Coil winding of electromagnetic component

Abstract

The invention discloses a coil winding for manufacturing a surface-mounted electromagnetic component. The coil windings include at least one substantially U-shaped conductive structure made of a metal conductive material and an insulating structure substantially wrapping at least one of the at least one substantially U-shaped conductive structure made of a metal conductive material. The coil winding manufactured by the conductive structures and the insulation structures solves the problem of electrical insulation of the coil winding which cannot be solved by the coil winding manufactured by the traditional method. The coil windings can be used for manufacturing surface-mounted electromagnetic components.

Description

Technical Field

[0001] The invention relates to a coil winding of an electromagnetic component and applications thereof, in particular to a coil winding of a surface mounted inductor component and applications thereof. Background Art

[0002] Switching power supplies are core components of power systems such as communications, data management, artificial intelligence, and automotive electronics. With the increase in the speed of chips such as CPUs and GPUs and the acceleration of operating frequencies, people have higher and higher requirements for the efficiency, power density, and manufacturing costs of switching power supplies. Higher power conversion efficiency, smaller size, and lower manufacturing costs are the current and future development trends of switching power supplies. As one of the most basic and indispensable electronic components of switching power supplies, inductors, especially high-current inductors, are very important in the efficiency, volume, and cost of switching power supplies. Inductor manufacturers have been committed to optimizing the core materials and core shapes of inductors in order to pursue higher inductor efficiency while reducing costs as much as possible.

[0003] An inductor generally consists of a magnetic core and a coil winding wound on or through the magnetic core. The magnetic core may be made of magnetic material and is usually formed into a certain shape before winding. The coil winding may be formed by winding one or more turns of an insulated conductor, one or more turns of a bare conductor, or by bending a conductor into a certain shape.

[0004] The inductor device used in the switching power supply that provides electrical energy to the CPU or GPU in the data center or server may generally include multiple separate discrete inductor devices, or use an integrated coupled inductor device.

[0005] Traditional coupled inductors usually include at least two inductors integrated together, such as two, three, or even five, six or more inductors integrated together, which are usually called multi-phase coupled inductors. Multi-phase coupled inductors usually have an independent coil winding for each phase, but each phase shares a magnetic core with other phases that contains multi-phase characteristics, and the coupling is usually generated by the magnetic flux of a certain phase flowing through the magnetic core containing multi-phase characteristics to other phases. The coil windings of traditional coupled inductor devices are usually formed by winding a bare conductor in one or more turns, or by folding a bare conductor into a certain shape.

[0006] With the increase in the operating speed of CPU and GPU and the increase in the requirements for the stability of CPU and GPU input voltage, a new type of multi-phase synchronous switching power supply circuit and operation mode are proposed. The circuit of this new type of multi-phase synchronous switching power supply requires a new type of coupled inductor. This new type of coupled inductor can and preferably is a separate discrete type. The circuit realizes the function of a traditional integrated coupled inductor by connecting multiple separate discrete coupled inductors. The magnetic core of this new type of coupled inductor is similar to that of a traditional single-phase inductor, but unlike the traditional single-phase inductor, this new type of coupled inductor requires two coil windings, and there must be a certain degree of electrical insulation between the two coil windings, such as passing a DC voltage withstand test of at least 100V between the two coil windings. Therefore, the traditional coil windings, which are usually wound by bare conductors, cannot achieve this function well.

[0007] One purpose of the present invention is to solve and obtain the DC voltage withstand performance that cannot be obtained by the conventional coil winding formed by winding a bare conductor. Another purpose of the present invention is to improve the electrical performance of the new coupled inductor. Another purpose of the present invention is also to improve the manufacturability of the new coupled inductor and reduce its manufacturing cost. Summary of the invention

[0008] The purpose of the present invention is to solve the deficiencies of the prior art and to provide a coil winding of an electromagnetic component and an application thereof.

[0009] The first technical solution of the present invention:

[0010] A coil winding for making a surface mounted electromagnetic component, comprising:

[0011] A substantially U-shaped conductive structure made of a metallic conductive material and an insulating structure substantially enveloping the substantially U-shaped conductive structure and having a substantially uniform thickness;

[0012] The cross-sectional shape of the substantially U-shaped conductive structure is substantially rectangular and substantially includes a first bending section, a second bending section, a third bending section, a fourth bending section and a fifth bending section; wherein the first bending section is substantially perpendicular to the second bending section, the second bending section is substantially perpendicular to the third bending section, the third bending section is substantially perpendicular to the fourth bending section, and the fourth bending section is substantially perpendicular to the fifth bending section; wherein the first bending section and the fifth bending section are substantially symmetrical, and the second bending section and the fourth bending section are substantially symmetrical; wherein the first bending section includes a first surface mount soldering terminal, and the fifth bending section includes a second surface mount soldering terminal; wherein the first surface mount soldering terminal and the second surface mount soldering terminal are substantially coplanar;

[0013] The conductive structure has substantially the same thickness from the first bending section to the fifth bending section and the thickness is substantially between 0.15 mm and 2 mm;

[0014] The insulating structure having substantially uniform thickness substantially wraps around most of the substantially U-shaped conductive structure except for at least a portion of the first surface mount solder terminal and at least a portion of the second surface mount solder terminal.

[0015] The metal conductive material is copper or a copper alloy.

[0016] The conductive structure is formed by stamping and bending a copper material, or by bending a flat copper wire with or without an insulating layer, wherein the insulating structure is formed by covering the conductive structure with insulating paint, insulating glue or other insulating materials through spraying, infiltration, or electrophoresis, or by molding an insulating material around the conductive structure, or by molding an insulating material around a conductive structure coated with insulating material, or by covering the conductive structure with the same or different insulating materials through a variety of processes.

[0017] The insulating structure basically wraps around most of the area of ​​the basically U-shaped conductive structure except for at least a portion of the first surface mount welding terminal and at least a portion of the second surface mount welding terminal, wherein most of the area of ​​the basically U-shaped conductive structure does not include the feeding points required for the insulating structure during the manufacturing process and the fixing points required for the basically U-shaped conductive structure.

[0018] Corresponding inductors can be manufactured using or according to the coil windings for manufacturing surface mounted electromagnetic components described in the first technical solution of the present invention, including but not limited to coupled inductors.

[0019] The second technical solution of the present invention:

[0020] A coil winding for making a surface mounted electromagnetic component, comprising:

[0021] A substantially U-shaped conductive structure made of a metallic conductive material and an insulating structure substantially enveloping the substantially U-shaped conductive structure and having a substantially uniform thickness;

[0022] The cross-sectional shape of the substantially U-shaped conductive structure is substantially rectangular and includes at least three bending sections; two of the at least three bending sections include a first surface mount soldering terminal and a second surface mount soldering terminal; the first surface mount soldering terminal and the second surface mount soldering terminal are substantially coplanar;

[0023] The at least three bending sections of the substantially U-shaped conductive structure have substantially the same thickness and are substantially between 0.15 mm and 2 mm;

[0024] wherein the insulating structure having a substantially uniform thickness substantially wraps around a majority of the substantially U-shaped conductive structure except for at least a portion of the first surface mount solder terminal and at least a portion of the second surface mount solder terminal;

[0026] The metal conductive material is copper or a copper alloy.

[0027] The conductive structure is formed by stamping and bending copper material, or by bending flat copper wire with or without insulating layer. The insulating structure is formed by covering the conductive structure with insulating paint, insulating glue or other insulating materials through spraying, infiltration, or electrophoresis, or by molding insulating materials around the conductive structure, or by molding insulating materials around the conductive structure covered with insulating materials, or by covering the conductive structure with the same or different insulating materials through various processes.

[0028] The coil winding for making surface mounted electromagnetic components described in the second technical solution of the present invention can be used to make corresponding inductors, including but not limited to coupled inductors.

[0029] The third technical solution of the present invention:

[0030] A coil winding for making a surface mounted electromagnetic component, comprising:

[0031] The first is a substantially U-shaped conductive structure made of a metallic conductive material;

[0032] a second substantially U-shaped conductive structure made of a metallic conductive material; and

[0033] an insulating structure, wherein the insulating structure is formed by molding an insulating material around the first substantially U-shaped conductive structure or / and the second substantially U-shaped conductive structure, and the insulating structure at least covers a majority of the first substantially U-shaped conductive structure or / and the second substantially U-shaped conductive structure;

[0034] The cross-sectional shape of the first substantially U-shaped conductive structure is substantially rectangular and includes at least three bending segments; two of the at least three bending segments include a first surface mount soldering terminal and a second surface mount soldering terminal, and the first surface mount soldering terminal and the second surface mount soldering terminal are substantially coplanar;

[0035] The cross-sectional shape of the second substantially U-shaped conductive structure is substantially rectangular and includes at least three bending segments; wherein two of the at least three bending segments include a third surface mount soldering terminal and a fourth surface mount soldering terminal, and the third surface mount soldering terminal and the fourth surface mount soldering terminal are substantially coplanar;

[0036] wherein the first surface mount soldering terminal and the second surface mount soldering terminal of the first substantially U-shaped conductive structure are substantially coplanar with the third surface mount soldering terminal and the fourth surface mount soldering terminal of the second substantially U-shaped conductive structure;

[0037] The at least three bending sections of the first substantially U-shaped conductive structure have substantially the same thickness and are substantially between 0.15 mm and 2 mm;

[0038] wherein the at least three bending segments of the second substantially U-shaped conductive structure have substantially the same thickness and the thickness is substantially between 0.15 mm and 1.0 mm;

[0039] wherein the first substantially U-shaped conductive structure at least partially surrounds at least a portion of the second substantially U-shaped conductive structure from the outside;

[0040] The second substantially U-shaped conductive structure is isolated from the first substantially U-shaped conductive structure by an insulating structure, and the thickness of the isolation is substantially between 0.1 mm and 1 mm.

[0041] The metal conductive material is copper or a copper alloy.

[0042] At least one of the first and second substantially U-shaped conductive structures is formed by stamping and bending a copper material, or at least one of the first and second substantially U-shaped conductive structures is formed by bending a flat copper wire with or without an insulating layer.

[0043] Wherein the insulating structure at least wraps around most of the first basically U-shaped conductive structure or / and the second basically U-shaped conductive structure; when the insulating structure at least wraps around the first basically U-shaped conductive structure, the insulating structure at least wraps around most of the first basically U-shaped conductive structure except at least a portion of the first surface mount soldering terminal and at least a portion of the second surface mount soldering terminal; when the insulating structure at least wraps around the second basically U-shaped conductive structure, the insulating structure at least wraps around most of the second basically U-shaped conductive structure except at least a portion of the third surface mount soldering terminal and at least a portion of the fourth surface mount soldering terminal.

[0044] Corresponding inductors can be manufactured using or according to the coil winding for manufacturing surface mounted electromagnetic components described in the third technical solution of the present invention, including but not limited to coupled inductors.

[0045] A production process of a substantially U-shaped conductive structure in the first technical solution generally includes but is not limited to the following steps:

[0046] S1, select a raw material plate with a certain length and basically in a long strip shape,

[0047] S2, dividing the raw material plate into several unit pieces from front to back along the length direction of the raw material plate, and dividing each unit piece into the first bending section, the second bending section, the third bending section, the fourth bending section and the fifth bending section in sequence from front to back along the length direction, wherein the lengths of the first bending section and the fifth bending section are substantially the same, and the lengths of the second bending section and the fourth bending section are substantially the same.

[0048] S3, fixing the third bending segment, bending the first bending segment upward so that the first bending segment is perpendicular to the second bending segment, and bending the fifth bending segment upward so that the fifth bending segment is perpendicular to the fourth bending segment.

[0049] S4, the second bending segment is bent upward so that the second bending segment is perpendicular to the third bending segment; the fourth bending segment is bent upward so that the fourth bending segment is perpendicular to the third bending segment.

[0050] A preferred solution also includes S5, in which a fixing device is used to guide the bending during the bending process of the first bending segment, the second bending segment, the third bending segment, the fourth bending segment and the fifth bending segment, so that at least most of the side surfaces of at least the second bending segment, the third bending segment and the fourth bending segment among the first bending segment, the second bending segment, the third bending segment, the fourth bending segment and the fifth bending segment are basically aligned after bending.

[0051] A preferred solution is to further include S6, electroplating a part or all of the surface of the substantially U-shaped conductive structure.

[0052] A preferred solution is that the raw material plate is a copper sheet formed by stamping a copper material of a certain thickness.

[0053] A preferred solution is that the thickness of the copper sheet is substantially between 0.15 mm and 2 mm.

[0054] Another preferred solution is that the raw material plate is a flat copper wire.

[0055] The production process of the substantially U-shaped conductive structure in the second and third technical solutions is substantially similar to the production process of the substantially U-shaped conductive structure in the first technical solution.

[0056] The production process of the insulating structure in the first technical solution generally includes but is not limited to covering the above-mentioned basically U-shaped conductive structure with insulating paint or insulating glue or other insulating materials through spraying, infiltration, or electrophoresis, or injection molding the insulating material around the above-mentioned basically U-shaped conductive structure, or injection molding the insulating material around the basically U-shaped conductive structure covered with insulating material, or covering the above-mentioned basically U-shaped conductive structure with the same or different insulating materials through multiple processes.

[0057] The production process of the coil winding of an electromagnetic component in the first technical solution generally includes but is not limited to the following steps:

[0058] S1, pre-fabricate a single-cavity or multi-cavity injection mold having a cavity slightly larger than the basically U-shaped conductive structure but with basically the same shape.

[0059] S2, arrange, place and fix the basically U-shaped conductive structure that has been bent into shape and partially or fully surface-plated in the cavity of the injection mold, so that all parts of the basically U-shaped conductive structure except for part of the side surfaces and the entire bottom surface of the first bending section and part of the side surfaces and the entire bottom surface of the fifth bending section are in the cavity of the injection mold.

[0060] S3, melting the selected insulating material into liquid.

[0061] S4, injecting the melted insulating material into the mold cavity of the injection mold so that the mold cavity is fully filled.

[0062] S5, cooling the mold to shape the insulating material.

[0063] S6, open the mold, demould and take out the formed coil winding.

[0064] A preferred solution is to select the size of the injection mold cavity and place and position the substantially U-shaped conductive structure in the mold cavity so that the thickness of the injection molded insulating structure is at least substantially uniform and substantially wraps at least most of the substantially U-shaped conductive structure.

[0065] A preferred solution is that the thickness of the insulating structure that substantially wraps at least most of the substantially U-shaped conductive structure is substantially between 0.1 mm and 1 mm.

[0066] A preferred solution is that the entire bottom surface of the first bending section and the entire bottom surface of the fifth bending section of the substantially U-shaped conductive structure are not wrapped by the insulating structure.

[0067] A preferred solution is that the insulating material is a plastic material that can withstand a general SMT reflow oven.

[0068] The production process of the coil winding of an electromagnetic component in the second and third technical solutions is basically similar to the production process of the coil winding of an electromagnetic component in the first technical solution.

[0069] In summary, the above technical solutions have the following beneficial effects: after the conductive structure is bent, a layer of insulating structure is wrapped on its surface, which firmly and effectively establishes the electrical insulation between the coil windings of the new coupled inductor. At the same time, because the thickness of the insulating structure can be well controlled during injection molding, the coupling coefficient between the coil windings can also be well controlled.

[0070] The above description is only an overview of the technical solution of the present invention. In order to more clearly understand the technical means of the present invention, it can be implemented in accordance with the contents of the specification. In order to make the above and other purposes, features and advantages of the present invention more obvious and easy to understand, the following specifically cites the preferred embodiments and describes them in detail with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0071] Figure 1A It is a schematic diagram of a new type of single-phase coupled inductor;

[0072] Figure 1B It is a cross-sectional view of a new type of single-phase coupled inductor;

[0073] Figure 2A is a schematic diagram of a first exemplary embodiment of a coil winding of an electromagnetic component in the present invention;

[0074] Figure 2B is a cross-sectional view of a first exemplary embodiment 2A of a coil winding of an electromagnetic component in the present invention;

[0075] Figure 2C is a schematic diagram of a second exemplary embodiment of a coil winding of an electromagnetic component in the present invention;

[0076] Figure 3A is a schematic diagram of a third exemplary embodiment of a coil winding of an electromagnetic component in the present invention;

[0077] Figure 3B is a cross-sectional view of a third exemplary embodiment 3A of a coil winding of an electromagnetic component in the present invention;

[0078] Figure 4A is a schematic diagram of a novel single-phase coupled inductor according to the present invention;

[0079] Figure 4B is a cross-sectional view of a novel single-phase coupled inductor 4A according to the present invention; DETAILED DESCRIPTION

[0080] To illustrate the concept and purpose of the present invention, the present invention will be further described below in conjunction with the accompanying drawings and specific embodiments. These embodiments jointly or individually realize and obtain the required electrical insulation characteristics between the coil windings in the new coupled inductor, which are difficult to achieve using traditional technologies, and these embodiments have lower manufacturing costs than other known implementation methods. The manufacturing principles, methods and steps of the coil windings in other new coupled inductors are obvious and are fully included in the scope of this technology, and no special explanation is required here.

[0081] like Figure 1A and Figure 1B As shown, the novel single-phase coupled inductor 100 includes a left half magnetic core 110, a right half magnetic core 120, a first coil winding 130, and a second coil winding 140. The left and right half magnetic cores are substantially symmetrical to each other and are substantially E-shaped, wherein the right half magnetic core 120 includes side columns 121 and 122, and a middle column 123. The first coil winding 130 includes two surface mount solder terminals 131 and 132. The second coil winding 140 includes two surface mount solder terminals 141 and 142. The first coil winding 130 and the second coil winding 140 are both arranged in the cavity of the E-shaped magnetic core, and the first coil winding 130 at least partially surrounds at least a portion of the second coil winding 140. Compared with the first coil winding 130, the second coil winding 140 usually has a smaller thickness. The first coil winding 130 usually has no insulation wrapped on its surface, and can usually be made by bending a bare copper wire or stamping and bending a bare copper sheet. The second coil winding 140 is usually formed by bending an enameled flat wire. Since the bending process is performed after the enameled wire is formed, the insulating paint on the flat wire may be damaged during the bending process, resulting in a decrease in the insulation performance between the first coil winding 130 and the second coil winding 140, thereby failing to pass the insulation property test. The two surface mount soldering terminals 131 and 132 of the first coil winding 130 and the two surface mount soldering terminals 141 and 142 of the second coil winding 140 are usually substantially on the same plane.

[0082] Figure 2A A first exemplary embodiment of a coil winding of an electromagnetic component of the present invention is shown, Figure 2B A cross section of an exemplary embodiment 2A of the coil winding of the electromagnetic component is shown. Figure 2A and 2BAs shown, the first exemplary embodiment 200 of the coil winding of the electromagnetic component described in the present invention includes a conductive structure 220 and an insulating structure 210 basically wrapped on the conductive structure 220, wherein the conductive structure 220 has a first, second, third, fourth, and fifth bending sections in sequence. The first bending section is substantially perpendicular to the second bending section, the second bending section is substantially perpendicular to the third bending section, the third bending section is substantially perpendicular to the fourth bending section, and the fourth bending section is substantially perpendicular to the fifth bending section. The first, second, third, fourth, and fifth bending sections are substantially aligned when viewed from the side after bending. The second bending section and the fourth bending section are substantially symmetrical and have substantially the same length, and the first bending section and the fifth bending section are substantially symmetrical and have substantially the same length. The first bending section and the fifth bending section sequentially include two surface mount welding terminals 221 and 222 of the coil winding of the electromagnetic component, and the two surface mount welding terminals 221 and 222 are substantially on the same plane. The insulating structure 210 is formed by molding an insulating material that is injection molded around the conductive structure 220. The insulating structure 210 may be formed by melting a commonly used plastic material or other insulating material and injecting it into the mold cavity of a mold in which the conductive structure is placed, or may be formed by other forms of injection molding of a commonly used plastic material or other insulating material on the conductive structure. The insulating structure 210 may also be formed by spraying, soaking, electrophoresis, or other processes of insulating paint or insulating glue or other insulating materials on the conductive structure, or by molding an insulating material that is molded around the conductive structure that has been coated with insulating material, or by covering the conductive structure with the same or different insulating materials through various processes.

[0083] The insulating structure 210 basically wraps most of the conductive structure 220 except at least a part of the surface mount soldering terminal 221 and at least a part of the surface mount soldering terminal 222. At least a part of the surface mount soldering terminal 221 includes the soldering surface of the surface mount soldering terminal 221 and its extension. At least a part of the surface mount soldering terminal 222 includes the soldering surface of the surface mount soldering terminal 222 and its extension. The conductive structure 220 has a substantially uniform thickness. The thickness of the conductive structure is basically between 0.15 mm and 2 mm. The insulating structure basically uniformly wraps the conductive structure, but usually leaves several exposed points of the conductive structure, which are usually left for pouring insulating materials and fixing the conductive structure during the process of making coil windings. These exposed points can be covered by post-processing methods such as dispensing glue. The conductive structure 220 can be formed by bending a substantially uniform flat copper wire, or by stamping and bending a flat copper material.

[0084] In the first exemplary embodiment, the cross-sections of the first, second, third, fourth, and fifth bending sections of the conductive structure are substantially rectangular, and have width and thickness. The thickness of the conductive structure described above can be understood as the thickness of the cross-section of the bending section that is substantially rectangular. In the first exemplary embodiment, the substantially rectangular cross-sections of the first, second, third, fourth, and fifth bending sections have substantially the same width. It should be noted that in similar embodiments, the substantially rectangular cross-sections of the first, second, third, fourth, and fifth bending sections may also have different widths, respectively. For example, the width of the substantially rectangular cross-sections of the first bending section and the fifth bending section including the surface mount welding terminal is greater than the width of the substantially rectangular cross-sections of the second, third, and fourth bending sections.

[0085] Other shapes and structures and other coil windings similar to the first exemplary embodiment may include conductive structures with less than or more than five bending segments, but may achieve substantially the same functions. For example, the coil winding of an electromagnetic component includes a conductive structure and an insulating structure that substantially wraps the conductive structure. The conductive structure includes three bending segments, the first bending segment is substantially perpendicular to the second bending segment, and the second bending segment is substantially perpendicular to the third bending segment; the first bending segment and the third bending segment are substantially symmetrical, and the first bending segment includes a surface mount welding terminal, the third bending segment includes a surface mount welding terminal, and the surface mount welding terminal included in the first bending segment and the surface mount welding terminal included in the third bending segment are substantially on the same plane.

[0086] Figure 2C A second exemplary embodiment of a coil winding of an electromagnetic component of the present invention is shown. Figure 2C As shown, the second exemplary embodiment 250 of the coil winding of the electromagnetic component of the present invention includes a conductive structure 252 and an insulating structure 251 that basically wraps the conductive structure 252. The insulating structure 251 is formed by molding an insulating material around the conductive structure 252. The insulating structure 251 can usually be formed by injecting a commonly used plastic material or other insulating material into a mold cavity of a mold in which the conductive structure is placed, or it can be formed by injecting a commonly used plastic material or other insulating material into the conductive structure. The insulating structure 251 can also be formed by spraying, soaking, electrophoresis, or other processes on the conductive structure with insulating paint or insulating glue or other insulating materials, or by molding an insulating material that is molded around the conductive structure that has been coated with insulating material, or by covering the conductive structure with the same or different insulating materials through a variety of processes.

[0087] The conductive structure 252 has a first, second, third, fourth, and fifth bending sections, the first bending section includes a surface mount welding terminal 255, the fifth bending section includes a surface mount welding terminal 256, and the surface mount welding terminal of the first bending section and the surface mount welding terminal of the fifth bending section have basic coplanarity. The first bending section is basically perpendicular to the second bending section, the second bending section is basically perpendicular to the third bending section, the third bending section is basically perpendicular to the fourth bending section, and the fourth bending section is basically perpendicular to the fifth bending section. The cross-sections of the first, second, third, fourth, and fifth bending sections are basically rectangular and have width and thickness. The substantially rectangular cross-sections of the first bending section, the second bending section, the third bending section, the fourth bending section, and the fifth bending section have substantially equal thickness, and the thickness, that is, the thickness of the conductive structure, is basically between 0.15 mm and 2 mm. The substantially rectangular cross-sections of the first bending section, the second bending section, the third bending section, the fourth bending section, and the fifth bending section can have different widths. For example, the substantially rectangular cross-sections of the first bending segment and the fifth bending segment have substantially the same width A, and the substantially rectangular cross-sections of the second bending segment, the third bending segment, and the fourth bending segment have substantially the same width B, and the width A may be greater than the width B, or may be less than the width B. 255 and 256 are two surface mount welding terminals of the coil winding, 253 is an opening for introducing insulating material during the injection molding process of the coil winding manufacturing process, wherein the opening for introducing insulating material during the injection molding process may have one or more openings. 254 is a positioning point for fixing the conductive structure in the injection molding cavity during the injection molding process of the coil winding manufacturing process, and usually at least two positioning points are required during the injection molding process, such as Figure 2C The illustrated 254 includes 4 symmetrical pairs of eight positioning points in total. The insulating structure 251 substantially uniformly wraps around the conductive structure 252 except for the welding surfaces of 255 and 256 and their extensions and most of the area 253 and 254. The insulating structure has a substantially uniform thickness, and its thickness ranges substantially between 0.01 mm and 0.5 mm. The conductive structure 252 can generally be formed by stamping and bending a flat copper material.

[0088] Other shapes and structures and other coil windings similar to the second exemplary embodiment may include conductive structures with less than or more than five bending segments, but may achieve substantially the same functions. For example, the coil winding of an electromagnetic component includes a conductive structure and an insulating structure that substantially wraps the conductive structure. The conductive structure includes three bending segments, the first bending segment is substantially perpendicular to the second bending segment, and the second bending segment is substantially perpendicular to the third bending segment; the first bending segment and the third bending segment are substantially symmetrical, and the first bending segment includes a surface mount soldering terminal, the third bending segment includes a surface mount soldering terminal, and the surface mount soldering terminal included in the first bending segment and the surface mount soldering terminal included in the third bending segment are substantially coplanar.

[0089] Figure 3A is a schematic diagram of a third exemplary embodiment of a coil winding of an electromagnetic component in the present invention, Figure 3B yes Figure 3A A cross-sectional view of an exemplary embodiment. Figure 3A , 3B As shown, the third exemplary embodiment 300 of the coil winding of the electromagnetic component of the present invention includes a first conductive structure 320, a second conductive structure 330, and an insulating structure 310 that wraps the first conductive structure 320 and the second conductive structure 330. The first conductive structure 320 includes a first, a second, a third, a fourth, and a fifth bending section, wherein the first bending section thereof includes a surface mount soldering terminal 321, and the fifth bending section includes a surface mount soldering terminal 322. The second conductive structure 330 includes a first, a second, a third, a fourth, and a fifth bending section, wherein the first bending section thereof includes a surface mount soldering terminal 331, and the fifth bending section includes a surface mount soldering terminal 332. The first conductive structure 320 at least partially substantially surrounds at least a portion of the second conductive structure 330 from the outside. The insulating structure 310 is formed by molding an insulating material that is injection molded around the first conductive structure 320 or / and the second conductive structure 330. The insulating structure 310 basically and evenly wraps most of the first conductive structure 320 and the second conductive structure 330 except for the surface mounted soldering terminals, the openings for feeding materials during the injection molding process, and the positioning points for fixing the conductive structures in the injection mold cavity during the injection molding process. Alternatively, the insulating structure 310 can also wrap part of the surface mounted soldering terminals of the first conductive structure 320 and the second conductive structure 330, the openings for feeding materials during the injection molding process, and the positioning points for fixing the conductive structures in the injection mold cavity during the injection molding process; at the same time, the insulating structure 310 basically and evenly wraps most of the first conductive structure 320 and the second conductive structure 330 except for the surface mounted soldering terminals, the openings for feeding materials during the injection molding process, and the positioning points for fixing the conductive structures in the injection mold cavity during the injection molding process. Figure 3B As shown, the insulating structure 310 has a cross section 311. The insulating structure 310 not only substantially uniformly wraps around the majority of the first conductive structure 320 and the second conductive structure 330, but also substantially uniformly isolates the first conductive structure 320 and the second conductive structure 330, so that the first conductive structure 320 and the second conductive structure 330 can be physically isolated and electrically insulated. The thickness of the first conductive structure 320 is substantially between 0.15 mm and 2 mm. The thickness of the second conductive structure 330 is generally substantially between 0.15 mm and 1 mm. The insulating structure that wraps and isolates the conductive structures has a substantially uniform thickness, and its thickness ranges substantially between 0.01 mm and 0.5 mm.

[0090] Other shapes and structures and other coil windings similar to the third exemplary embodiment may include conductive structures with less than or more than five bending segments, but may achieve substantially the same functions. For example, the coil winding of the electromagnetic component includes a first conductive structure and a second conductive structure and an insulating structure that substantially wraps at least one of the first conductive structure and the second conductive structure. At least one of the first conductive structure and the second conductive structure includes three bending segments.

[0091] The first exemplary embodiment, the second exemplary embodiment, the third exemplary embodiment and the coil windings of electromagnetic components with similar shapes, structures, and manufacturing principles can be used to manufacture electromagnetic components and electromagnetic systems, for example, can be used to manufacture inductors.

[0092] Figure 4A is a schematic diagram of a novel single-phase coupled inductor according to the present invention, Figure 4B Is a single-phase coupled inductor Figure 4A A cross-sectional view of Figure 4A and 4BThe single-phase coupled inductor 400 includes a magnetic core 410, a first conductive structure 420 arranged and placed in the magnetic core, a second conductive structure 430, and an insulating structure 440 that basically wraps the second conductive structure 430. The magnetic core is made of ferrite material and includes two half cores, and the two half cores are basically symmetrical. The half core of the magnetic core is basically an E-shaped structure and includes two side pillars 411 and 412 and a middle pillar 413. The first conductive structure 420 and the second conductive structure 430 and the insulating structure 440 that basically wraps the second conductive structure 430 are basically U-shaped and arranged between the two side pillars and the middle pillar of the magnetic core. The second conductive structure 430 and the insulating structure 440 that basically wraps the second conductive structure 430 have been formed and combined together before manufacturing and assembling the single-phase coupled inductor 400. Part of the first conductive structure 420 basically surrounds the assembly combination of part of the second conductive structure 430 and the insulating structure 440 from the outside. The first conductive structure 420 includes two surface mount soldering terminals 421 and 422, and the second conductive structure 430 includes two surface mount soldering terminals 431 and 432, wherein the surface mount soldering terminals 421, 422, 431 and 432 are used to connect the single-phase coupled inductor 400 to a circuit, wherein the surface mount soldering terminals 421, 422, 431 and 432 are substantially on the same plane. The first conductive structure 420 and the second conductive structure 430 are isolated and electrically insulated by an insulating structure 440 wrapped on the second conductive structure 430, and the second conductive structure 430 and the magnetic core are also isolated and electrically insulated by the insulating structure 440 wrapped on the second conductive structure 430. The insulating structure 440 at least wraps around most of the first basically U-shaped conductive structure 420 and / or the second basically U-shaped conductive structure 430; when the insulating structure 440 at least wraps around the first basically U-shaped conductive structure 420, the insulating structure 440 at least wraps around most of the first basically U-shaped conductive structure 420 except at least a portion of the first surface mount welding terminal 421 and at least a portion of the second surface mount welding terminal 422; when the insulating structure 440 at least wraps around the second basically U-shaped conductive structure 430, the insulating structure 440 at least wraps around most of the second basically U-shaped conductive structure 430 except at least a portion of the third surface mount welding terminal 431 and at least a portion of the fourth surface mount welding terminal 432.

[0093] At least one of the first and second substantially U-shaped conductive structures is formed by bending a flat copper wire with or without an insulating layer.

[0094] In some embodiments, an inductive component includes a coil winding for making a surface mount electromagnetic component.

[0095] Other types, other geometries, and other configurations of electromagnetic component coil windings and electromagnetic components may benefit from the above teachings, including inductive components other than coupled inductors, and also transformer components.

[0096] This written description uses some exemplary embodiments to illustrate the present invention, so that those skilled in the art can understand and practice the direct or indirect contents, principles, and methods involved in the present invention, including the use of any part or system to design and manufacture any similar coil winding, electromagnetic components or electromagnetic systems, and implement any possible combination thereof. The patent scope of the present invention is defined by the claims, and may include other examples encountered or thought of by those skilled in the art.

Claims

1. A coil winding for making surface mounted electromagnetic components, characterized in that: include: A substantially U-shaped conductive structure made of a metallic conductive material and an insulating structure substantially enveloping the substantially U-shaped conductive structure and having a substantially uniform thickness; The cross-sectional shape of the substantially U-shaped conductive structure is substantially rectangular and substantially includes a first bending section, a second bending section, a third bending section, a fourth bending section and a fifth bending section; wherein the first bending section is substantially perpendicular to the second bending section, the second bending section is substantially perpendicular to the third bending section, the third bending section is substantially perpendicular to the fourth bending section, and the fourth bending section is substantially perpendicular to the fifth bending section; wherein the first bending section and the fifth bending section are substantially symmetrical, and the second bending section and the fourth bending section are substantially symmetrical; wherein the first bending section includes a first surface mount soldering terminal, and the fifth bending section includes a second surface mount soldering terminal; wherein the first surface mount soldering terminal and the second surface mount soldering terminal are substantially coplanar; The conductive structure has substantially the same thickness from the first bending section to the fifth bending section and the thickness is substantially between 0.15 mm and 2 mm; The insulating structure having substantially uniform thickness substantially wraps around most of the substantially U-shaped conductive structure except for at least a portion of the first surface mount soldering terminal and at least a portion of the second surface mount soldering terminal.

2. The coil winding for making surface mounted electromagnetic components according to claim 1, characterized in that: The metal conductive material is copper or a copper alloy.

3. The coil winding for making surface mounted electromagnetic components according to claim 1, characterized in that: The conductive structure is formed by stamping and bending a copper material.

4. The coil winding for making surface mounted electromagnetic components according to claim 1, characterized in that: The conductive structure is formed by bending a flat copper wire with or without an insulating layer.

5. The coil winding for making surface mounted electromagnetic components according to claim 1, characterized in that: The insulating structure is formed by covering the conductive structure with insulating paint or insulating glue or other insulating materials through spraying, infiltration, or electrophoresis, or by molding the insulating material around the conductive structure, or by molding the insulating material around the conductive structure covered with insulating material, or by covering the conductive structure with the same or different insulating materials through multiple processes.

6. The coil winding for making surface mounted electromagnetic components according to claim 1, characterized in that: The insulating structure having a substantially uniform thickness substantially wraps around most of the substantially U-shaped conductive structure except for at least a portion of the first surface mount solder terminal and at least a portion of the second surface mount solder terminal.

7. An inductor component, characterized in that: The invention comprises the coil winding for making surface mounted electromagnetic components as described in claim 1.

8. A coil winding for making surface mounted electromagnetic components, characterized in that: include: A substantially U-shaped conductive structure made of a metallic conductive material and an insulating structure substantially enveloping the substantially U-shaped conductive structure and having a substantially uniform thickness; The cross-sectional shape of the substantially U-shaped conductive structure is substantially rectangular and includes at least three bending segments; two of the at least three bending segments include a first surface mount soldering terminal and a second surface mount soldering terminal, and the first surface mount soldering terminal and the second surface mount soldering terminal are substantially coplanar; The at least three bending sections of the substantially U-shaped conductive structure have substantially the same thickness and are substantially between 0.15 mm and 2 mm; The insulating structure having substantially uniform thickness substantially wraps around most of the substantially U-shaped conductive structure except for at least a portion of the first surface mount soldering terminal and at least a portion of the second surface mount soldering terminal.

9. The coil winding for manufacturing surface mounted electromagnetic components according to claim 8, characterized in that: The metal conductive material is copper or a copper alloy.

10. The coil winding for manufacturing surface mounted electromagnetic components according to claim 8, characterized in that: The conductive structure is formed by stamping and bending a copper material.

11. The coil winding for manufacturing surface mounted electromagnetic components according to claim 8, characterized in that: The conductive structure is formed by bending a flat copper wire with or without an insulating layer.

12. The coil winding for manufacturing surface mounted electromagnetic components according to claim 8, characterized in that: The insulating structure is formed by covering the conductive structure with insulating paint, insulating glue or other insulating materials through spraying, infiltration or electrophoresis, or by molding the insulating material around the conductive structure, or by molding the insulating material around the conductive structure covered with insulating material, or by covering the conductive structure with the same or different insulating materials through various processes.

13. An inductor component, characterized in that: The invention comprises the coil winding for manufacturing surface mounted electromagnetic components as described in claim 8.

14. A coil winding for making surface mounted electromagnetic components, characterized in that: include: The first is a substantially U-shaped conductive structure made of a metallic conductive material; a second substantially U-shaped conductive structure made of a metallic conductive material; as well as an insulating structure, wherein the insulating structure is formed by molding an insulating material that is at least injected around the first substantially U-shaped conductive structure or / and the second substantially U-shaped conductive structure, and the insulating structure wraps around most of the first substantially U-shaped conductive structure or / and the second substantially U-shaped conductive structure; The cross-sectional shape of the first substantially U-shaped conductive structure is substantially rectangular and includes at least three bending segments; two of the at least three bending segments include a first surface mount soldering terminal and a second surface mount soldering terminal, and the first surface mount soldering terminal and the second surface mount soldering terminal are substantially coplanar; The cross-sectional shape of the second substantially U-shaped conductive structure is substantially rectangular and includes at least three bending segments; two of the at least three bending segments include a third surface mount soldering terminal and a fourth surface mount soldering terminal, and the third surface mount soldering terminal and the fourth surface mount soldering terminal are substantially coplanar; wherein the first surface mount soldering terminal and the second surface mount soldering terminal of the first substantially U-shaped conductive structure are substantially coplanar with the third surface mount soldering terminal and the fourth surface mount soldering terminal of the second substantially U-shaped conductive structure; The first substantially U-shaped conductive structure comprises at least three bent sections, the thickness of which is substantially the same and the thickness of which is substantially between 0.15 mm and 2 mm; The at least three bent sections of the second substantially U-shaped conductive structure have substantially the same thickness and are substantially between 0.15 mm and 1.0 mm; The first substantially U-shaped conductive structure at least partially surrounds at least a portion of the second substantially U-shaped conductive structure.

15. The coil winding for manufacturing surface mounted electromagnetic components according to claim 14, characterized in that: The metal conductive material is copper or a copper alloy.

16. The coil winding for manufacturing surface mounted electromagnetic components according to claim 14, characterized in that: At least one of the first and second substantially U-shaped conductive structures is formed by stamping and bending copper material.

17. The coil winding for manufacturing surface mounted electromagnetic components according to claim 14, characterized in that: At least one of the first and second substantially U-shaped conductive structures is formed by bending a flat copper wire with or without an insulating layer.

18. The coil winding for manufacturing surface mounted electromagnetic components according to claim 14, characterized in that: The insulating structure includes an insulating structure, which at least wraps around a first basically U-shaped conductive structure or / and most of the second basically U-shaped conductive structure; when the insulating structure at least wraps around the first basically U-shaped conductive structure, the insulating structure at least wraps around most of the first basically U-shaped conductive structure except at least a portion of the first surface mount soldering terminal and at least a portion of the second surface mount soldering terminal; when the insulating structure at least wraps around the second basically U-shaped conductive structure, the insulating structure at least wraps around most of the second basically U-shaped conductive structure except at least a portion of the third surface mount soldering terminal and at least a portion of the fourth surface mount soldering terminal.

19. An inductor component, characterized in that: The invention comprises the coil winding for making surface mounted electromagnetic components as described in claim 14.

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