Magnetic device

Abstract

The application relates to the technical field of magnetic devices, and discloses a magnetic device which comprises a magnetic core, a magnetic cover plate, windings and metal terminals; the magnetic core comprises a middle column and a side end plate, the magnetic cover plate is connected to the magnetic core, the windings are arranged on the middle column, each winding has a winding lead connector, the metal terminals are connected to the side end plate, a first functional groove is arranged on the side of the side end plate away from the magnetic cover plate, the first functional groove is located between adjacent metal terminals, the winding lead connector is electrically connected to the metal terminal through the first functional groove, a second functional groove is arranged on the side end plate, the metal terminal is bonded in the second functional groove, one side of the metal terminal is provided with a first connecting pin which faces the side end plate, two sides of the side end plate are provided with first matching grooves which are connected to and communicate with the second functional groove, and the first connecting pin is connected in the first matching groove. The application improves the structural reliability of the magnetic device, reduces the magnetic leakage of the magnetic device, avoids the loss of the magnetic field, and optimizes the performance of the magnetic device.

Description

Technical Field

[0001] This application relates to the field of magnetic device technology, and specifically to a magnetic device. Background Technology

[0002] Magnetic devices are widely used in the automotive industry to handle power filtering and power conversion, helping to reduce common-mode noise in power lines and ensure the normal operation of electronic devices in automobiles. They also effectively reduce electromagnetic interference through their application in automotive cables and signal lines, helping automotive systems meet electromagnetic compatibility standards. However, in the actual operating conditions of automobiles, the accompanying mechanical vibrations, uncertain mechanical shocks, operating temperatures ranging from -50℃ to +150℃, as well as various humidity conditions, salt spray conditions, and altitudes, pose significant challenges to the reliable operation of magnetic devices in related technologies. In order to better meet the requirements of the automotive environment for magnetic devices, it is necessary to design a magnetic device with excellent reliability. Summary of the Invention

[0003] In view of this, this application provides a magnetic device to improve the reliability of magnetic devices.

[0004] To achieve the above objectives, the technical solution adopted is as follows:

[0005] A magnetic device includes: a magnetic core, including a central column and side end plates connected to both ends of the central column; a magnetic cover plate, connected to the magnetic core and forming a closed magnetic circuit with the magnetic core; windings, wound on the central column according to a preset rule, each winding having a winding lead; and metal terminals, arranged opposite each other and maintained at a certain interval, connected to the side end plates; wherein, a first functional slot is formed on the side of the side end plate away from the magnetic cover plate, and the first functional slot is located between adjacent metal terminals, the winding lead is electrically connected to the metal terminal through the first functional slot, a second functional slot is formed on the side end plate, the metal terminal is bonded to the second functional slot, a first connecting foot is provided on one side of the metal terminal facing the side end plate, and first mating slots connected and communicating with the second functional slots are formed on both sides of the side end plate, the first connecting foot being connected to the first mating slot.

[0006] This application is further configured such that: a second connecting foot is provided on the other side of the metal terminal facing the side end plate, and a second mating groove is provided on the side end plate at a position corresponding to the second connecting foot, and the second connecting foot is connected in the second mating groove.

[0007] This application is further configured such that: a third functional slot is provided on the side of the side end plate away from the magnetic cover plate, which is connected and communicates with the second functional slot; a third connecting foot is provided on the metal terminal and at the position corresponding to the third functional slot; the third connecting foot is matched in the third functional slot and protrudes from the side end plate.

[0008] This application is further configured such that the first connecting pin, the second connecting pin, and the third connecting pin are integrally formed with the metal terminal and are all perpendicular to the metal terminal.

[0009] This application is further configured such that: each of the metal terminals is integrally connected with a welding part, and the winding lead is fixed to the adjacent welding part after passing through the first functional groove to form an electrical connection.

[0010] This application is further configured such that: a first adhesive layer for fixed connection is provided between the side end plate and the metal terminal, and a mating through hole is provided at the connection between the second connecting foot and the metal terminal, and the first adhesive layer extends into the first mating groove, the second mating groove and the mating through hole respectively.

[0011] This application is further configured such that: a second adhesive layer for fixed connection is provided between the magnetic cover plate and the side end plate; a first auxiliary groove is provided on both sides of the side end plate; a second auxiliary groove is provided on the side of the magnetic cover plate and at a position corresponding to the first auxiliary groove; the first auxiliary groove and the second auxiliary groove are connected and communicate with each other; and the second adhesive layer extends into the first auxiliary groove and the second auxiliary groove respectively.

[0012] This application is further configured such that: a third auxiliary groove is provided on the side of the side end plate near the magnetic cover plate, and the third auxiliary groove is located between adjacent metal terminals; a fourth auxiliary groove is provided on the magnetic cover plate at a position corresponding to the third auxiliary groove; the third auxiliary groove and the fourth auxiliary groove are connected and communicate with each other; and the second adhesive layer extends into the third auxiliary groove and the fourth auxiliary groove respectively.

[0013] This application further specifies that the cross-sectional profile of the first auxiliary groove, the second auxiliary groove, the third auxiliary groove, or the fourth auxiliary groove is arc-shaped, sawtooth-shaped, triangular, or wedge-shaped.

[0014] This application further specifies that: the integrally connected central column and the side end plate form an I-shaped structure, the portion of the side end plate protruding from the central column forms a side leg wall, and the height of the side leg wall relative to the central column is greater than the height of the winding relative to the central column.

[0015] In summary, compared with the prior art, this application discloses a magnetic device in which a magnetic cover plate is connected to a magnetic core and forms a closed magnetic circuit with the magnetic core. The winding is wound on the central column of the magnetic core according to a preset rule. Metal terminals are arranged opposite each other and at a certain interval on the side end plates at both ends of the central column. The side end plate away from the magnetic cover plate has a first functional slot located between adjacent metal terminals. The winding leads at both ends of each layer of winding are electrically connected to the metal terminals through the first functional slot, and the metal terminals are bonded to the second functional slot on the side end plate. The first connecting pin of the metal terminal is connected to the first mating slot on both sides of the side end plate. That is, through the above configuration, this application improves the structural reliability of the magnetic device and optimizes the overall performance of the magnetic device. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of this application, 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 this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the overall structure of the magnetic device in this embodiment;

[0018] Figure 2 This is a schematic diagram of the first side view structure of the magnetic device in this embodiment;

[0019] Figure 3 This is a schematic diagram of the second side view structure of the magnetic device in this embodiment.

[0020] Reference numerals: 1. Magnetic core; 11. Central column; 12. Side end plate; 13. First functional slot; 14. First mating slot; 15. Second mating slot; 16. Third functional slot; 17. First auxiliary slot; 18. Third auxiliary slot; 2. Winding; 21. Winding lead; 3. Metal terminal; 31. First connecting foot; 32. Second connecting foot; 33. Third connecting foot; 34. Welding part; 35. Mating through hole; 4. Magnetic cover plate; 41. Second auxiliary slot; 42. Fourth auxiliary slot; 51. First adhesive layer; 52. Second adhesive layer; 6. Second functional slot; 7. Side leg wall. Detailed Implementation

[0021] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numerals in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this application as detailed in the appended claims.

[0022] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes that element. Furthermore, components, features, and elements with the same names in different embodiments of this application may have the same meaning or different meanings, the specific meaning of which must be determined by its interpretation in that specific embodiment or further in conjunction with the context of that specific embodiment.

[0023] It should be understood that the specific embodiments described herein are merely illustrative of this application and are not intended to limit this application.

[0024] In the following description, the use of suffixes such as "module," "part," or "unit" to denote elements is solely for the purpose of illustrative purposes and has no specific meaning in itself. Therefore, "module," "part," or "unit" may be used interchangeably.

[0025] In the description of this application, it should be noted that the terms "upper," "lower," "left," "right," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on this application. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0026] The technical solutions shown in this application will be described in detail below through specific embodiments. It should be noted that the order of description of the following embodiments is not intended to limit the priority of the embodiments.

[0027] As described in the background section, magnetic devices are widely used in automotive systems. However, in the actual operating conditions of automobiles, there are mechanical vibrations, uncertain mechanical shocks, operating temperatures ranging from -50℃ to +150℃, as well as various humidity conditions, salt spray conditions, and altitudes. Magnetic devices in related technologies do not possess the reliability required to handle these conditions, thus failing to guarantee a good service life. Based on this, this embodiment discloses a magnetic device.

[0028] Please refer to Figure 1 , Figure 2 as well as Figure 3 The magnetic device in this embodiment may include a magnetic core 1, a winding 2, a metal terminal 3, and a magnetic cover plate 4.

[0029] Specifically, the magnetic core 1 includes a central column 11 and side end plates 12 connected to both ends of the central column 11. The windings 2 are wound on the central column 11 according to a preset rule, and each winding 2 has a winding lead 21 at both ends. The metal terminals 3 are arranged opposite each other and at a certain interval on the side end plates 12. The winding lead 21 is electrically connected to the metal terminals 3. The magnetic cover plate 4 is connected to the magnetic core 1 and forms a closed magnetic circuit with the magnetic core 1.

[0030] In the specific implementation process, the side end plate 12 is provided with a first functional slot 13 on the side away from the magnetic cover plate 4, and the first functional slot 13 is located between adjacent metal terminals 3. The winding lead 21 is electrically connected to the metal terminal 3 through the first functional slot 13. By limiting the position of the first functional slot 13, the winding lead 21 of each winding 2 can pass through the first functional slot 13 at the same end and be connected to the metal terminal 3, thereby optimizing the structural processing of the magnetic core 1 and improving the cost performance of the magnetic device.

[0031] Furthermore, a second functional groove 6 is provided on the side end plate 12, and the metal terminal 3 is bonded to the second functional groove 6. The outline shape of the metal terminal 3 can match the groove shape of the second functional groove 6 so as to facilitate the fixed connection between the metal terminal 3 and the magnetic core 1.

[0032] The metal terminal 3 has a first connecting foot 31 facing the side end plate 12 on one side. The side end plate 12 has a first mating groove 14 on both sides that connects and communicates with the second functional groove 6. The first connecting foot 31 is connected in the first mating groove 14. Through the structural design of the second functional groove 6 and the first mating groove 14, the metal terminal 3 is fixedly connected to the side end plate 12 through the first connecting foot 31, thereby making the metal terminal 3 and the magnetic core 1 firmly connected as a whole, thus improving the structural reliability of the magnetic device.

[0033] On the other hand, in order to further strengthen the stable connection between the metal terminal 3 and the magnetic core 1, a second connecting foot 32 facing the side end plate 12 is provided on the other side of the metal terminal 3. A second mating groove 15 is provided on the side end plate 12 and at the position corresponding to the second connecting foot 32. The second connecting foot 32 is connected in the second mating groove 15. The second mating groove 15 can be located in the second functional groove 6 as a settling groove.

[0034] In this embodiment, the side end plate 12 away from the magnetic cover plate 4 is also provided with a third functional slot 16 that is connected and communicates with the second functional slot 6. A third connecting foot 33 is provided on the metal terminal 3 at the position corresponding to the third functional slot 16. The third connecting foot 33 is matched in the third functional slot 16 and protrudes from the side end plate 12 so that the magnetic device can be externally connected through the third connecting foot 33.

[0035] The third connecting pins 33 are located on the same plane and can be kept parallel to the side end plate 12 to facilitate the external installation of magnetic devices.

[0036] It should be noted that the first connecting pin 31, the second connecting pin 32 and the third connecting pin 33 are integrally formed with the metal terminal 3 and are all perpendicular to the metal terminal 3, so that the metal terminal 3 can be conveniently and reliably assembled on the magnetic core 1.

[0037] In the specific implementation process, each metal terminal 3 is integrally connected with a welding part 34. After the winding lead 21 passes through the first functional groove 13, it is fixed to the adjacent welding part 34 respectively, so as to facilitate the electrical connection between the winding lead 21 and the metal terminal 3. The fixing method here can be laser welding or hard pressure welding.

[0038] The end of the welding part 31 away from the metal terminal 3 can also be set in a spherical structure, so as to ensure that the winding connector 21 can be easily and quickly wound on the welding part 31, and the smooth spherical structure can also prevent the winding connector 21 from being scratched. That is, through the end set in the spherical structure, it is ensured that the winding connector 21 can be neatly and evenly applied to the welding part 31.

[0039] It should be noted that the winding connector 21 is led out from both ends of the winding 2. Taking two stacked windings 2 as an example, the windings 2 at the same end can lead out two winding connectors 21 of different layers. These two winding connectors 21 pass through the same first functional slot 13 and are wound one-to-one with the symmetrically arranged welding parts 31 to facilitate welding and fixing in subsequent processes and the construction of coil loops.

[0040] It is understandable that the metal terminals 3 on the side end plate 12 are arranged opposite each other and maintain a certain distance to avoid accidental contact between adjacent metal terminals 3. The winding 2 is wound according to a preset rule. The preset rule may be to select several windings 2 with the same winding direction, or to adopt an alternating direction design to reduce leakage inductance; or to specify the number of layers of the winding 2, the winding density of the winding 2, and the wire material used for the winding 2, etc.

[0041] In the specific implementation process, a first adhesive layer 51 for fixed connection is provided between the side end plate 12 and the metal terminal 3. Furthermore, a mating through hole 35 is provided at the connection between the second connecting foot 32 and the metal terminal 3. The first adhesive layer 51 extends into the mating through hole 35 so as to ensure a stable connection between the metal terminal 3 and the magnetic core 1 through the first adhesive layer 51.

[0042] In order to further strengthen the stable connection between the metal terminal 3 and the magnetic core 1, the first adhesive layer 51 can also be extended into the first mating groove 14 and the second mating groove 15 respectively.

[0043] In this embodiment, a second adhesive layer 52 for fixed connection is provided between the magnetic cover plate 4 and the side end plate 12. Specifically, an embedded groove can be provided on the side of the side end plate 12 facing the magnetic cover plate 4, and / or on the side of the magnetic cover plate 4 facing the side end plate 12, so as to accommodate the second adhesive layer 52 through the embedded groove, thereby ensuring the fixed connection between the side end plate 12 and the magnetic cover plate 4.

[0044] Furthermore, a first auxiliary groove 17 is provided on both sides of the side end plate 12, and a second auxiliary groove 41 is provided on the side of the magnetic cover plate 4 at a position corresponding to the first auxiliary groove 17. The first auxiliary groove 17 and the second auxiliary groove 41 are connected and communicate with each other. The second adhesive layer 52 extends into the first auxiliary groove 17 and the second auxiliary groove 41 respectively. In this way, the magnetic cover plate 4 and the magnetic core 1 are firmly connected as a whole through the second adhesive layer 52, thereby improving the structural reliability of the magnetic device.

[0045] On the other hand, combining Figure 2 A third auxiliary groove 18 can be provided on the side of the side plate 12 near the magnetic cover plate 4, and the third auxiliary groove 18 is located between adjacent metal terminals 3. A fourth auxiliary groove 42 is provided on the magnetic cover plate 4 at the position corresponding to the third auxiliary groove 18. The third auxiliary groove 18 and the fourth auxiliary groove 42 are connected and communicate with each other. The second adhesive layer 52 extends into the third auxiliary groove 18 and the fourth auxiliary groove 42 respectively, that is, the second adhesive layer 52 further strengthens the stable connection between the magnetic cover plate 4 and the magnetic core 1.

[0046] It should be noted that the third auxiliary slot 18 can correspond to the first functional slot 13 in position. That is, the mating position of the magnetic cover plate 4 and the magnetic core 1 can be calibrated through the third auxiliary slot 18 to prevent accidental displacement or offset of the magnetic cover plate 4, thereby ensuring the integrity of the overall structure of the magnetic device.

[0047] In this embodiment, the cross-sectional contours of the first auxiliary groove 17, the second auxiliary groove 41, the third auxiliary groove 18, or the fourth auxiliary groove 42 are arc-shaped, sawtooth-shaped, triangular, or wedge-shaped to ensure sufficient contact between the first adhesive layer 51 and the second adhesive layer 52 and the fixed bonding after contact, thereby ensuring the overall connection stability of the magnetic device.

[0048] It should be noted that the integrally connected central column 11 and side end plate 12 form an I-shaped structure, and the part of the side end plate 12 protruding from the central column 11 forms the side leg wall 7. The height of the side leg wall 7 relative to the central column 11 is greater than the height of the winding 2 relative to the central column 11, so as to facilitate the winding of the winding 2 and also to facilitate the construction of the closed magnetic circuit of the magnetic cover plate 4 and the magnetic core 1.

[0049] Furthermore, the third connecting foot 33 in this embodiment can be extended to be flush with the side leg wall 7. Based on the structural design of the side leg wall 7, the magnetic device in this embodiment can prevent magnetic field loss and reduce magnetic leakage of the magnetic core 1, thereby reducing the impact on surrounding electromagnetically sensitive devices during actual operation and thus improving the overall performance of the magnetic device.

[0050] In this embodiment, both the magnetic core 1 and the magnetic cover plate 4 are made of magnetic materials. These magnetic materials can include one or more of ferrite materials, magnetic metal alloy materials, iron-silicon alloy materials, or soft magnetic materials to meet the working requirements of the magnetic device.

[0051] In this embodiment, the central column 11 can be designed as a rectangular structure to facilitate the stacking of the windings 2, thereby providing more winding space. The edges and corners of the rectangular body can also be used to adjust the magnetic field distribution of the magnetic device, which helps to optimize the performance of the inductor and makes it easier to process and manufacture in the production process.

[0052] In summary, this application discloses a magnetic device in which a magnetic cover plate 4 is connected to a magnetic core 1 and forms a closed magnetic circuit with the magnetic core 1. A winding 2 is wound on the central column 11 of the magnetic core 1 according to a preset rule. Metal terminals 3 are arranged opposite each other and at certain intervals on the side end plates 12 at both ends of the central column 11. The side end plate 12 has a first functional slot 13 on the side away from the magnetic cover plate 4, located between adjacent metal terminals 3. The winding leads 21 at both ends of each layer of winding 2 are electrically connected to the metal terminals 3 through the first functional slot 13. The metal terminals 3 are bonded to the second functional slot 6 on the side end plate 12. The metal terminals 3 are adapted to the first mating slot 14, the second mating slot 15, and the third functional slot 16 of the side end plate 12 through the first connecting foot 31, the second connecting foot 32, and the third connecting foot 33. With the reinforcement of the first adhesive layer 51 and the second adhesive layer 52, the overall structural reliability of the magnetic device is improved, thereby improving the comprehensive performance of the magnetic device.

[0053] The present application has been described in detail above. Specific examples have been used to illustrate the principles and implementation methods of the present application. The description of the above embodiments is only for the purpose of helping to understand the core ideas of the present application. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of the present application. Therefore, the content of this specification should not be construed as a limitation of the present application.

Claims

1. A magnetic device, characterized in that, include: A magnetic core, including a central post and side end plates connected to both ends of the central post; A magnetic cover plate is connected to the magnetic core and forms a closed magnetic circuit with the magnetic core. The windings are wound on the central column according to a preset rule, and each winding has a winding lead. Metal terminals are connected to the side end plate, which are arranged opposite each other and maintained at a distance. The side end plate has a first functional slot on the side opposite to the magnetic cover plate, and the first functional slot is located between adjacent metal terminals. The winding lead is electrically connected to the metal terminal through the first functional slot. The side end plate has a second functional slot, and the metal terminal is bonded to the second functional slot. One side of the metal terminal has a first connecting foot facing the side end plate. The two sides of the side end plate have first mating slots that connect and communicate with the second functional slot. The first connecting foot is connected to the first mating slot. The other side of the metal terminal has a second connecting foot facing the side end plate. The side end plate has a second mating slot at a position corresponding to the second connecting foot. The second connecting foot is connected to the second mating slot. The second mating slot is located in the second functional slot as a settling groove.

2. The magnetic device as described in claim 1, characterized in that, The side end plate, away from the magnetic cover plate, also has a third functional slot that is connected and communicates with the second functional slot. A third connecting foot is provided on the metal terminal at a position corresponding to the third functional slot. The third connecting foot is matched in the third functional slot and protrudes from the side end plate.

3. The magnetic device as described in claim 2, characterized in that, The first connecting pin, the second connecting pin, and the third connecting pin are integrally formed with the metal terminal and are all perpendicular to the metal terminal.

4. The magnetic device as described in claim 1, characterized in that, Each of the metal terminals is integrally connected to a welding part, and the winding lead is fixed to the adjacent welding part after passing through the first functional slot to form an electrical connection.

5. The magnetic device as described in claim 1, characterized in that, A first adhesive layer for fixed connection is provided between the side end plate and the metal terminal. A mating through hole is provided at the connection between the second connecting foot and the metal terminal. The first adhesive layer extends into the first mating groove, the second mating groove and the mating through hole respectively.

6. The magnetic device as described in claim 1, characterized in that, A second adhesive layer for fixed connection is provided between the magnetic cover plate and the side end plate. A first auxiliary groove is also provided on both sides of the side end plate. A second auxiliary groove is provided on the side of the magnetic cover plate and at a position corresponding to the first auxiliary groove. The first auxiliary groove and the second auxiliary groove are connected and communicate with each other. The second adhesive layer extends into the first auxiliary groove and the second auxiliary groove respectively.

7. The magnetic device as described in claim 6, characterized in that, A third auxiliary groove is provided on the side of the side end plate near the magnetic cover plate, and the third auxiliary groove is located between adjacent metal terminals. A fourth auxiliary groove is provided on the magnetic cover plate at a position corresponding to the third auxiliary groove. The third auxiliary groove and the fourth auxiliary groove are connected and communicate with each other. The second adhesive layer extends into the third auxiliary groove and the fourth auxiliary groove respectively.

8. The magnetic device as described in claim 7, characterized in that, The cross-sectional profiles of the first auxiliary groove, the second auxiliary groove, the third auxiliary groove, or the fourth auxiliary groove are arc-shaped, sawtooth-shaped, triangular, or wedge-shaped.

9. The magnetic device according to any one of claims 1 to 8, characterized in that, The integrally connected central column and the side end plate form an I-shaped structure. The portion of the side end plate protruding from the central column forms a side leg wall. The height of the side leg wall relative to the central column is greater than the height of the winding relative to the central column.

Images