High thermal conductive inductor and manufacturing method thereof

Abstract

The application discloses a high-heat-conductivity inductor and a manufacturing method thereof, which comprises a ceramic base, a flat coil one, a flat coil two, a flat coil three, a left-end ceramic fixing sheet, a middle ceramic fixing sheet and a right-end ceramic fixing sheet. Three grooves are arranged on the left, middle and right parts of the ceramic base respectively, the flat coil one, the flat coil two and the flat coil three are arranged in the three grooves respectively and the free ends of the coils are upward, the left-end ceramic fixing sheet, the middle ceramic fixing sheet and the right-end ceramic fixing sheet are respectively covered on the three grooves, the right end of the left-end ceramic fixing sheet and the left end of the right-end ceramic fixing sheet are provided with corresponding notches at the positions corresponding to the coils, and the middle ceramic fixing sheet is arranged in a front-back symmetrical mode by two ceramic fixing sheets and each ceramic fixing sheet is provided with a notch at the position corresponding to the coil. The application can realize better high-heat-conductivity, improve the heat dissipation effect and the service life of the product.

Description

Technical Field

[0001] This invention relates to a high thermal conductivity inductor and its manufacturing method, belonging to the technical field of high thermal conductivity inductors. Background Technology

[0002] Existing thick-wire inductors are basically made of thick (2mm or more) round copper wire wound around a ferrite core. When carrying a large current, the round copper wire cannot carry a large current, is prone to overheating and has poor thermal conductivity, and in severe cases, it may even burn out the product, seriously affecting its use. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a high thermal conductivity inductor and its manufacturing method, so as to solve the problems existing in the prior art.

[0004] The technical solution adopted in this invention is as follows: a high thermal conductivity inductor, comprising a ceramic base, a flat coil I, a flat coil II, a flat coil III, a left-end ceramic fixing plate, a middle ceramic fixing plate, and a right-end ceramic fixing plate. The ceramic base is provided with a horizontal semi-circular groove III, a vertical semi-circular groove II, and a horizontal semi-circular groove I in the left, middle, and right parts, respectively. The flat coil I, flat coil II, and flat coil III are respectively placed in the semi-circular groove III, semi-circular groove II, and semi-circular groove I with the free ends of the coils facing upwards. The left-end ceramic fixing plate, the middle ceramic fixing plate, and the right-end ceramic fixing plate cover the semi-circular groove III, semi-circular groove II, and semi-circular groove I, respectively. The right end of the left-end ceramic fixing plate and the left end of the right-end ceramic fixing plate are provided with corresponding notches at the coil positions. The middle ceramic fixing plate consists of two symmetrically arranged ceramic fixing plates, with a notch provided at the inner end of each ceramic fixing plate corresponding to the coil position.

[0005] Preferably, the above-mentioned semi-circular groove one, semi-circular groove two and semi-circular groove three are respectively bonded to flat coil three, flat coil two and flat coil one by applying adhesive.

[0006] Preferably, the aforementioned left-end ceramic fixing plate, middle ceramic fixing plate, and right-end ceramic fixing plate are all fixedly connected to the ceramic base by ceramic screws.

[0007] Preferably, the threaded portion of the ceramic screw is provided with a dotted adhesive layer.

[0008] Preferably, the left ceramic fixing piece, the middle ceramic fixing piece, and the right ceramic fixing piece are all provided with a dotted adhesive layer on the ceramic base.

[0009] A method for fabricating a high thermal conductivity inductor, the method comprising the following steps:

[0010] 1) Wire end treatment: Perform wire end treatment on flat coil one, flat coil two and flat coil three;

[0011] 2) Assembly: Place the flat coil one, flat coil two and flat coil three after the wire end treatment in step 1) into the ceramic base and attach them to the three grooves respectively; fix the left ceramic fixing plate, the middle ceramic fixing plate and the right ceramic fixing plate to the three grooves to obtain a high thermal conductivity inductor.

[0012] Preferably, the above-mentioned wire end processing method includes the following steps: 1.1 Stretch the second flat coil, the inductance of the second flat coil is 1.9uH~2.1uH; 1.2 For the first and third flat coils, use needle-nose pliers with tape wrapped around the tip to clamp the solder port of the free end of the coil, bend it 180° into a hook shape, and the two hooks are in the same direction; 1.3 For the second flat coil, use needle-nose pliers with tape wrapped around the tip to clamp the solder port of the free end of the coil, bend it 180° into a hook shape, and the two hooks are in opposite directions.

[0013] Preferably, the specific operation method for the above assembly is as follows: 2.1. Dispensing machine parameter settings: needle inner diameter: 1.0mm; air pressure: 80kg / cm²; time: 1s~2s; 2.2. Place the ceramic base on a horizontal workbench, apply E107HF-W glue around the ceramic base and in the three grooves for 1~2s, and use a plastic sheet to apply an appropriate amount of VK-886 thermal grease evenly to the bottom of each of the three flat coils (flat coil one, flat coil two, and flat coil three), and place the three coils in the center of the three grooves of the ceramic base; 2.3. First, take two T-shaped ceramic pieces for fixing. 2.4. Pass the second piece through the flat coil 2 and align it with the threaded hole. Then, take the first and third ceramic fixing pieces and pass them through the first and third flat coils respectively. 2.5. Take eight ceramic screws and place them into the eight threaded holes on the ceramic base and rotate them to fix the ceramic fixing pieces. Then, use a cotton swab dipped in alcohol to wipe away the excess glue and remove foreign matter from the product surface. Finally, apply E107HF-W glue to the edges of the three flat coils. 2.6. Place the cleaned assembled product on a turntable and send it to the baking oven for baking. Baking temperature: 125℃±10℃, baking time: 90±10 minutes.

[0014] The beneficial effects of the present invention are as follows: Compared with the prior art, the present invention uses a flat coil that can withstand high current, a ceramic base with high thermal conductivity, and thermal grease with good thermal conductivity for better and more efficient heat dissipation. The present invention can achieve better thermal conductivity, improve heat dissipation effect and product lifespan. Attached Figure Description

[0015] Figure 1 This is a three-dimensional structural schematic diagram of the present invention;

[0016] Figure 2 This is a top view of the ceramic base structure.

[0017] Figure 3 This is a schematic diagram of the front view of the ceramic base;

[0018] Figure 4 This is a schematic diagram of the ceramic base from the left. Detailed Implementation

[0019] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0020] Example 1: As Figure 1-4 As shown, a high thermal conductivity inductor includes a ceramic base 1, a flat coil 1 2, a flat coil 2 3, a flat coil 3 4, a left-end ceramic fixing plate 5, a middle ceramic fixing plate 6, and a right-end ceramic fixing plate 7. The ceramic base 1 has a horizontal semi-circular groove 3 10, a vertical semi-circular groove 2 9, and a horizontal semi-circular groove 1 8 respectively in the left, middle, and right parts. The flat coil 1 2, flat coil 2 3, and flat coil 3 4 are respectively placed in the semi-circular groove 3 10, semi-circular groove 2 9, and semi-circular groove 1 8 with the free ends of the coils facing upwards. The left-end ceramic fixing plate 5, the middle ceramic fixing plate 6, and the right-end ceramic fixing plate 7 cover the semi-circular groove 3 10, semi-circular groove 2 9, and semi-circular groove 1 8 respectively. The right end of the left-end ceramic fixing plate 5 and the left end of the right-end ceramic fixing plate 7 are provided with corresponding notches at the coil positions. The middle ceramic fixing plate 6 consists of two symmetrical ceramic fixing plates arranged opposite each other, and each ceramic fixing plate has a notch at the inner end corresponding to the coil position.

[0021] Preferably, the semi-circular groove 1 8, semi-circular groove 2 9 and semi-circular groove 3 10 are all bonded to the flat coil 3 4, flat coil 2 3 and flat coil 1 2 respectively by applying adhesive.

[0022] Preferably, the left ceramic fixing piece 5, the middle ceramic fixing piece 6, and the right ceramic fixing piece 7 are all fixedly connected to the ceramic base 1 by ceramic screws 11.

[0023] Preferably, the threaded portion of the ceramic screw 11 is provided with a dotted adhesive layer.

[0024] Preferably, the left ceramic fixing piece 5, the middle ceramic fixing piece 6, and the right ceramic fixing piece 7 are all provided with a dotted adhesive layer on the ceramic base 1.

[0025] Example 2: A method for manufacturing a high thermal conductivity inductor, the method comprising the following steps:

[0026] 1) Wire end treatment: Perform wire end treatment on flat coil one, flat coil two and flat coil three;

[0027] The wire end processing method includes the following steps: 1.1 Stretch the second flat coil, ensuring that the inductance of the second flat coil meets the requirement of 1.9uH~2.1uH; 1.2 For the first and third flat coils, use needle-nose pliers with tape wrapped around the tip to clamp the solder port of the free end of the coil, bend it 180° into a hook shape, and ensure that the two hooks are in the same direction; 1.3 For the second flat coil, use needle-nose pliers with tape wrapped around the tip to clamp the solder port of the free end of the coil, bend it 180° into a hook shape, and ensure that the two hooks are in opposite directions.

[0028] 2) Assembly: Place the flat coil one, flat coil two and flat coil three after the wire end treatment in step 1) into the ceramic base and attach them to the three grooves respectively; fix the left ceramic fixing plate, the middle ceramic fixing plate and the right ceramic fixing plate to the three grooves to obtain a high thermal conductivity inductor;

[0029] The specific assembly operation method is as follows: 2.1. Dispensing machine parameter settings: needle inner diameter: 1.0mm; air pressure: 80kg / cm²; time: 1s~2s; 2.2. Place the ceramic base on a horizontal workbench, apply E107HF-W glue around the ceramic base and into the three grooves for 1~2s. Apply an appropriate amount of VK-886 thermal grease evenly to the bottom of each of the three flat coils (flat coil one, flat coil two, and flat coil three) using a plastic sheet, and place the three coils in the center of the three grooves of the ceramic base; 2.3. First, take two T-shaped ceramic fixing plates and insert them... 1. Pass the flat coil 2 through the threaded hole, then take ceramic fixing plate 1 and ceramic fixing plate 3 and pass them through flat coil 1 and flat coil 3 respectively; 2.4. Take eight ceramic screws and place them into the eight threaded holes on the ceramic base and rotate them to fix the ceramic fixing plates. Then, use a cotton swab dipped in alcohol to wipe away the excess glue and remove foreign matter from the product surface. Finally, apply E107HF-W glue to the edges of the three flat coils; 2.5. Place the cleaned assembled product on a turntable and send it to the baking oven for baking. Baking temperature: 125℃±10℃, baking time: 90±10 minutes;

[0030] 3) Temperature shock procedure: 1. The product is placed in a product tray and sent to the reliability laboratory for temperature shock test; 2. Test conditions: Temperature shock range: -55℃~+105℃, extreme temperature test time: 15min, intermediate transition time: ≤5min, cycle: 5 cycles; 3. After the test, the product should be allowed to recover at room temperature for 1~2 hours before testing.

[0031] 4) Testing: 1. Test items: A. Ls: 100% determination;

[0032] 2. Test conditions and test instruments: Ls: 100kHz / 0.1V, HP4285A or equivalent instrument, SLXD-C405, SLXD-C442, SLXD-C407 or equivalent 1m fixture;

[0033] 3. Testing Methods:

[0034] A. The test fixture must be in full contact with the end of the product to be tested before reading the value;

[0035] B. Determine whether the product is good or defective based on whether the values ​​displayed by the testing instrument are within the acceptable range;

[0036] C. Defective products should be promptly removed and clearly labeled with the identified defective items.

[0037] 4. No tolerance control is implemented within Ls.

[0038] 5) External Inspection: 1. Check for any damage or chips in the product; 2. Check for any cracks in the product;

[0039] 6) Packaging: 1. Place the product on VSCN7336 antistatic pearl cotton (which has a matching ceramic base and a groove for placing the entire product), with the product facing the same direction; 2. Seal the product with another layer of VSCN7336 antistatic pearl cotton and secure it with transparent tape.

[0040] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of protection of the claims.

Claims

1. A high thermal conductivity inductor, characterized in that: The system includes a ceramic base (1), a flat coil one (2), a flat coil two (3), a flat coil three (4), a left-end ceramic fixing plate (5), a middle ceramic fixing plate (6), and a right-end ceramic fixing plate (7). The ceramic base (1) has a horizontal semi-circular groove three (10), a vertical semi-circular groove two (9), and a horizontal semi-circular groove one (8) respectively on the left, middle, and right sides. The flat coil one (2), flat coil two (3), and flat coil three (4) are placed in the semi-circular groove three (10), semi-circular groove two (9), and semi-circular groove one (8) respectively, with the free ends of the coils facing upwards. The left-end ceramic fixing plate (5), the middle ceramic fixing plate (6), and the right-end ceramic fixing plate (7) respectively cover the semi-circular grooves. On groove three (10), semi-circular groove two (9) and semi-circular groove one (8), the right end of the left ceramic fixing piece (5) and the left end of the right ceramic fixing piece (7) are provided with corresponding notches at the coil positions. The middle ceramic fixing piece (6) adopts two ceramic fixing pieces arranged symmetrically front and back, and each ceramic fixing piece is provided with a notch at the coil position at the inner end. The semi-circular groove one (8), semi-circular groove two (9) and semi-circular groove three (10) are all glued to the flat coil three (4), flat coil two (3) and flat coil one (2) respectively. The left ceramic fixing piece (5), the middle ceramic fixing piece (6) and the right ceramic fixing piece (7) are all fixedly connected to the ceramic base (1) by ceramic screws (11).

2. The high thermal conductivity inductor according to claim 1, characterized in that: The threaded portion of the ceramic screw (11) is provided with a layer of adhesive.

3. The high thermal conductivity inductor according to claim 1, characterized in that: The left ceramic fixing plate (5), the middle ceramic fixing plate (6) and the right ceramic fixing plate (7) are all provided with a dotted adhesive layer on the ceramic base (1).

4. A method for manufacturing a high thermal conductivity inductor according to any one of claims 1-3, characterized in that: The method includes the following steps: 1) Wire end treatment: Perform wire end treatment on flat coil one, flat coil two and flat coil three; 2) Assembly: Place the flat coil one, flat coil two and flat coil three after the wire end treatment in step 1) into the ceramic base and attach them to the three grooves respectively; fix the left ceramic fixing plate, the middle ceramic fixing plate and the right ceramic fixing plate to the three grooves to obtain a high thermal conductivity inductor.

5. The method for manufacturing a high thermal conductivity inductor according to claim 4, characterized in that: The wire end processing method includes the following steps: 1.1 Stretch the second flat coil, the inductance of the second flat coil is 1.9uH~2.1uH; 1.2 For the first and third flat coils, use needle-nose pliers with tape wrapped around the tip to clamp the solder port of the free end of the coil, bend it 180° into a hook shape, and the two hooks are in the same direction; 1.3 For the second flat coil, use needle-nose pliers with tape wrapped around the tip to clamp the solder port of the free end of the coil, bend it 180° into a hook shape, and the two hooks are in opposite directions.

6. The method for manufacturing a high thermal conductivity inductor according to claim 4, characterized in that: The specific assembly operation method is as follows: 2.1 Dispensing machine parameter settings: needle inner diameter: 1.0mm; air pressure: 80kg / cm²; Time: 1s~2s; 2.2 Place the ceramic base on a horizontal workbench. Apply E107HF-W glue for 1~2s around the ceramic base and into the three grooves. Apply an appropriate amount of VK-886 thermal grease evenly to the bottom of each of the three flat coils using a plastic sheet. Place the three coils in the center of the three grooves on the ceramic base. 2.3 First, take two T-shaped ceramic fixing plates and pass them through the flat coil 2, aligning them with the threaded holes. Then, take ceramic fixing plates 1 and 3 and pass them through the flat coil 1 and flat coil 3 respectively. 2.4 Take eight ceramic screws and place them into the eight threaded holes on the ceramic base. Rotate the screws to fix the ceramic fixing plates. Then, use an alcohol-soaked cotton swab to wipe away any excess glue and remove any foreign matter from the product surface. Finally, apply E107HF-W glue to the edges of the three flat coils. 2.5 Place the cleaned assembled product on a turntable and place it in an oven for baking. Baking temperature: 125℃±10℃, baking time: 90±10 minutes.

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