A flat wire double wire cross winding process and coupled inductor prepared by the process

Abstract

The invention discloses a flat wire double-wire cross-lap winding process and a coupled inductor prepared therefrom, and relates to the technical field of flat wire double-wire cross-lap winding, and includes the following steps: Step 1: Wind two flat wires in the same direction around a winding jig, and start winding the double wires at the same time, and adjust the height of the winding center axis according to the wire thickness; Step 2: The winding jig includes an upper mold and a lower mold, and when the upper mold and the lower mold are in an open mold state, the wire feeding system starts to feed the wire toward the lower mold, and after the wire feeding is completed, the upper mold descends, and in this process the flat wire is fixed between the winding center axis and the fixed pin, and after the upper and lower molds are closed, the upper mold starts to rotate clockwise, and the flat wire is cut after reaching the set number of turns, and after the upper mold rotates counterclockwise, the pulling force on the lead-out end of the flat wire is removed, and the flat wire double-wire stacked coil can be obtained. The invention creates a flat wire double-wire stacking technology, which realizes the simultaneous cross-lapping of the flat wire double wires to improve the magnetic coupling coefficient of the two coils, which is as high as 97% or more. At the same time, automatic winding can be realized, and production efficiency is improved.

Description

Technical Field

[0001] The invention relates to the technical field of double-wire cross-winding of flat wires, and in particular to a double-wire cross-winding process of flat wires and a coupled inductor prepared therefrom. Background Art

[0002] Inductors are key components in various multiphase topologies. Using two single inductors is basically sufficient for most applications, but coupled inductors can significantly reduce the size and improve the efficiency of the circuit. In a coupled inductor, two windings are wound on a common core. This allows L1 and L2 to be magnetically coupled, allowing the energy stored in the core to be transferred between the two coils. The efficiency of the magnetic coupling between the primary and secondary windings is defined by the coupling coefficient K.

[0003] The existing coupled inductor production process is to use round enameled wire to double-wind on an I-shaped magnetic core to form an inductor coil structure, and assemble it with a magnetic cover to produce a coupled inductor. The disadvantage is that it is difficult to achieve the low DCR of a flat wire structure with the same volume of coil round wire. At the same time, its magnetic shielding effect is inferior to that of a flat wire one-piece molding structure. In order to solve the above problems, the present invention creates a flat wire double-wire cross-winding process and a coupled inductor prepared by the process. Summary of the invention

[0004] In order to solve the above technical problems, the present invention provides a flat wire double-wire cross-winding process, comprising the following steps: Step 1: Wind two flat wires in the same direction around a winding jig, and wind the double wires at the same time, and adjust the height of the winding center axis according to the wire thickness; Step 2: The winding jig comprises an upper mold and a lower mold. When the upper mold and the lower mold are in an open mold state, the wire feeding system starts to feed the wire toward the lower mold. After the wire feeding is completed, the upper mold descends. During this process, the flat wire is fixed between the winding center axis and the fixing pin. After the upper and lower molds are closed, the upper mold starts to rotate clockwise, and the flat wire is cut after reaching the set number of turns. The upper mold rotates counterclockwise to remove the pulling force on the lead-out end of the flat wire, so that a flat wire double-wire stacked coil can be obtained.

[0005] Furthermore, in step one: the same direction in step one is clockwise or counterclockwise.

[0006] Furthermore, in step 2: the difference in winding angles of the two flat wires is 180°. The two flat wires are wound around the winding fixture in the same direction, clockwise or counterclockwise, and the difference between the winding angle of the first wire and the winding angle of the second wire is 180°.

[0007] Further, in step 2: the long end of the flat wire in step 2 is the wire feeding position. When the upper and lower molds are in the open mold state, the wire feeding system starts to feed the wire to the lower mold. After the wire feeding is completed, the upper mold descends. In this process, the flat wire is fixed between the winding center shaft and the fixing pin.

[0008] Further, in step 2: in step 2, the upper mold rises every time the upper mold rotates 1°

[0009] Furthermore, in step 2: in step 2, the counterclockwise rotation angle of the upper mold is 25°.

[0010] A coupled inductor prepared by a flat wire double-wire cross-winding process, wherein the coupled inductor is made by combining a flat wire double-wire cross-winding coil with a T-core and using a hot pressing process.

[0011] Compared with the prior art, the present invention has the following beneficial effects:

[0012] (1) The present invention creates a flat wire double-wire overlapping winding technology, which realizes the simultaneous cross-winding of the flat wire double-wire to improve the magnetic coupling coefficient of the two coils to more than 97%. At the same time, it can realize automated winding and improve production efficiency.

[0013] (2) The present invention combines a flat wire double-wire stacked coil with a T-core and uses a hot pressing process to produce an integrated magnetically coupled inductor to achieve a fully shielded structure. Compared with traditional round wire magnetically coupled inductors, it has lower magnetic loss and copper loss and excellent magnetic shielding effect. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 This is a schematic diagram of the flat wire double-wire cross-winding process of the present invention;

[0015] Figure 2 It is a schematic diagram of the combination of a flat wire double-wire cross-wound coil and a T-core according to the present invention.

[0016] In the figure: 1. Upper die; 2. Lower die; 3. Flat wire; 4. Middle shaft; 5. Fixing pin; 6. Long wire end; 7. T-core. DETAILED DESCRIPTION

[0017] The present invention is further described in detail below in conjunction with the accompanying drawings and specific embodiments. The embodiments of the present invention are provided for the purpose of illustration and description, and are not intended to be exhaustive or to limit the present invention to the disclosed forms. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiments are selected and described in order to better illustrate the principles and practical applications of the present invention, and to enable those of ordinary skill in the art to understand the present invention and thereby design various embodiments with various modifications suitable for specific uses.

[0018] For example, see Figure 1-Figure 2 The present invention is a flat wire double-wire cross-winding process, comprising the following steps:

[0019] Step 1: Wind the two flat wires 3 around the winding fixture in the same direction, wind the two wires at the same time, and adjust the height of the winding center axis 4 according to the wire thickness;

[0020] Step 2: The winding fixture includes an upper die 1 and a lower die 2. When the upper die 1 and the lower die 2 are in the open state, the wire feeding system starts to feed the wire toward the lower die 2. After the wire feeding is completed, the upper die 1 descends. During this process, the flat wire 3 is fixed between the winding center axis 4 and the fixing pin 5. After the upper and lower dies are closed, the upper die 1 starts to rotate clockwise, and the flat wire 3 is cut after reaching the set number of turns. The upper die 1 rotates counterclockwise to remove the tension on the lead-out end of the flat wire 3, and a flat wire double-wire stacked coil can be obtained.

[0021] In step one: the same direction in step one is clockwise or counterclockwise.

[0022] In step 2: the difference in winding angles of the two flat wires 3 is 180°.

[0023] When in use, two flat wires 3 are wound around the winding fixture in the same direction, clockwise or counterclockwise. The winding angle of the first flat wire 3 differs from that of the second flat wire 3 by 180°. The two wires are wound at the same time, and the height of the winding center axis 4 is adjusted according to the thickness of the wires.

[0024] In step 2: In step 2, the long line end 6 of the flat line 3 is the line entry position.

[0025] In step 2: In step 2, the upper mold 1 rises every time the upper mold 1 rotates 1°.

[0026] In step 2: In step 2, the upper mold 1 is rotated counterclockwise by 25°.

[0027] When in use, the long wire end 6 is the wire feeding part. When the upper mold 1 and the lower mold 2 are in the mold opening state, the wire feeding system starts to feed the wire to the lower mold 2. After the wire feeding is completed, the upper mold 1 descends. In this process, the flat wire 3 is fixed between the winding center shaft 4 and the fixing pin 5. After the upper and lower molds are closed, the upper mold 1 starts to rotate clockwise. Every time it rotates 1°, the upper mold 1 rises. After the upper die 1 rotates 1.5 times, it rises 0.45mm in total. Then the flat wire 3 is cut, and the upper die 1 rotates 25° counterclockwise to remove the tension on the lead-out end of the flat wire 3, and a double-wire stacked coil of the flat wire can be obtained.

[0028] For example 2, please refer to Figure 1-Figure 2 The present invention is a flat wire double-wire cross-winding process, comprising the following steps:

[0029] Step 1: Wind the two flat wires 3 around the winding fixture in the same direction, wind the two wires at the same time, and adjust the height of the winding center axis 4 according to the wire thickness;

[0030] Step 2: The winding fixture includes an upper die 1 and a lower die 2. When the upper die 1 and the lower die 2 are in the open state, the wire feeding system starts to feed the wire toward the lower die 2. After the wire feeding is completed, the upper die 1 descends. During this process, the flat wire 3 is fixed between the winding center axis 4 and the fixing pin 5. After the upper and lower dies are closed, the upper die 1 starts to rotate clockwise, and the flat wire 3 is cut after reaching the set number of turns. The upper die 1 rotates counterclockwise to remove the tension on the lead-out end of the flat wire 3, and a flat wire double-wire stacked coil can be obtained.

[0031] In step one: the same direction in step one is clockwise or counterclockwise.

[0032] In step 2: the difference in winding angles of the two flat wires 3 is 180°.

[0033] When in use, two flat wires 3 are wound around the winding fixture in the same direction, clockwise or counterclockwise, the winding angle of the first flat wire 3 is 0°, and the winding angle of the second flat wire 3 is 180°. The two wires are wound at the same time, and the height of the winding center axis 4 is adjusted according to the thickness of the wire.

[0034] In step 2: In step 2, the long line end 6 of the flat line 3 is the line entry position.

[0035] In step 2: In step 2, the upper mold 1 rises every time the upper mold 1 rotates 1°.

[0036] In step 2: In step 2, the upper mold 1 is rotated counterclockwise by 25°.

[0037] When in use, the long wire end 6 is the wire feeding part. When the upper mold 1 and the lower mold 2 are in the mold opening state, the wire feeding system starts to feed the wire to the lower mold 2. After the wire feeding is completed, the upper mold 1 descends. In this process, the flat wire 3 is fixed between the winding center shaft 4 and the fixing pin 5. After the upper and lower molds are closed, the upper mold 1 starts to rotate clockwise. Every time it rotates 1°, the upper mold 1 rises. After the upper die 1 rotates 1.5 times, it rises 0.45mm in total. Then the flat wire 3 is cut, and the upper die 1 rotates 25° counterclockwise to remove the tension on the lead-out end of the flat wire 3, and a double-wire stacked coil of the flat wire can be obtained.

[0038] For example 3, please refer to Figure 1-Figure 2 The present invention is a flat wire double-wire cross-winding process, comprising the following steps:

[0039] Step 1: Wind the two flat wires 3 around the winding fixture in the same direction, wind the two wires at the same time, and adjust the height of the winding center axis 4 according to the wire thickness;

[0040] Step 2: The winding fixture includes an upper die 1 and a lower die 2. When the upper die 1 and the lower die 2 are in the open state, the wire feeding system starts to feed the wire toward the lower die 2. After the wire feeding is completed, the upper die 1 descends. During this process, the flat wire 3 is fixed between the winding center axis 4 and the fixing pin 5. After the upper and lower dies are closed, the upper die 1 starts to rotate clockwise and then cuts the flat wire 3. The upper die 1 rotates counterclockwise to remove the tension on the lead-out end of the flat wire 3, and a flat wire double-wire stacked coil can be obtained.

[0041] In step one: the same direction in step one is clockwise or counterclockwise.

[0042] In step 2: the difference in winding angles of the two flat wires 3 is 180°.

[0043] When in use, two flat wires 3 are wound around the winding fixture in the same direction, clockwise or counterclockwise, the winding angle of the first flat wire 3 is 180°, and the winding angle of the second flat wire 3 is 0°. The two wires are wound at the same time, and the height of the winding center axis 4 is adjusted according to the thickness of the wire.

[0044] In step 2: In step 2, the long line end 6 of the flat line 3 is the line entry position.

[0045] In step 2: In step 2, the upper mold 1 rises every time the upper mold 1 rotates 1°.

[0046] In step 2: In step 2, the upper mold 1 is rotated counterclockwise by 25°.

[0047] When in use, the long wire end 6 is the wire feeding part. When the upper mold 1 and the lower mold 2 are in the mold opening state, the wire feeding system starts to feed the wire to the lower mold 2. After the wire feeding is completed, the upper mold 1 descends. In this process, the flat wire 3 is fixed between the winding center shaft 4 and the fixing pin 5. After the upper and lower molds are closed, the upper mold 1 starts to rotate clockwise. Every time it rotates 1°, the upper mold 1 rises. After the upper die 1 rotates 1.5 times, it rises 0.45mm in total. Then the flat wire 3 is cut, and the upper die 1 rotates 25° counterclockwise to remove the tension on the lead-out end of the flat wire 3, and a double-wire stacked coil of the flat wire can be obtained.

[0048] Example 4, please refer to Figure 1-Figure 2 The present invention is a flat wire double-wire cross-winding process, comprising the following steps:

[0049] Step 1: Wind the two flat wires 3 around the winding fixture in the same direction, wind the two wires at the same time, and adjust the height of the winding center axis 4 according to the wire thickness;

[0050] Step 2: The winding fixture includes an upper die 1 and a lower die 2. When the upper die 1 and the lower die 2 are in the open state, the wire feeding system starts to feed the wire toward the lower die 2. After the wire feeding is completed, the upper die 1 descends. During this process, the flat wire 3 is fixed between the winding center axis 4 and the fixing pin 5. After the upper and lower dies are closed, the upper die 1 starts to rotate clockwise and then cuts the flat wire 3. The upper die 1 rotates counterclockwise to remove the tension on the lead-out end of the flat wire 3, and a flat wire double-wire stacked coil can be obtained.

[0051] In step one: the same direction in step one is clockwise or counterclockwise.

[0052] In step 2: the difference in winding angles of the two flat wires 3 is 180°.

[0053] When in use, two flat wires 3 are wound around the winding fixture in the same direction, clockwise or counterclockwise. The winding angle of the first flat wire 3 differs from that of the second flat wire 3 by 180°. The two wires are wound at the same time, and the height of the winding center axis 4 is adjusted according to the thickness of the wires.

[0054] In step 2: In step 2, the long line end 6 of the flat line 3 is the line entry position.

[0055] In step 2: In step 2, the upper mold 1 rises every time the upper mold 1 rotates 1°.

[0056] In step 2: In step 2, the upper mold 1 is rotated counterclockwise by 25°.

[0057] When in use, the long wire end 6 is the wire feeding part. When the upper mold 1 and the lower mold 2 are in the mold opening state, the wire feeding system starts to feed the wire to the lower mold 2. After the wire feeding is completed, the upper mold 1 descends. In this process, the flat wire 3 is fixed between the winding center shaft 4 and the fixing pin 5. After the upper and lower molds are closed, the upper mold 1 starts to rotate clockwise. Every time it rotates 1°, the upper mold 1 rises. After the upper die 1 rotates 2 times, it rises 0.9mm in total. Then the flat wire 3 is cut, and the upper die 1 rotates 25° counterclockwise to remove the tension on the lead-out end of the flat wire 3, and a double-wire stacked coil of the flat wire can be obtained.

[0058] For example 5, please refer to Figure 1-Figure 2 The present invention is a flat wire double-wire cross-winding process, comprising the following steps:

[0059] Step 1: Wind the two flat wires 3 around the winding fixture in the same direction, wind the two wires at the same time, and adjust the height of the winding center axis 4 according to the wire thickness;

[0060] Step 2: The winding fixture includes an upper die 1 and a lower die 2. When the upper die 1 and the lower die 2 are in the open state, the wire feeding system starts to feed the wire toward the lower die 2. After the wire feeding is completed, the upper die 1 descends. During this process, the flat wire 3 is fixed between the winding center axis 4 and the fixing pin 5. After the upper and lower dies are closed, the upper die 1 starts to rotate clockwise and then cuts the flat wire 3. The upper die 1 rotates counterclockwise to remove the tension on the lead-out end of the flat wire 3, and a flat wire double-wire stacked coil can be obtained.

[0061] In step one: the same direction in step one is clockwise or counterclockwise.

[0062] In step 2: the difference in winding angles of the two flat wires 3 is 180°.

[0063] When in use, two flat wires 3 are wound around the winding fixture in the same direction, clockwise or counterclockwise, and the winding angle of the first wire differs from that of the second wire by 180°. The two wires are wound at the same time, and the height of the winding center axis 4 is adjusted according to the wire thickness.

[0064] In step 2: In step 2, the long line end 6 of the flat line 3 is the line entry position.

[0065] In step 2: In step 2, the upper mold 1 rises every time the upper mold 1 rotates 1°.

[0066] In step 2: In step 2, the upper mold 1 is rotated counterclockwise by 25°.

[0067] When in use, the long wire end 6 is the wire feeding part. When the upper mold 1 and the lower mold 2 are in the mold opening state, the wire feeding system starts to feed the wire to the lower mold 2. After the wire feeding is completed, the upper mold 1 descends. In this process, the flat wire 3 is fixed between the winding center shaft 4 and the fixing pin 5. After the upper and lower molds are closed, the upper mold 1 starts to rotate clockwise. Every time it rotates 1°, the upper mold 1 rises. After the upper die 1 rotates 3 times, it rises 1.35mm in total. Then the flat wire 3 is cut, and the upper die 1 rotates 25° counterclockwise to remove the tension on the lead-out end of the flat wire 3, and a flat wire double-wire stacked coil can be obtained.

[0068] Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field and related fields without creative work should fall within the scope of protection of the present invention. The structures, devices and operating methods not specifically described and explained in the present invention are implemented according to the conventional means in the field unless otherwise specified and limited.

Claims

1. A flat wire double-wire cross-winding process, characterized in that: The following steps are involved: Step 1: Wind two flat wires (3) around a winding fixture in the same direction, winding the two wires simultaneously, and adjusting the height of the winding center axis (4) according to the wire thickness; Step 2: The winding fixture comprises an upper die (1) and a lower die (2). When the upper die (1) and the lower die (2) are in an open die state, the wire feeding system starts to feed the wire toward the lower die (2). After the wire feeding is completed, the upper die (1) descends. During this process, the flat wire (3) is fixed between the winding center axis (4) and the fixing pin (5). After the upper and lower dies are closed, the upper die (1) starts to rotate clockwise and then cuts the flat wire (3). The upper die (1) rotates counterclockwise to remove the tension on the lead-out end of the flat wire (3), thereby obtaining a double-wire stacked coil of the flat wire. The same direction in step 1 is clockwise or counterclockwise; The difference in winding angles between the two flat wires (3) is 180°; In the step 2, the long wire end (6) of the flat wire (3) is the wire entry position; In the step 2, the upper mold (1) rises every time it rotates 1°. In the step 2, the counterclockwise rotation angle of the upper mold (1) is 25°.

2. A coupled inductor prepared by a flat wire double-wire cross-winding process, characterized in that: The coupled inductor is manufactured by combining a flat wire bifilar stacked coil with a T-core (7) using a hot pressing process.

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