Magnetic core structure

Abstract

A magnetic core structure comprises a winding part, a first flange, a second flange, a first electrode, a second electrode, a third electrode, a fourth electrode, a fifth electrode, a sixth electrode, a seventh electrode and an eighth electrode. The first flange and the second flange are arranged on the two opposite sides of the winding part in the extending direction of the winding part. The first electrode and the second electrode are arranged on the first flange and arranged in the longitudinal direction perpendicular to the extending direction. The third electrode and the fourth electrode are arranged on the first flange and are arranged along the extending direction. The fifth electrode and the sixth electrode are arranged on the second flange and are arranged along the longitudinal direction. The seventh electrode and the eighth electrode are arranged on the second flange and arranged in the extending direction. The magnetic core structure can improve the welding quality.

Description

Technical Field

[0001] The present invention relates to a magnetic core structure, and in particular to a magnetic core structure with eight electrodes. Background Art

[0002] In electronic products, the power supply usually needs to be converted by a transformer to meet the appropriate driving power of each electronic component. The transformer is mainly composed of a magnetic core and a primary coil and a secondary coil wound on the magnetic core.

[0003] The US patent publication number: US20100109827A1 proposes a chip pulse transformer to shorten the winding operation time, which has 6 electrodes. Since two of the electrodes (hereinafter referred to as "common electrodes") will have two copper wires welded thereon, and these two copper wires are welded to the common electrode twice, the common electrode must have a high strength to withstand the pressure and heat applied during hot melt welding. Two hot melt weldings will be performed on the common electrode, and the heat during the welding process will destroy the original electroplating layer of the common electrode. Due to the tin accumulation on the common electrode during the first welding process, one of the copper wires of the heated primary coil will be difficult to weld. In addition, increasing the thickness of the electroplating layer will result in poor coplanarity of the product and affect the appearance. If the electroplating layer is too thin, it will be difficult to weld the copper wire of the subsequent secondary coil. Furthermore, two hot-melt welding operations will be performed on the common electrode. The welding pressure will destroy the strength of the electrode. If it is a plated electrode, it is easy to cause the electrode to break (pad break); if it is a metal terminal electrode, it is easy to cause the metal terminal to fall off under the influence of heat. On the other hand, two copper wires need to be hot-melt welded on the common electrode in succession. Since the magnetic core itself and the machine have certain dimensional errors, and since the width of the common electrode is usually only about 0.5 millimeters, if the two copper wires are not accurately positioned during welding, the two copper wires will cross and overlap (wire overlap) above the common electrode, which will affect the reliability of its welding. Finally, the residual insulating material on the electrode will affect the surface mount technology (SMT) process, resulting in cold or false welding. Since the common electrodes are covered by two copper wires respectively, the area of ​​the original electroplating layer that is not damaged by the high temperature of hot melt welding is smaller than that of other electrodes (the original electroplating layer is beneficial to the SMT process), and the proportion of the area contaminated by the residual insulating material (insulation contamination) will be larger, which increases the risk of poor solder joints or false solder joints in the SMT process.

[0004] The above-mentioned problem of contamination caused by the cross-overlapping of the two copper wires above the electrode and the residual insulating material may be solved by dividing the electrode used to weld the two copper wires into two, that is, a pulse transformer with 8 electrodes, such as the US patent number: US20200013541A1 or US20170011843A1, etc. However, such a design requires that the upper surfaces of the four electrodes on the same side need to be on the same horizontal plane and must have good coplanarity (pads co-planarity), otherwise poor welding will occur when welding (hot pressing) the copper wire. Specifically, if the height of a certain metal terminal is too high, the copper wire at the solder joint will be easily broken (or wire break) due to excessive welding, and if the height of a certain metal terminal is too low, the welding (pressure and heat) will be insufficient, resulting in a cold solder joint or a false solder joint that affects subsequent customer use. In other words, the design of 8 electrodes requires higher manufacturing precision, or for core manufacturers, the risk of poor coplanarity caused by the design of 8 electrodes is higher. On the other hand, since a minimum insulation distance needs to be maintained between the primary coil and the secondary coil (to avoid poor withstand voltage), and due to process reasons, a minimum distance needs to be maintained between two adjacent electrodes to avoid short circuits between the two adjacent electrodes. In a limited width range, if the 6-electrode design is changed to an 8-electrode design, the width of the electrode will inevitably be reduced, but the electrode with reduced width is usually less than 0.4mm wide. In this way, if the copper wire is not accurately positioned or the electrode itself is uneven (due to core forming and electroplating), the copper wire will fall off the electrode during welding (wire slipping), causing the automatic winding machine to stop. In other words, narrow electrode pads will cause wire drop problems. Furthermore, when welding (hot pressing) the secondary coil, the spot welding head will inevitably contact the welding point of the middle electrode to which the primary coil has been welded again. This not only affects the reliability of the welding point, but also because the welding point has been welded with copper wire (primary coil), the spot welding head is lifted up, thereby causing poor welding of the secondary coil and even a risk of disconnection when welding the secondary coil.

[0005] Therefore, how to propose an improved magnetic core structure to address the above problems has become a topic of concern to those skilled in the art. Summary of the invention

[0006] The object of the present invention is to provide a magnetic core structure comprising a winding portion, a first flange, a second flange, a first electrode, a second electrode, a third electrode, a fourth electrode, a fifth electrode, a sixth electrode, a seventh electrode and an eighth electrode. The first flange and the second flange are arranged on opposite sides of the winding portion along the extension direction of the winding portion. The first electrode and the second electrode are arranged on the first flange and arranged along a longitudinal direction perpendicular to the extension direction. The third electrode and the fourth electrode are arranged on the first flange and arranged along the extension direction. The fifth electrode and the sixth electrode are arranged on the second flange and arranged along the longitudinal direction. The seventh electrode and the eighth electrode are arranged on the second flange and arranged along the extension direction.

[0007] In some embodiments, the first electrode, the second electrode and the third electrode are sequentially arranged on the first flange along a first direction, wherein the fifth electrode, the sixth electrode and the seventh electrode are sequentially arranged on the second flange along a second direction, wherein the first direction is opposite to the second direction, and wherein the first direction and the second direction are parallel to the longitudinal direction.

[0008] In some embodiments, the third electrode is closer to the winding portion than the fourth electrode, and the seventh electrode is closer to the winding portion than the eighth electrode.

[0009] In some embodiments, each of the first electrode, the second electrode, the third electrode and the fourth electrode is an electroplating electrode formed on the first flange, and each of the fifth electrode, the sixth electrode, the seventh electrode and the eighth electrode is an electroplating electrode formed on the second flange.

[0010] In some embodiments, the winding portion is used for winding the primary coil and the secondary coil sequentially thereon, wherein a first spot welding position area where the spot welding head spot welds the primary coil on the first flange does not overlap with a second spot welding position area where the spot welding head spot welds the secondary coil on the first flange in an extension direction, and wherein a third spot welding position area where the spot welding head spot welds the primary coil on the second flange does not overlap with a fourth spot welding position area where the spot welding head spot welds the secondary coil on the second flange in an extension direction.

[0011] In some embodiments, each of the second electrode and the sixth electrode has a welding region and a non-welding region arranged along the extension direction, wherein the non-welding region becomes thinner in a direction away from the welding region and has an inclined surface.

[0012] In some embodiments, the non-welding area is closer to the winding portion than the welding area.

[0013] In some embodiments, the inclined surface has an electroplating layer.

[0014] In some embodiments, each of the first electrode and the fifth electrode has a welding area and a non-welding area arranged along the extension direction, wherein the non-welding area of ​​each of the first electrode and the fifth electrode becomes thinner in a direction away from the welding area of ​​each of the first electrode and the fifth electrode and has an inclined surface.

[0015] In some embodiments, an arrangement direction of the welding area and the non-welding area of ​​each of the second electrode and the sixth electrode is opposite to an arrangement direction of the welding area and the non-welding area of ​​each of the first electrode and the fifth electrode.

[0016] In the above-mentioned magnetic core structure, the welding quality can be improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The present invention will be better understood from the following detailed description in conjunction with the accompanying drawings. It should be noted that, in accordance with standard industry practice, the features are not drawn to scale. In fact, the dimensions of the features may be increased or decreased at will to make the discussion clearer.

[0018] Figure 1 is a front view of a magnetic core structure according to a first embodiment of the present invention.

[0019] Figure 2 is a top view of a magnetic core structure according to a first embodiment of the present invention.

[0020] Figure 3 is a top view of a magnetic core structure according to a first embodiment of the present invention.

[0021] Figure 4 is a front view of a magnetic core structure according to a second embodiment of the present invention.

[0022] Figure 5 is a top view of a magnetic core structure according to a second embodiment of the present invention.

[0023] Figure 6 is a front view of a magnetic core structure according to a third embodiment of the present invention.

[0024] Figure 7 is a top view of a magnetic core structure according to a third embodiment of the present invention.

[0025] Figure 8 is a front view of a magnetic core structure according to a fourth embodiment of the present invention.

[0026] Fig. 9 is a top view of a magnetic core structure according to a fourth embodiment of the present invention. DETAILED DESCRIPTION

[0027] The following is a detailed discussion of embodiments of the present invention. However, it is understood that the embodiments provide many applicable concepts that can be implemented in a variety of specific contexts. The embodiments discussed and disclosed are for illustration only and are not intended to limit the scope of the present invention. As used herein, "first", "second", ..., etc., do not specifically refer to the meaning of order or sequence, but are only used to distinguish between elements or operations described in the same technical terms.

[0028] Figure 1 1 is a front view of a magnetic core structure 10 according to a first embodiment of the present invention. The magnetic core structure 10 comprises a winding portion 12, a first flange 14 and a second flange 16. The first flange 14 and the second flange 16 are disposed on opposite sides of the winding portion 12 along an extension direction D1 of the winding portion 12.

[0029] The magnetic core structure 10 further includes a first electrode P11, a second electrode P12, a third electrode P13, a fourth electrode P14, a fifth electrode P15, a sixth electrode P16, a seventh electrode P17, and an eighth electrode P18. The first electrode P11 and the second electrode P12 are disposed on the first flange 14 and arranged along a longitudinal direction D2 perpendicular to the extension direction D1. The third electrode P13 and the fourth electrode P14 are disposed on the first flange 14 and arranged along the extension direction D1. The fifth electrode P15 and the sixth electrode P16 are disposed on the second flange 16 and arranged along the longitudinal direction D2. The seventh electrode P17 and the eighth electrode P18 are disposed on the second flange 16 and arranged along the extension direction D1.

[0030] The first electrode P11, the second electrode P12 and the third electrode P13 are sequentially disposed on the first flange 14 along the first direction D3, and the first electrode P11, the second electrode P12 and the fourth electrode P14 are sequentially disposed on the first flange 14 along the first direction D3. The fifth electrode P15, the sixth electrode P16 and the seventh electrode P17 are sequentially disposed on the second flange 16 along the second direction D4, and the fifth electrode P15, the sixth electrode P16 and the eighth electrode P18 are sequentially disposed on the second flange 16 along the second direction D4. The first direction D3 is opposite to the second direction D4, and the first direction D3 and the second direction D4 are parallel to the longitudinal direction D2.

[0031] In detail, the first electrode P11 and the second electrode P12 are adjacent to each other and are disposed on one side of the first flange 14 in the longitudinal direction D2, the third electrode P13 and the fourth electrode P14 are adjacent to each other and are disposed on the other side of the first flange 14 in the longitudinal direction D2, the fifth electrode P15 and the sixth electrode P16 are adjacent to each other and are disposed on one side of the second flange 16 in the longitudinal direction D2, and the seventh electrode P17 and the eighth electrode P18 are adjacent to each other and are disposed on the other side of the second flange 16 in the longitudinal direction D2. The second electrode P12 is closer to the third electrode P13 and the fourth electrode P14 than the first electrode P11, and the sixth electrode P16 is closer to the seventh electrode P17 and the eighth electrode P18 than the fifth electrode P15. The third electrode P13 is closer to the winding portion 12 than the fourth electrode P14, and the seventh electrode P17 is closer to the winding portion 12 than the eighth electrode P18.

[0032] In other words, the first electrode P11 and the second electrode P12 are arranged transversely along the extension direction D1, the third electrode P13 and the fourth electrode P14 are arranged longitudinally along the extension direction D1, the fifth electrode P15 and the sixth electrode P16 are arranged transversely along the extension direction D1, and the seventh electrode P17 and the eighth electrode P18 are arranged longitudinally along the extension direction D1.

[0033] In the existing 8-electrode design, the 8 electrodes are arranged horizontally along the extension direction of the winding part, which results in that the width of the electrode must be reduced. However, the reduced width electrode is usually only less than 0.4 mm wide. In this way, if the copper wire is not accurately positioned or the electrode itself is uneven (due to core forming and electroplating), the copper wire will fall off the electrode during welding (wire slipping), thereby causing the automatic winding machine to stop. Relatively speaking, in an embodiment of the present invention, the third electrode P13 and the fourth electrode P14 are changed to be arranged longitudinally along the extension direction D1 (rather than arranged transversely), and the seventh electrode P17 and the eighth electrode P18 are also changed to be arranged longitudinally along the extension direction D1 (rather than arranged transversely). In this way, not only the third electrode P13, the fourth electrode P14, the seventh electrode P17 and the eighth electrode P18 can have space to be designed to be wider, but also the first electrode P11, the second electrode P12, the fifth electrode P15 and the sixth electrode P16 can have space to be designed to be wider. This is conducive to solving the undesirable phenomenon of wire slippage during welding due to inaccurate positioning, and is also conducive to solving the risk of line drop during welding due to repeated contact of the spot welding head with the welding point.

[0034] Each of the first electrode P11, the second electrode P12, the third electrode P13 and the fourth electrode P14 is an electroplated electrode formed on the first flange 14, and each of the fifth electrode P15, the sixth electrode P16, the seventh electrode P17 and the eighth electrode P18 is an electroplated electrode formed on the second flange 16, but the present invention is not limited to this. In other embodiments of the present invention, each of the first electrode P11, the second electrode P12, the third electrode P13 and the fourth electrode P14 may also be a metal terminal electrode disposed on the first flange 14, and each of the fifth electrode P15, the sixth electrode P16, the seventh electrode P17 and the eighth electrode P18 may also be a metal terminal electrode disposed on the second flange 16.

[0035] Figure 2 1 is a top view of a magnetic core structure 10 according to a first embodiment of the present invention, which shows a schematic diagram of a coil being wound around a winding portion 12 of the magnetic core structure 10. Specifically, Figure 2 The left figure is a schematic diagram of the primary coil being wound on the winding part 12. Figure 2 The right figure of FIG. 1 is a schematic diagram of the primary coil and the secondary coil being wound on the winding portion 12. In addition, for convenience of representation, Figure 2 The number of turns of the primary coil and / or the secondary coil wound on the winding portion 12 of the magnetic core structure 10 is simplified. In fact, the number of turns of the primary coil and / or the secondary coil wound on the winding portion 12 of the magnetic core structure 10 is smaller than that of the secondary coil. Figure 2 There is much more than what is shown.

[0036] The winding portion 12 of the magnetic core structure 10 is used for winding the first winding W1, the second winding W2, the third winding W3 and the fourth winding W4 thereon, wherein the first winding W1 and the second winding W2 constitute a primary coil, wherein the third winding W3 and the fourth winding W4 constitute a secondary coil. In other words, the first winding W1 and the second winding W2 are firstly wound on the winding portion 12 to constitute a primary coil, and after the winding of the primary coil is completed, the third winding W3 and the fourth winding W4 are then wound on the winding portion 12 to constitute a secondary coil.

[0037] exist Figure 2 In the illustrated embodiment, two ends of the first winding W1 are respectively connected to the first electrode P11 and the seventh electrode P17, two ends of the second winding W2 are respectively connected to the third electrode P13 and the fifth electrode P15, two ends of the third winding W3 are respectively connected to the second electrode P12 and the eighth electrode P18, and two ends of the fourth winding W4 are respectively connected to the fourth electrode P14 and the sixth electrode P16.

[0038] Specifically, each electrode (each of the first electrode P11, the second electrode P12, the third electrode P13, the fourth electrode P14, the fifth electrode P15, the sixth electrode P16, the seventh electrode P17 and the eighth electrode P18) is welded with only one copper wire, and there is no situation where two copper wires need to be welded to one electrode, which can effectively avoid the problem of two copper wires crossing and overlapping (or stacking) on ​​the same electrode and the electrode pad being contaminated by residual insulating material.

[0039] exist Figure 2 In the embodiment, as far as the first flange 14 is concerned, the upper surface of the first electrode P11 connected to the first winding W1 of the primary coil needs to be flush with the upper surface of the third electrode P13 connected to the second winding W2 of the primary coil to achieve better welding quality, and the upper surface of the second electrode P12 connected to the third winding W3 of the secondary coil needs to be flush with the upper surface of the fourth electrode P14 connected to the fourth winding W4 of the secondary coil to achieve better welding quality. As far as the second flange 16 is concerned, the upper surface of the fifth electrode P15 connected to the second winding W2 of the primary coil needs to be flush with the upper surface of the seventh electrode P17 connected to the first winding W1 of the primary coil to achieve better welding quality, and the upper surface of the sixth electrode P16 connected to the fourth winding W4 of the secondary coil needs to be flush with the upper surface of the eighth electrode P18 connected to the third winding W3 of the secondary coil to achieve better welding quality.

[0040] In the existing 8-electrode design, the 8 electrodes are arranged horizontally along the extension direction of the winding portion, so the upper surfaces of the 4 electrodes on the same side are required to be on the same horizontal plane and must have good coplanarity, otherwise poor welding will occur during welding (hot pressing) of the copper wire, resulting in wire breakage. Relatively speaking, in the first embodiment of the present invention, the third electrode P13 and the fourth electrode P14 are arranged longitudinally along the extension direction D1 (rather than transversely), and the seventh electrode P17 and the eighth electrode P18 are arranged longitudinally along the extension direction D1 (rather than transversely). In this way, Figure 2In the illustrated embodiment, after the primary coil is wound and the first electrode P11 and the third electrode P13 are spot-welded on the first flange 14, as long as the upper surface of the first electrode P11 and the upper surface of the third electrode P13 have good coplanarity, the primary coil on the first flange 14 can achieve better welding quality (ensuring that the spot welding head will only contact the first electrode P11 and the third electrode P13 at the same time when spot welding the primary coil on the first flange 14, but not the second electrode P12 and the fourth electrode P14). After the primary coil is wound and the fifth electrode P15 and the seventh electrode P17 are spot-welded on the second flange 16, as long as the upper surface of the fifth electrode P15 and the upper surface of the seventh electrode P17 have good coplanarity, the primary coil on the second flange 16 can achieve better welding quality (ensuring that the spot welding head will only contact the fifth electrode P15 and the seventh electrode P17 at the same time when spot welding the primary coil on the second flange 16, but not the sixth electrode P16 and the eighth electrode P18). Then, after winding the secondary coil and spot welding the second electrode P12 and the fourth electrode P14 on the first flange 14, as long as the upper surface of the second electrode P12 and the upper surface of the fourth electrode P14 have a good coplanarity, the secondary coil on the first flange 14 can achieve a better welding quality electrode (ensuring that the spot welding head will only contact the second electrode P12 and the fourth electrode P14 at the same time when spot welding the secondary coil on the first flange 14 without contacting the first electrode P11 and the third electrode P13), after winding the secondary coil and spot welding the sixth electrode P16 and the eighth electrode P18 on the second flange 16, as long as the upper surface of the sixth electrode P16 and the upper surface of the eighth electrode P18 have a good coplanarity, the secondary coil on the second flange 16 can achieve a better welding quality electrode (ensuring that the spot welding head will only contact the sixth electrode P16 and the eighth electrode P18 at the same time when spot welding the secondary coil on the second flange 16 without contacting the fifth electrode P15 and the seventh electrode P17).

[0041] Specifically, in Figure 2 In the embodiment shown, after the secondary coil is wound and the second electrode P12 and the fourth electrode P14 are spot welded on the first flange 14, the position of the spot welding head can be adjusted left and right along the extension direction D1 on the first flange 14 to avoid the spot welding head from contacting or damaging the welding points of the first electrode P11 and the third electrode P13. After the secondary coil is wound and the sixth electrode P16 and the eighth electrode P18 are spot welded on the second flange 16, the position of the spot welding head can be adjusted left and right along the extension direction D1 on the second flange 16 to avoid the spot welding head from contacting or damaging the welding points of the fifth electrode P15 and the seventh electrode P17. Figure 2As shown, the first spot welding position area R11 on the first electrode P11 and the third electrode P13 on the first flange 14 where the spot welding head spot welds the primary coil does not overlap with the second spot welding position area R12 on the second electrode P12 and the fourth electrode P14 on the first flange 14 where the spot welding head spot welds the secondary coil in the extension direction D1, and the third spot welding position area R13 on the fifth electrode P15 and the seventh electrode P17 on the second flange 16 where the spot welding head spot welds the primary coil does not overlap with the fourth spot welding position area R14 on the sixth electrode P16 and the eighth electrode P18 on the second flange 16 where the spot welding head spot welds the secondary coil in the extension direction D1. In this way, not only the reliability of the primary coil's solder joints (i.e., the solder joints of the first electrode P11 and the third electrode P13 and the solder joints of the fifth electrode P15 and the seventh electrode P17) is improved (the solder joints of the primary coil will not contact the spot welding head again due to the secondary coil's spot welding), but also the solder joint quality of the second electrode P12 and the fourth electrode P14 is no longer affected by the poor coplanarity with the first electrode P11 and / or the third electrode P13, and the solder joint quality of the sixth electrode P16 and the eighth electrode P18 is no longer affected by the poor coplanarity with the fifth electrode P15 and / or the seventh electrode P17. As long as the second electrode P12 and the fourth electrode P14 have good coplanarity, and the sixth electrode P16 and the eighth electrode P18 have good coplanarity, a higher welding quality can be achieved to avoid wire breakage during spot welding.

[0042] In other words, in the existing 8-electrode design, the 8 electrodes are arranged horizontally along the extension direction of the winding portion, so the upper surfaces of the 4 electrodes on the same side are required to be on the same horizontal plane and must have good coplanarity. Figure 2 As for the first flange 14 of the magnetic core structure 10 shown in the figure, as long as the first electrode P11 and the third electrode P13 have the same coplanarity and the second electrode P12 and the fourth electrode P14 have the same coplanarity, the welding can be ensured to be continuous (without requiring the first electrode P11, the second electrode P12, the third electrode P13 and the fourth electrode P14 to have the same coplanarity). Figure 2 For the second flange 16 of the magnetic core structure 10 shown, as long as the fifth electrode P15 and the seventh electrode P17 have consistent coplanarity and the sixth electrode P16 and the eighth electrode P18 have consistent coplanarity, it is possible to ensure that the welding is not broken (without requiring the fifth electrode P15, the sixth electrode P16, the seventh electrode P17 and the eighth electrode P18 to have consistent coplanarity). This not only reduces the breakage rate but also reduces the manufacturing precision required by the design of the eight electrodes.

[0043] Furthermore, the magnetic core structure 10 designs the third electrode P13 and the fourth electrode P14 to be arranged longitudinally along the extension direction D1 and designs the seventh electrode P17 and the eighth electrode P18 to be arranged longitudinally along the extension direction D1, so that the third electrode P13, the fourth electrode P14, the seventh electrode P17 and the eighth electrode P18 only contact the spot welding head once during the entire welding process of the primary coil and the secondary coil, which is beneficial to ensuring the welding quality and the service life of the welding spot head.

[0044] Please go back Figure 1 , the winding portion 12 is an octagonal column, but the present invention is not limited thereto. In other embodiments of the present invention, the winding portion is a rectangular column. Specifically, the winding portion 12 is an octagonal column, which has at least the following advantages: (1) When the coil is wound on the magnetic core structure 10, the magnetic core structure 10 will rotate at high speed with the center of the octagonal cross section as the axis, so that the coil is wound on the middle column of the magnetic core structure 10 (i.e., the winding portion 12). Since the octagonal cross section is closer to a circle than the rectangular cross section, the mechanism for performing winding can more easily wind the coil on the eight side surfaces of the winding portion 12 to ensure the consistency of the winding performance. (2) There are four inclined surfaces as transitions between the horizontal side surface and the vertical side surface of the winding portion 12, which avoids the right angle (or quasi-right angle) bending angle of the winding caused by the existing rectangular cross-section magnetic core middle column. The transition inclined surface is conducive to making the coil fit the winding portion 12. The reduced bending angle makes the coil fit the winding portion 12 better, which can prevent the problem of poor high voltage. (3) When the bevel transitions to the vertical or horizontal side surface, the bending angle of the coil has been changed from the existing right angle to an obtuse angle, and the mechanical stress of the coil at the turning point is greatly reduced, which can effectively prevent the insulation layer of the coil from falling off, thereby improving the product's withstand voltage performance. (4) The transition bevel is more conducive to maintaining the consistency of the winding without overlapping wires.

[0045] like Figure 1 As shown, the first flange 14 further has an inclined portion 15, which is a straight-line slope extending from one end of the winding portion 12 to the fourth electrode P14 on the first flange 14 with almost no step difference. Figure 1 As shown, the second flange 16 also has an inclined portion 17, which is a straight-line slope extending from the other end of the winding portion 12 to the eighth electrode P18 on the second flange 16 with almost no step difference. The inclined portion 15 and the inclined portion 17 have at least the following advantages: (1) The first flange 14 has the inclined portion 15 for guiding the fourth winding W4 to the fourth electrode P14, so that the fourth winding W4 can be better guided from one end of the winding portion 12 to the fourth electrode P14, and the second flange 16 has the inclined portion 17 for guiding the third winding W3 to the eighth electrode P18, so that the third winding W3 can be better guided from the other end of the winding portion 12 to the eighth electrode P18.

[0046] Figure 3 1 is a top view of a magnetic core structure 10 according to a first embodiment of the present invention, which shows a schematic diagram of a coil being wound around a winding portion 12 of the magnetic core structure 10. Specifically, Figure 3 The left figure is a schematic diagram of the primary coil being wound on the winding part 12. Figure 3 The right figure of FIG. 1 is a schematic diagram of the primary coil and the secondary coil being wound on the winding portion 12. In addition, for convenience of representation, Figure 3 The number of turns of the primary coil and / or the secondary coil wound on the winding portion 12 of the magnetic core structure 10 is simplified. In fact, the number of turns of the primary coil and / or the secondary coil wound on the winding portion 12 of the magnetic core structure 10 is smaller than that of the secondary coil. Figure 3 There is much more than what is shown.

[0047] exist Figure 3 In the illustrated embodiment, two ends of the first winding W1 are respectively connected to the second electrode P12 and the seventh electrode P17, two ends of the second winding W2 are respectively connected to the third electrode P13 and the sixth electrode P16, two ends of the third winding W3 are respectively connected to the first electrode P11 and the eighth electrode P18, and two ends of the fourth winding W4 are respectively connected to the fourth electrode P14 and the fifth electrode P15.

[0048] exist Figure 3 In the illustrated embodiment, with respect to the first flange 14, the upper surface of the second electrode P12 connected to the first winding W1 of the primary coil needs to be flush with the upper surface of the third electrode P13 connected to the second winding W2 of the primary coil to achieve better welding quality, and the upper surface of the first electrode P11 connected to the third winding W3 of the secondary coil needs to be flush with the upper surface of the fourth electrode P14 connected to the fourth winding W4 of the secondary coil to achieve better welding quality. With respect to the second flange 16, the upper surface of the sixth electrode P16 connected to the second winding W2 of the primary coil needs to be flush with the upper surface of the seventh electrode P17 connected to the first winding W1 of the primary coil to achieve better welding quality, and the upper surface of the fifth electrode P15 connected to the fourth winding W4 of the secondary coil needs to be flush with the upper surface of the eighth electrode P18 connected to the third winding W3 of the secondary coil to achieve better welding quality.

[0049] In the existing 8-electrode design, the 8 electrodes are arranged horizontally along the extension direction of the winding portion, so the upper surfaces of the 4 electrodes on the same side are required to be on the same horizontal plane and must have good coplanarity, otherwise poor welding will occur during welding (hot pressing) of the copper wire, resulting in wire breakage. Relatively speaking, in the first embodiment of the present invention, the third electrode P13 and the fourth electrode P14 are arranged longitudinally along the extension direction D1 (rather than transversely), and the seventh electrode P17 and the eighth electrode P18 are arranged longitudinally along the extension direction D1 (rather than transversely). In this way, Figure 3In the illustrated embodiment, after the primary coil is wound and the second electrode P12 and the third electrode P13 are spot-welded on the first flange 14, as long as the upper surface of the second electrode P12 and the upper surface of the third electrode P13 have good coplanarity, the primary coil on the first flange 14 can achieve better welding quality (ensuring that the spot welding head will only contact the second electrode P12 and the third electrode P13 at the same time when spot welding the primary coil on the first flange 14, but not contact the first electrode P11 and the fourth electrode P14). After the primary coil is wound and the sixth electrode P16 and the seventh electrode P17 are spot-welded on the second flange 16, as long as the upper surface of the sixth electrode P16 and the upper surface of the seventh electrode P17 have good coplanarity, the primary coil on the second flange 16 can achieve better welding quality (ensuring that the spot welding head will only contact the sixth electrode P16 and the seventh electrode P17 at the same time when spot welding the primary coil on the second flange 16, but not contact the fifth electrode P15 and the eighth electrode P18). Then, after winding the secondary coil and spot welding the first electrode P11 and the fourth electrode P14 on the first flange 14, as long as the upper surface of the first electrode P11 and the upper surface of the fourth electrode P14 have a good coplanarity, the secondary coil on the first flange 14 can achieve a better welding quality electrode (ensuring that the spot welding head will only contact the first electrode P11 and the fourth electrode P14 at the same time when spot welding the secondary coil on the first flange 14, but not the second electrode P12 and the third electrode P13). After winding the secondary coil and spot welding the fifth electrode P15 and the eighth electrode P18 on the second flange 16, as long as the upper surface of the fifth electrode P15 and the upper surface of the eighth electrode P18 have a good coplanarity, the secondary coil on the second flange 16 can achieve a better welding quality electrode (ensuring that the spot welding head will only contact the fifth electrode P15 and the eighth electrode P18 at the same time when spot welding the secondary coil on the second flange 16, but not the sixth electrode P16 and the seventh electrode P17).

[0050] Specifically, in Figure 3 In the embodiment shown, after the secondary coil is wound and the first electrode P11 and the fourth electrode P14 are spot welded on the first flange 14, the position of the spot welding head can be adjusted left and right along the extension direction D1 on the first flange 14 to avoid the spot welding head from contacting or damaging the welding points of the second electrode P12 and the third electrode P13. After the secondary coil is wound and the fifth electrode P15 and the eighth electrode P18 are spot welded on the second flange 16, the position of the spot welding head can be adjusted left and right along the extension direction D1 on the second flange 16 to avoid the spot welding head from contacting or damaging the welding points of the sixth electrode P16 and the seventh electrode P17. Figure 3As shown, the first spot welding position area R21 on the second electrode P12 and the third electrode P13 on the first flange 14 where the spot welding head spot welds the primary coil does not overlap with the second spot welding position area R22 on the first electrode P11 and the fourth electrode P14 on the first flange 14 where the spot welding head spot welds the secondary coil in the extension direction D1, and the third spot welding position area R23 on the sixth electrode P16 and the seventh electrode P17 on the second flange 16 where the spot welding head spot welds the primary coil does not overlap with the fourth spot welding position area R24 on the fifth electrode P15 and the eighth electrode P18 on the second flange 16 where the spot welding head spot welds the secondary coil in the extension direction D1. In this way, not only the reliability of the primary coil's solder joints (i.e., the solder joints of the second electrode P12 and the third electrode P13 and the solder joints of the sixth electrode P16 and the seventh electrode P17) is improved (the solder joints of the primary coil will not contact the spot welding head again due to the secondary coil's spot welding), but also the solder joint quality of the first electrode P11 and the fourth electrode P14 is no longer affected by the poor coplanarity between the first electrode P11 and the fourth electrode P14 and the poor coplanarity between the fifth electrode P15 and the eighth electrode P18 and the sixth electrode P16 and / or the seventh electrode P17. As long as the first electrode P11 and the fourth electrode P14 have good coplanarity, and the fifth electrode P15 and the eighth electrode P18 have good coplanarity, a higher welding quality can be achieved to avoid wire breakage during spot welding.

[0051] In other words, in the existing 8-electrode design, the 8 electrodes are arranged horizontally along the extension direction of the winding portion, so the upper surfaces of the 4 electrodes on the same side are required to be on the same horizontal plane and must have good coplanarity. Figure 3 As for the first flange 14 of the magnetic core structure 10 shown in the figure, as long as the first electrode P11 and the fourth electrode P14 have the same coplanarity and the second electrode P12 and the third electrode P13 have the same coplanarity, the welding can be ensured to be continuous (without requiring the first electrode P11, the second electrode P12, the third electrode P13 and the fourth electrode P14 to have the same coplanarity). Figure 3 For the second flange 16 of the magnetic core structure 10 shown, as long as the fifth electrode P15 and the eighth electrode P18 have consistent coplanarity and the sixth electrode P16 and the seventh electrode P17 have consistent coplanarity, the welding can be guaranteed to be unbroken (without requiring the fifth electrode P15, the sixth electrode P16, the seventh electrode P17 and the eighth electrode P18 to have consistent coplanarity). This can not only reduce the breakage rate but also reduce the manufacturing precision required by the design of the eight electrodes.

[0052] Figure 42 is a front view schematic diagram of a magnetic core structure 20 according to a second embodiment of the present invention. The magnetic core structure 20 includes a winding portion 12, a first flange 24 and a second flange 26. Figure 4 As shown, the magnetic core structure 20 further includes a first electrode P11 , a second electrode P22 , a third electrode P13 , a fourth electrode P14 , a fifth electrode P15 , a sixth electrode P26 , a seventh electrode P17 and an eighth electrode P18 .

[0053] The magnetic core structure 20 is substantially similar to the magnetic core structure 10, except that the second electrode P22 of the magnetic core structure 20 is different from the second electrode P12 of the magnetic core structure 10, and the sixth electrode P26 of the magnetic core structure 20 is different from the sixth electrode P16 of the magnetic core structure 10. For the identical parts of the magnetic core structure 20 and the magnetic core structure 10 and the advantages they can bring, please refer to the aforementioned content and will not be repeated here.

[0054] In the second embodiment of the present invention, each of the second electrode P22 and the sixth electrode P26 of the magnetic core structure 20 has a welding area S1 and a non-welding area S2 arranged along the extension direction D1. The non-welding area S2 is closer to the winding portion 12 than the welding area S1. The non-welding area S2 becomes thinner along the extension direction D1 and in a direction away from the welding area S1 and has an inclined surface.

[0055] Figure 5 1 is a schematic top view of a magnetic core structure 20 according to a second embodiment of the present invention, which shows a schematic diagram of a coil being wound on the winding portion 12 of the magnetic core structure 20. Specifically, Figure 5 The left figure is a schematic diagram of the primary coil being wound on the winding portion 12 of the magnetic core structure 20. Figure 5 The right figure of FIG. 1 is a schematic diagram of the primary coil and the secondary coil being wound on the winding portion 12 of the magnetic core structure 20. In addition, for convenience of representation, Figure 5 The number of turns of the primary coil and / or the secondary coil wound on the winding portion 12 of the magnetic core structure 20 is simplified. In fact, the number of turns of the primary coil and / or the secondary coil wound on the winding portion 12 of the magnetic core structure 20 is smaller than that of the secondary coil. Figure 5 There is much more than what is shown.

[0056] It is worth mentioning that Figure 5 The coil shown is connected to 8 electrodes in a configuration similar to Figure 2 The coil is connected to an 8-electrode configuration. Figure 5 The advantages of the configuration of the coil connected to 8 electrodes can be seen in the above Figure 2 The following will describe the additional advantages brought by the difference between the magnetic core structure 20 and the magnetic core structure 10 (the second electrode P22 and the sixth electrode P26 both have the welding area S1 and the non-welding area S2 with an inclined surface).

[0057] In the second embodiment of the present invention, one end of the third winding W3 is welded to the welding area S1 of the second electrode P22 but not welded to the non-welding area S2 of the second electrode P22, and one end of the fourth winding W4 is welded to the welding area S1 of the sixth electrode P26 but not welded to the non-welding area S2 of the sixth electrode P26.

[0058] The second electrode P22 has an inclined surface in its non-welding area S2, which not only increases the strength of the electrode against impact and vibration, but also effectively avoids excessive contact between the spot welding head and the non-welding area S2 of the second electrode P22 when the first winding W1 of the primary coil is welded to the first electrode P11. The sixth electrode P26 has an inclined surface in its non-welding area S2, which effectively avoids excessive contact between the spot welding head and the non-welding area S2 of the sixth electrode P26 when the second winding W2 of the primary coil is welded to the fifth electrode P15. Specifically, the magnetic core structure 20 designs the second electrode P22 and the sixth electrode P26 to also have a non-welding area S2 with an inclined surface, so that the second electrode P22 and the sixth electrode P26 only contact the spot welding head once during the entire welding process of the primary coil and the secondary coil (since the non-welding area S2 of the second electrode P22 is an inclined surface, when the spot welding head welds the first winding W1 of the primary coil to the first electrode P11, the spot welding head basically does not contact the non-welding area S2 of the second electrode P22; since the non-welding area S2 of the sixth electrode P26 is an inclined surface, when the spot welding head welds the second winding W2 of the primary coil to the fifth electrode P15, the spot welding head basically does not contact the non-welding area S2 of the sixth electrode P26), which is beneficial to ensuring the welding quality and the service life of the spot welding head.

[0059] On the other hand, the inclined surface of the non-welding area S2 of each of the second electrode P22 and the sixth electrode P26 is also designed with an electroplating layer. The inclined surface can alleviate the aggregation of all the plated tin to the solder joint to a certain extent, and the inclined surface is not easily contaminated by insulating residues, thereby improving the welding reliability of subsequent SMT processes.

[0060] Figure 6 3 is a front view schematic diagram of a magnetic core structure 30 according to a third embodiment of the present invention. The magnetic core structure 30 includes a winding portion 12, a first flange 34 and a second flange 36. Figure 6 As shown, the magnetic core structure 30 further includes a first electrode P31 , a second electrode P22 , a third electrode P13 , a fourth electrode P34 , a fifth electrode P35 , a sixth electrode P26 , a seventh electrode P17 and an eighth electrode P38 .

[0061] The magnetic core structure 30 is substantially similar to the magnetic core structure 20, except that the first electrode P31 of the magnetic core structure 30 is different from the first electrode P11 of the magnetic core structure 20, and the fifth electrode P35 of the magnetic core structure 30 is different from the fifth electrode P15 of the magnetic core structure 20. For the identical parts of the magnetic core structure 30 and the advantages they can bring, please refer to the aforementioned content and will not be repeated here.

[0062] In the third embodiment of the present invention, each of the first electrode P31 and the fifth electrode P35 of the magnetic core structure 30 has a welding area S1 and a non-welding area S2 arranged along the extension direction D1, and the welding area S1 of each of the first electrode P31 and the fifth electrode P35 is closer to the winding portion 12 than the non-welding area S2, and the non-welding area S2 of each of the first electrode P31 and the fifth electrode P35 is thinner along the extension direction D1 and in a direction away from the welding area S1 and has an inclined surface. The non-welding area S2 of each of the second electrode P22 and the sixth electrode P26 of the magnetic core structure 30 is closer to the winding portion 12 than the welding area S1. In other words, the arrangement direction of the welding area S1 and the non-welding area S2 of each of the second electrode P22 and the sixth electrode P26 of the magnetic core structure 30 is opposite to the arrangement direction of the welding area S1 and the non-welding area S2 of each of the first electrode P31 and the fifth electrode P35 of the magnetic core structure 30.

[0063] Figure 7 is a schematic top view of a magnetic core structure 30 according to a third embodiment of the present invention, which shows a schematic diagram of a coil being wound on the winding portion 12 of the magnetic core structure 30. Specifically, Figure 7 The left figure is a schematic diagram of the primary coil being wound on the winding portion 12 of the magnetic core structure 30. Figure 7 The right figure of FIG. 3 is a schematic diagram of the primary coil and the secondary coil being wound on the winding portion 12 of the magnetic core structure 30. In addition, for convenience of representation, Figure 7 The number of turns of the primary coil and / or the secondary coil wound on the winding portion 12 of the magnetic core structure 30 is simplified. In fact, the number of turns of the primary coil and / or the secondary coil wound on the winding portion 12 of the magnetic core structure 30 is smaller than that of the secondary coil. Figure 7 There is much more than what is shown.

[0064] It is worth mentioning that Figure 7 The coil shown is connected to 8 electrodes in a configuration similar to Figure 2 The coil is connected to an 8-electrode configuration. Figure 7 The advantages of the configuration of the coil connected to 8 electrodes can be seen in the above Figure 2The following will describe the additional advantages brought by the difference between the magnetic core structure 30 and the magnetic core structure 20 (the first electrode P31 and the fifth electrode P35 both have the welding area S1 and the non-welding area S2 with an inclined surface).

[0065] In the third embodiment of the present invention, one end of the first winding W1 is welded to the welding area S1 of the first electrode P31 but not welded to the non-welding area S2 of the first electrode P31, and one end of the second winding W2 is welded to the welding area S1 of the fifth electrode P35 but not welded to the non-welding area S2 of the fifth electrode P35.

[0066] The first electrode P31 has an inclined surface in its non-welding area S2, which not only increases the strength of the electrode against impact and vibration, but also effectively avoids excessive contact between the spot welding head and the non-welding area S2 of the first electrode P31 when the third winding W3 of the secondary coil is welded to the second electrode P22. The fifth electrode P35 has an inclined surface in its non-welding area S2, which effectively avoids excessive contact between the spot welding head and the non-welding area S2 of the fifth electrode P35 when the fourth winding W4 of the secondary coil is welded to the sixth electrode P26. Specifically, the magnetic core structure 30 designs the first electrode P31 and the fifth electrode P35 to also have a non-welding area S2 with an inclined surface, so that the first electrode P31 and the fifth electrode P35 only contact the spot welding head once during the entire welding process of the primary coil and the secondary coil (since the non-welding area S2 of the first electrode P31 is an inclined surface, when the spot welding head welds the third winding W3 of the secondary coil to the second electrode P22, the spot welding head basically does not contact the non-welding area S2 of the first electrode P31; since the non-welding area S2 of the fifth electrode P35 is an inclined surface, when the spot welding head welds the fourth winding W4 of the secondary coil to the sixth electrode P26, the spot welding head basically does not contact the non-welding area S2 of the fifth electrode P35), which is beneficial to ensuring the welding quality and the service life of the spot welding head.

[0067] On the other hand, the inclined surface of the non-welding area S2 of each of the first electrode P31 and the fifth electrode P35 is also designed with an electroplating layer. The inclined surface can alleviate the aggregation of all the plated tin to the solder joint to a certain extent, and the inclined surface is not easily contaminated by insulating residues, thereby improving the welding reliability of subsequent SMT processes.

[0068] Another difference between the core structure 30 and the core structure 20 is that the fourth electrode P34 of the core structure 30 is different from the fourth electrode P14 of the core structure 20, and the eighth electrode P38 of the core structure 30 is different from the eighth electrode P18 of the core structure 20. In detail, the upper surfaces of the fourth electrode P14 and the eighth electrode P18 of the core structure 20 are rectangular, while the upper surfaces of the fourth electrode P34 and the eighth electrode P38 of the core structure 30 are non-rectangular, but have a missing corner on the basis of the rectangular shape, and the missing corner faces the inclined portion (the missing corner of the fourth electrode P34 faces the inclined portion 15 of the first flange 34, and the missing corner of the eighth electrode P38 faces the inclined portion 17 of the second flange 36). The fourth winding W4 is guided from one end of the winding portion 12 along the inclined portion 15 and the notch of the fourth electrode P34 to the fourth electrode P34, and the third winding W3 is guided from one end of the winding portion 12 along the inclined portion 17 and the notch of the eighth electrode P38 to the eighth electrode P38, thereby reducing the floating of the fourth winding W4 and the third winding W3, reducing the load on the fourth winding W4 and the third winding W3, and suppressing the bending of the fourth winding W4 and the third winding W3 and suppressing the breakage of the fourth winding W4 and the third winding W3.

[0069] Figure 8 4 is a front view schematic diagram of a magnetic core structure 40 according to a fourth embodiment of the present invention. The magnetic core structure 40 includes a winding portion 12, a first flange 44 and a second flange 46. Figure 8 As shown, the magnetic core structure 40 further includes a first electrode P41 , a second electrode P42 , a third electrode P13 , a fourth electrode P34 , a fifth electrode P45 , a sixth electrode P46 , a seventh electrode P17 and an eighth electrode P38 .

[0070] The magnetic core structure 40 is substantially similar to the magnetic core structure 30, except that the arrangement of the welding area S1 and the non-welding area S2 of each of the first electrode P41, the second electrode P42, the fifth electrode P45 and the sixth electrode P46 of the magnetic core structure 40 is opposite to the arrangement of the welding area S1 and the non-welding area S2 of each of the first electrode P31, the second electrode P22, the fifth electrode P35 and the sixth electrode P26 of the magnetic core structure 30. For the identical or similar parts of the magnetic core structure 40 and the magnetic core structure 30 and the advantages they can bring, please refer to the aforementioned content and will not be repeated here.

[0071] In the fourth embodiment of the present invention, each of the first electrode P41, the second electrode P42, the fifth electrode P45, and the sixth electrode P46 of the magnetic core structure 40 has a welding area S1 and a non-welding area S2 arranged along the extension direction D1, and the non-welding area S2 of each of the first electrode P41, the second electrode P42, the fifth electrode P45, and the sixth electrode P46 is thinned along the extension direction D1 and has an inclined surface in the direction away from the welding area S1. The non-welding area S2 of each of the first electrode P41 and the fifth electrode P45 is closer to the winding portion 12 than the welding area S1, and the welding area S1 of each of the second electrode P42 and the sixth electrode P46 is closer to the winding portion 12 than the non-welding area S2. In other words, the arrangement direction of the welding area S1 and the non-welding area S2 of each of the second electrode P42 and the sixth electrode P46 of the magnetic core structure 40 is opposite to the arrangement direction of the welding area S1 and the non-welding area S2 of each of the first electrode P41 and the fifth electrode P45 of the magnetic core structure 40.

[0072] Fig. 9 1 is a schematic top view of a magnetic core structure 40 according to a fourth embodiment of the present invention, which shows a schematic diagram of a coil being wound around the winding portion 12 of the magnetic core structure 40. Specifically, Fig. 9 The left figure is a schematic diagram of the primary coil being wound on the winding portion 12 of the magnetic core structure 40. Fig. 9 The right figure of FIG. 4 is a schematic diagram of the primary coil and the secondary coil being wound on the winding portion 12 of the magnetic core structure 40. In addition, for convenience of representation, Fig. 9 The number of turns of the primary coil and / or the secondary coil wound on the winding portion 12 of the magnetic core structure 40 is simplified. In fact, the number of turns of the primary coil and / or the secondary coil wound on the winding portion 12 of the magnetic core structure 40 is smaller than that of the secondary coil. Fig. 9 There is much more than what is shown.

[0073] It is worth mentioning that Fig. 9 The coil shown is connected to 8 electrodes in a configuration similar to Figure 3 The coil is connected to an 8-electrode configuration. Fig. 9 The advantages of the configuration of the coil connected to 8 electrodes can be seen in the above Figure 3 The relevant contents that have been stated will not be repeated here.

[0074] In the fourth embodiment of the present invention, one end of the first winding W1 is welded to the welding area S1 of the second electrode P42 but not to the non-welding area S2 of the second electrode P42, one end of the second winding W2 is welded to the welding area S1 of the sixth electrode P46 but not to the non-welding area S2 of the sixth electrode P46, one end of the third winding W3 is welded to the welding area S1 of the first electrode P41 but not to the non-welding area S2 of the first electrode P41, and one end of the fourth winding W4 is welded to the welding area S1 of the fifth electrode P45 but not to the non-welding area S2 of the fifth electrode P45.

[0075] The first electrode P41 has an inclined surface in its non-welding area S2, which not only increases the strength of the electrode against impact and vibration, but also effectively avoids excessive contact between the spot welding head and the non-welding area S2 of the second electrode P42 when the first winding W1 of the primary coil is welded to the second electrode P42. The second electrode P42 has an inclined surface in its non-welding area S2, which effectively avoids excessive contact between the spot welding head and the non-welding area S2 of the first electrode P41 when the third winding W3 of the secondary coil is welded to the first electrode P41. The fifth electrode P45 has an inclined surface in its non-welding area S2, which effectively avoids excessive contact between the spot welding head and the non-welding area S2 of the fifth electrode P45 when the second winding W2 of the primary coil is welded to the sixth electrode P46. The sixth electrode P46 has an inclined surface in its non-welding area S2, which effectively avoids excessive contact between the spot welding head and the non-welding area S2 of the sixth electrode P46 when the fourth winding W4 of the secondary coil is welded to the fifth electrode P45. Specifically, the magnetic core structure 40 designs the first electrode P41, the second electrode P42, the fifth electrode P45 and the sixth electrode P46 to have a non-welding area S2 that is an inclined surface, so that the first electrode P41, the second electrode P42, the fifth electrode P45 and the sixth electrode P46 can only contact the spot welding head once during the entire welding process of the primary coil and the secondary coil (because the non-welding area S2 of the first electrode P41 is an inclined surface, when the spot welding head welds the first winding W1 of the primary coil to the second electrode P42, the spot welding head basically does not contact the non-welding area S2 of the first electrode P41; because the non-welding area S2 of the second electrode P42 is an inclined surface, When the spot welding head welds the third winding W3 of the secondary coil to the first electrode P41, the spot welding head basically does not touch the non-welding area S2 of the second electrode P42; since the non-welding area S2 of the fifth electrode P45 is an inclined surface, when the spot welding head welds the second winding W2 of the primary coil to the sixth electrode P46, the spot welding head basically does not touch the non-welding area S2 of the fifth electrode P45; since the non-welding area S2 of the sixth electrode P46 is an inclined surface, when the spot welding head welds the fourth winding W4 of the secondary coil to the fifth electrode P45, the spot welding head basically does not touch the non-welding area S2 of the sixth electrode P46), which is beneficial to ensure the welding quality and the service life of the welding spot head.

[0076] According to the above, for the magnetic core structure 40, all 8 electrodes (the first electrode P41, the second electrode P42, the third electrode P13, the fourth electrode P34, the fifth electrode P45, the sixth electrode P46, the seventh electrode P17 and the eighth electrode P38) will only contact the spot welding head once during the entire welding process of the primary coil and the secondary coil, which is conducive to better ensuring the welding quality and the service life of the welding spot head.

[0077] On the other hand, the inclined surface of the non-welding area S2 of each of the first electrode P41, the second electrode P42, the fifth electrode P45 and the sixth electrode P46 is also designed to have a plating layer. The inclined surface can alleviate the aggregation of all the plating tin to the solder joint to a certain extent, and the inclined surface is not easily contaminated by insulating residues, which can improve the welding reliability of the subsequent SMT process.

[0078] In summary, the present invention proposes a magnetic core structure, in which the first electrode and the second electrode on the first flange on one side of the winding portion are arranged transversely along the extension direction of the winding portion, while the third electrode and the fourth electrode on the first flange are arranged longitudinally along the extension direction (rather than transversely), and the fifth electrode and the sixth electrode on the second flange on the other side of the winding portion are arranged transversely along the extension direction, while the seventh electrode and the eighth electrode on the second flange are arranged longitudinally along the extension direction (rather than transversely). In this way, not only the third electrode, the fourth electrode, the seventh electrode and the eighth electrode can have space to be designed to be wider, but also the first electrode, the second electrode, the fifth electrode and the sixth electrode can have space to be designed to be wider, which is conducive to solving the undesirable phenomenon of wire slippage during welding due to inaccurate positioning, and is also conducive to solving the risk of line drop during welding due to repeated contact of the spot welding head with the welding point.

[0079] The features of several embodiments are summarized above, so that those skilled in the art can better understand the aspects of the present invention. Those skilled in the art should understand that they can easily use the present invention as a basis to design or modify other processes and structures to achieve the same goals and / or achieve the same advantages as the embodiments introduced herein. Those skilled in the art should also understand that these equivalent constructions do not depart from the spirit and scope of the present invention, and they can make various changes, substitutions and modifications without departing from the spirit and scope of the present invention.

[0080]

Explanation of symbols

[0081] 10,20,30,40: core structure

[0082] 12: Winding part

[0083] 14,24,34,44: First flange

[0084] 15,17: Inclined part

[0085] 16,26,36,46: Second flange

[0086] D1: Extension direction

[0087] D2: Vertical direction

[0088] D3: first direction

[0089] D4: Second direction

[0090] P11, P31, P41: first electrode

[0091] P12, P22, P42: Second electrode

[0092] P13: The third electrode

[0093] P14, P34: Fourth electrode

[0094] P15, P35, P45: Fifth electrode

[0095] P16, P26, P46: Sixth electrode

[0096] P17: Seventh electrode

[0097] P18, P38: The eighth electrode

[0098] R11, R21: First spot welding position area

[0099] R12, R22: Second spot welding position area

[0100] R13, R23: The third spot welding position area

[0101] R14, R24: The fourth spot welding position area

[0102] S1: welding area

[0103] S2: Non-welding area

[0104] W1: First winding

[0105] W2: Second winding

[0106] W3: The third winding

[0107] W4: The fourth winding.

Claims

1. A magnetic core structure, characterized in that: include: Winding part; A first flange and a second flange are arranged on opposite sides of the winding portion along an extending direction of the winding portion; A first electrode and a second electrode are disposed on the first flange and arranged along a longitudinal direction perpendicular to the extending direction; A third electrode and a fourth electrode are disposed on the first flange and arranged along the extending direction; a fifth electrode and a sixth electrode, disposed on the second flange and arranged along the longitudinal direction; and The seventh electrode and the eighth electrode are disposed on the second flange and arranged along the extending direction.

2. The magnetic core structure according to claim 1, characterized in that: The first electrode, the second electrode and the third electrode are sequentially arranged on the first flange along a first direction, the fifth electrode, the sixth electrode and the seventh electrode are sequentially arranged on the second flange along a second direction, the first direction is opposite to the second direction, and the first direction and the second direction are parallel to the longitudinal direction.

3. The magnetic core structure according to claim 1, characterized in that: The third electrode is closer to the winding portion than the fourth electrode, and the seventh electrode is closer to the winding portion than the eighth electrode.

4. The magnetic core structure according to claim 1, characterized in that: Each of the first electrode, the second electrode, the third electrode and the fourth electrode is an electroplating electrode formed on the first flange, and each of the fifth electrode, the sixth electrode, the seventh electrode and the eighth electrode is an electroplating electrode formed on the second flange.

5. The magnetic core structure according to claim 1, characterized in that: The winding portion is used for winding the primary coil and the secondary coil thereon in sequence, wherein a first spot welding position area where the spot welding head spot welds the primary coil on the first flange does not overlap with a second spot welding position area where the spot welding head spot welds the secondary coil on the first flange in the extension direction, and wherein a third spot welding position area where the spot welding head spot welds the primary coil on the second flange does not overlap with a fourth spot welding position area where the spot welding head spot welds the secondary coil on the second flange in the extension direction.

6. The magnetic core structure according to claim 1, characterized in that: Each of the second electrode and the sixth electrode has a welding area and a non-welding area arranged along the extending direction, wherein the non-welding area becomes thinner in a direction away from the welding area and has an inclined surface.

7. The magnetic core structure according to claim 6, characterized in that: The non-welding area is closer to the winding portion than the welding area.

8. The magnetic core structure according to claim 6, characterized in that: The inclined surface has an electroplating layer.

9. The magnetic core structure according to claim 6, characterized in that: Each of the first electrode and the fifth electrode has a welding area and a non-welding area arranged along the extension direction, wherein the non-welding area of ​​each of the first electrode and the fifth electrode becomes thinner in a direction away from the welding area of ​​each of the first electrode and the fifth electrode and has an inclined surface.

10. The magnetic core structure according to claim 9, characterized in that: The arrangement direction of the welding area and the non-welding area of ​​each of the second electrode and the sixth electrode is opposite to the arrangement direction of the welding area and the non-welding area of ​​each of the first electrode and the fifth electrode.

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