steps: S1. Adjust the angle of the magnetic core so that the locking hole on the magnetic core faces directly upward. Sleeve the bracket and fix it to the lower part of the magnetic core, and wind the flat coil on the magnetic core. S2. Insert the magnetic core into the frame so that the lower part of the bracket is inserted into the mounting groove at the bottom of the frame. S3. Press down to insert the lower end of the locking bolt at the top of the frame into the locking hole at the top of the magnetic core, and weld the upper end of the locking bolt to the annular part at the top of the frame. S4. Weld the two ends of the flat coil to the two sets of terminals on the frame respectively.

5. The packaging method for a firmly welded flat wire vertically wound inductor according to claim 4, characterized in that: Before performing step S2, align the two sets of recesses on the inside of the magnetic core with the two sets of positioning posts in the middle of the frame. While inserting the lower part of the bracket into the mounting groove, make the positioning posts pass through the recesses.

6. The packaging method for a welded, firmly wound flat wire inductor according to claim 4, characterized in that: It also includes the step of selecting pins, that is, according to the installation conditions that the inductor will face, the base plate is moved by turning the adjusting bolt, thereby connecting the flat coil with the corresponding pin to conduct electricity.

Images