T-shaped magnetic core inductor structure
By designing a hanging wire structure with a tapering size to the outside on the side of the blade of the T-core inductive structure, the problem of "holes" and insufficient strength in the prior art due to the inability of copper wire to fit on the side of the T-core blade is solved, and higher molding quality and mechanical strength are achieved, and product reliability and performance are improved.
Patent Information
- Application Number
- CN202411544735.0
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-10-31
- Publication Date
- 2025-02-25
AI Technical Summary
During the molding process, the existing T-shaped magnetic core inductor structure cannot fit on the side of the T-shaped magnetic core blade when the wire is hung at the tail, resulting in "holes" and insufficient strength, which affects the reliability and performance of the product.
A T-shaped magnetic core inductance structure is designed, and a hanging wire structure with a tapered outward dimension is arranged on the sides of the T-shaped magnetic core blade, so that the coil lead wire can closely fit the sides of the T-shaped magnetic core blade when bent, so that more magnetic powder is filled in during the molding process to avoid the formation of "holes".
Through the hanging structure with a tapering size to the outside, the forming quality and mechanical strength of the inductive structure are significantly improved, the problems of insufficient strength and density caused by insufficient powder filling are avoided, and the reliability and performance of the product are improved.
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Figure CN119517561A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to electronic components, in particular to a T-shaped magnetic core inductor structure. Background Art
[0002] One-piece molded inductors with T-core structure have the characteristics of high density, small size and high saturation. They are increasingly used in circuit applications and tend to gradually replace NR inductors. This is the development trend of power inductors. Therefore, it is necessary to continuously optimize this type of product to make its performance and reliability higher and higher.
[0003] At present, the main manufacturing processes of T-core inductors are T-core molding, winding, and product molding. During the production process, the magnetic powder is pressed into a T-core; after winding the T-core, it becomes a semi-finished winding product; when the product is formed, the semi-finished winding product is placed in a mold / jig, and then filled with powder, pressed and formed to form the product. Figure 1 shown.
[0004] T-type core structure Figure 2 As shown, it includes a T-shaped magnetic core blade 1 and a T-shaped magnetic core middle column 2. The wire hanging position of the T-shaped magnetic core blade 1 is designed with a notch so that the wire tail does not protrude from the outer dimensions of the T-shaped magnetic core blade 1 after hanging, ensuring that the coil 4 will not be exposed on the side when the product is formed later. Figure 3a , Figure 3b , Figure 3c Generally, when the wire diameter is small or thin (diameter or thickness 0.2mm or less), the inner side of the wire tail will be close to the side of the blade when hanging the wire, and there will be a certain gap in the notch design of the T-shaped magnetic core blade 1, such as Figure 3c When the wire diameter is thicker or thicker, when the wire tail is hung, because the copper wire has a certain bending radius, the copper wire cannot fit on the side of the T-shaped magnetic core blade 1, and there is an arc-shaped space 6 on the side of the T-shaped magnetic core blade 1, as shown in FIG. Figure 4 When the product is pressed, the semi-finished winding product is first placed in the mold / jig, and then filled with powder to form the peripheral magnetic structure 5. However, Figure 5 As shown, when there is space between the hanging wire of the semi-finished winding product and the side of the T-shaped magnetic core blade 1, the filled powder is not easy to enter the space, forming a "void". At the same time, the space outside the lead becomes smaller, and the amount of powder filled in the space outside the lead is less. After pressing and forming, the strength of the side and bottom surfaces of this place is seriously affected due to the small amount of powder and insufficient strength, which will cause chipping and cracks, resulting in low pad strength and unqualified peeling force. Moreover, due to the void on the inside, less powder is filled in, and the density after forming is insufficient.
[0005] It should be noted that the information disclosed in the above background technology section is only used for understanding the background of the present application, and therefore may include information that does not constitute prior art known to ordinary technicians in the field. Summary of the invention
[0006] The main purpose of the present invention is to overcome the defects existing in the above-mentioned background technology and provide a T-shaped magnetic core inductor structure.
[0007] To achieve the above object, the present invention adopts the following technical solutions:
[0008] A T-shaped magnetic core inductor structure, comprising:
[0009] A prefabricated T-shaped magnetic core, wherein the T-shaped magnetic core comprises a T-shaped magnetic core blade and a T-shaped magnetic core center column, and a hanging wire structure with a size gradually decreasing toward the outside is provided on the side of the T-shaped magnetic core blade;
[0010] A coil, wherein the coil is wound on the middle column of the T-shaped magnetic core, and a lead wire of the coil is bent through the hanging wire structure with a gradually reduced size toward the outside to form an electrode lead structure;
[0011] The peripheral magnetic structure is combined with the T-shaped magnetic core by filling magnetic powder and pressing.
[0012] Furthermore, the wire hanging structure with a gradually decreasing size toward the outside is an arc-shaped or multi-step wire hanging structure.
[0013] Furthermore, the multi-step wire hanging structure has 1 to 3 steps.
[0014] Furthermore, the lead wires of the coil are led out toward the back direction of the T-shaped magnetic core blades.
[0015] Furthermore, the height of the electrode lead-out structure is higher than, equal to or lower than the non-electrode portion of the T-shaped magnetic core blade on the same surface.
[0016] Furthermore, the shape of the center column of the T-shaped magnetic core is circular, racetrack-shaped or elliptical.
[0017] Furthermore, the shape of the intersection between the T-shaped magnetic core blades and the T-shaped magnetic core center column is square, circular, elliptical or racetrack.
[0018] Furthermore, the intersection angle between the T-shaped magnetic core blades and the T-shaped magnetic core center column is equal to or not equal to 90°.
[0019] Further, the coil is a round wire or a flat wire.
[0020] Furthermore, the coil is wound in a horizontal winding manner or a opposite winding manner.
[0021] The present invention has the following beneficial effects:
[0022] The T-type magnetic core inductor structure of the present invention significantly improves the molding quality and mechanical strength of the inductor structure by cleverly designing a hanging wire structure with a tapered size toward the outside on the side of the T-type magnetic core blade. By using the hanging wire structure with a tapered size toward the outside, the coil lead wire can fit closely to the side of the T-type magnetic core blade when bending. Such a design reduces the bending radius of the coil copper wire, reduces the inner circle space, and increases the space outside the lead wire accordingly. When the product is pressed and formed, more magnetic powder can be filled to the outside of the lead wire, effectively avoiding the "void" formed due to insufficient powder filling, and reducing the problem of insufficient side and bottom strength of the outside of the lead wire due to the small amount of powder filling. Therefore, the present invention effectively solves the problem of arc space formed by the inability of copper wire to fit the side of the T-type magnetic core blade in the prior art, thereby preventing the problems of insufficient strength on the outside of the lead wire, insufficient density on the inside, and easy collapse and cracking, low pad strength, etc. after forming, improving the peeling force and pad strength, and improving the reliability and performance of the product.
[0023] Other beneficial effects of the embodiments of the present invention will be further described below. BRIEF DESCRIPTION OF THE DRAWINGS
[0024] Figure 1 This is a structural diagram of an existing T-core inductor winding semi-finished product.
[0025] Figure 2 This is a structural diagram of the existing T-core inductor blade gap design.
[0026] Figure 3a to Figure 3c The figure is a schematic diagram of the existing T-shaped magnetic core inductor winding and hanging wires.
[0027] Figure 4 A schematic diagram of an arc space formed on the side of an existing T-shaped magnetic core inductor.
[0028] Figure 5 This is a schematic diagram of the product after the existing T-shaped magnetic core inductor structure is formed.
[0029] Figure 6 It is a schematic diagram of the product forming process of the T-shaped magnetic core inductor structure according to an embodiment of the present invention.
[0030] Figure 7 It is a schematic diagram of a formed product (horizontally wound coil) according to an embodiment of the present invention.
[0031] Figure 8 This is a schematic diagram of the semi-finished product structure using a pair-wound coil. DETAILED DESCRIPTION
[0032] The following is a detailed description of the embodiments of the present invention. It should be emphasized that the following description is only exemplary and is not intended to limit the scope and application of the present invention.
[0033] It should be noted that when an element is referred to as being "fixed to" or "disposed on" another element, it can be directly on the other element or indirectly on the other element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or indirectly connected to the other element. In addition, connection can be used for fixing as well as for coupling or communication.
[0034] It should be understood that the orientation or position relationship indicated by terms such as "length", "width", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside" and "outside" are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing the embodiments of the present invention and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.
[0035] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of the embodiments of the present invention, the meaning of "plurality" is two or more, unless otherwise clearly and specifically defined.
[0036] See also Figure 6 to Figure 7An embodiment of the present invention provides a T-type magnetic core inductor structure, comprising: a prefabricated T-type magnetic core, the T-type magnetic core comprising a T-type magnetic core blade 1 and a T-type magnetic core center column 2, the side of the T-type magnetic core blade 1 is provided with a hanging wire structure 3 with a size gradually reduced toward the outside; a coil 4, the coil 4 is wound on the T-type magnetic core center column 2, and the lead wire of the coil 4 is bent through the hanging wire structure 3 with a size gradually reduced toward the outside to form an electrode lead structure; a peripheral magnetic structure 5, the peripheral magnetic structure 5 is combined with the T-type magnetic core by filling magnetic powder and pressing. Due to the arrangement of the hanging wire structure 3 with a gradually decreasing size toward the outside, the wire tail of the coil 4 fits more closely to the side of the T-shaped magnetic core blade 1 when the wire is wound, so that the bending radius of the copper wire of the coil becomes smaller, the space of the inner circle of the bending becomes smaller, and at the same time the space outside the lead wire becomes larger, so that more powder can be filled into the outside of the lead wire when the product is pressed into shape, thereby effectively solving the problem of the existing T-shaped magnetic core inductor structure that the copper wire cannot fit into the side of the T-shaped magnetic core blade when the wire tail is hung, resulting in a "void" formed on the side of the T-shaped magnetic core blade where powder is not easy to enter when the product is formed, and at the same time the space outside the lead wire becomes smaller, resulting in less powder filling here, and the lack of strength here after pressing and forming, resulting in problems such as chipping and cracks.
[0037] See also Figure 6 to Figure 7 In some embodiments, the wire hanging structure 3 with a gradually decreasing size toward the outside is a multi-step wire hanging structure. In other embodiments, the wire hanging structure with a gradually decreasing size toward the outside is an arc shape.
[0038] In some embodiments, the multi-step wire hanging structure has a number of steps of 1 to 3. The present invention does not limit the specific number of steps, which can be determined based on the thickness of the blade and the thickness of the wire diameter.
[0039] In some embodiments, the lead wires of the coil are led out toward the back direction of the T-shaped magnetic core blade 1 .
[0040] In some embodiments, the height of the electrode lead-out structure is higher, equal to, or lower than the non-electrode portion of the T-shaped magnetic core blade 1 on the same surface.
[0041] In some embodiments, the shape of the T-shaped magnetic core center column 2 is circular, racetrack-shaped or elliptical.
[0042] In some embodiments, the shape of the intersection of the T-shaped magnetic core blade 1 and the T-shaped magnetic core center column 2 is square, circular, elliptical or racetrack.
[0043] In some embodiments, the angle at which the T-shaped magnetic core blade 1 intersects the T-shaped magnetic core center column 2 is equal to or not equal to 90°.
[0044] In some embodiments, the coil is a round wire or a flat wire.
[0045] In some embodiments, the winding method of the coil is horizontal winding method ( Figure 7 ) or winding method ( Figure 8 ).
[0046] In multiple embodiments of the present invention, the prefabricated T-core design of the T-core inductor structure includes a hanging wire structure on the side of the blade, which gradually decreases in size toward the outside and can be an arc-shaped or a multi-step hanging wire structure with 1 to 3 steps. This design allows the lead wire of the coil to be smoothly bent through the hanging wire structure to form an electrode lead structure after it is wound on the middle column 2 of the T-core. During the pressing process, the peripheral magnetic structure is filled with magnetic powder and combined with the T-core to ensure the integrity and strength of the inductor structure.
[0047] In these embodiments, the lead wires of the coil are usually led out toward the back direction of the T-shaped magnetic core blade 1, and the height of the electrode lead structure can be flexibly designed to be higher, equal to or lower than the non-electrode part of the T-shaped magnetic core blade 1 on the same plane. The shape of the T-shaped magnetic core center column 2 can be circular, runway-shaped or elliptical, and the blades intersecting with the center column can be square, circular, elliptical or runway-shaped. The angle of intersection between the two is not limited to 90°, which provides design flexibility. The design of the coil can be round wire or flat wire, and the winding method can be horizontal winding or opposite winding. The present invention does not limit the specific form.
[0048] The above content is a further detailed description of the present invention in combination with specific / preferred embodiments, and it cannot be determined that the specific implementation of the present invention is limited to these descriptions. For ordinary technicians in the technical field to which the present invention belongs, without departing from the concept of the present invention, it can also make several substitutions or modifications to these described embodiments, and these substitutions or modifications should be regarded as belonging to the protection scope of the present invention. In the description of this specification, the description of the reference terms "an embodiment", "some embodiments", "preferred embodiments", "examples", "specific examples", or "some examples" means that the specific features, structures, materials or characteristics described in combination with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representation of the above terms does not necessarily target the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner. In the absence of mutual contradiction, those skilled in the art can combine and combine the different embodiments or examples described in this specification and the features of different embodiments or examples. Although the embodiments of the present invention and their advantages have been described in detail, it should be understood that various changes, substitutions and modifications can be made herein without departing from the scope of protection of the patent application.
Claims
1. A T-shaped magnetic core inductor structure, characterized in that: include: A prefabricated T-shaped magnetic core, wherein the T-shaped magnetic core comprises a T-shaped magnetic core blade and a T-shaped magnetic core center column, and a hanging wire structure with a size gradually decreasing toward the outside is provided on the side of the T-shaped magnetic core blade; A coil, wherein the coil is wound on the middle column of the T-shaped magnetic core, and a lead wire of the coil is bent through the hanging wire structure with a gradually reduced size toward the outside to form an electrode lead structure; The peripheral magnetic structure is combined with the T-shaped magnetic core by filling magnetic powder and pressing.
2. The T-shaped magnetic core inductor structure according to claim 1, characterized in that: The hanging wire structure with a gradually decreasing size toward the outside is an arc-shaped or multi-step hanging wire structure.
3. The T-shaped magnetic core inductor structure according to claim 2, characterized in that: The multi-step wire hanging structure has 1 to 3 steps.
4. The T-shaped magnetic core inductor structure according to any one of claims 1 to 3, characterized in that: The lead wires of the coil are led out toward the back direction of the T-shaped magnetic core blades.
5. The T-shaped magnetic core inductor structure according to any one of claims 1 to 3, characterized in that: The height of the electrode lead-out structure is higher than, equal to or lower than the non-electrode portion of the T-shaped magnetic core blade on the same surface.
6. The T-shaped magnetic core inductor structure according to any one of claims 1 to 3, characterized in that: The shape of the middle column of the T-shaped magnetic core is circular, racetrack or elliptical.
7. The T-shaped magnetic core inductor structure according to any one of claims 1 to 3, characterized in that: The shape of the intersection of the T-shaped magnetic core blades and the T-shaped magnetic core center column is square, circular, elliptical or racetrack.
8. The T-shaped magnetic core inductor structure according to any one of claims 1 to 3, characterized in that: The angle at which the T-shaped magnetic core blades intersect the T-shaped magnetic core center column is equal to or not equal to 90°.
9. The T-shaped magnetic core inductor structure according to any one of claims 1 to 3, characterized in that: The coil is a round wire or a flat wire.
10. The T-shaped magnetic core inductor structure according to any one of claims 1 to 3, characterized in that: The coil is wound in a horizontal winding manner or a pair winding manner.