Open-circuit common-mode inductor and method of manufacture

Abstract

The application belongs to the technical field of inductance and provides an open common-mode inductor and a preparation method. The open common-mode inductor comprises a base, a connecting conductive part and a common-mode magnetic core group. The common-mode magnetic core group is fixed on the second side surface and comprises a magnetic frame and two winding coils. The two winding coils are arranged at different positions of the magnetic frame. The winding coils have two connecting ends which are electrically connected with the connecting conductive part one by one. When the common-mode inductor is installed, the mounting surface of the connecting conductive part can be abutted against the pad of the circuit board, and then the mounting part of the connecting conductive part is connected with the pad by welding, so that the surface mounting installation of the whole common-mode inductor is realized. The installation of the inductor is more convenient and fast. The setting of the mounting surface also increases the contact area of the connecting conductive part and the pad, so that the welding of the connecting conductive part and the pad is more firm, thereby the installation of the common-mode inductor is more firm.

Description

Technical Field

[0001] This invention belongs to the field of inductor technology, and particularly relates to an open common-mode inductor and its fabrication method. Background Technology

[0002] Inductors are one of the three major passive components in electronic circuits, primarily serving functions such as filtering, oscillation, delay, notch filtering, signal screening, noise filtering, current stabilization, and suppression of electromagnetic interference. With the rapid development of electronic technology, especially the widespread adoption of mobile consumer electronics, inductors are evolving towards miniaturization, thinning, higher frequency operation, higher current capacity, higher efficiency, and lower EMI. Currently, most existing inductors are installed using a pin-connected method, leading to inconvenience in installation. Summary of the Invention

[0003] The purpose of this invention is to provide an open common-mode inductor and its manufacturing method, which aims to solve the technical problem of inconvenient installation of existing common-mode inductors during use.

[0004] The present invention is implemented as follows: Firstly, an open-type common-mode inductor is provided, comprising:

[0005] The base has a first side and a second side that are positioned opposite to each other.

[0006] Multiple conductive connecting components are included. Each conductive connecting component has a mounting portion and a mounting portion. The mounting portion is used to connect to the base, and the mounting portion abuts against the first side surface. The side of the mounting portion opposite to the base is a mounting surface, which is used to contact the solder pads on the circuit board.

[0007] A common-mode magnetic core assembly, fixed on the second side, includes a magnetic frame and two winding coils. The two winding coils are wound at different positions on the magnetic frame. Each winding coil has two connection ends, which correspond one-to-one with the connecting conductive element and are electrically connected to the connecting conductive element.

[0008] In one optional embodiment, after the conductive connecting element is installed on the base, the mounting surfaces of the plurality of conductive connecting elements are all on the same plane.

[0009] In an optional embodiment, the first side surface also has a plurality of support protrusions, each of which protrudes from the first side surface. The plurality of support protrusions are arranged in a one-to-one correspondence with the plurality of connecting conductive parts. The end of each support protrusion facing away from the base has a pressing support surface, and the mounting part abuts against the pressing support surface.

[0010] In one optional embodiment, the support protrusion is provided with a mounting structure, and the mounting part is connected to the support protrusion through the mounting structure.

[0011] In an optional embodiment, the mounting structure includes a mounting hole disposed on the support protrusion, the two ends of the mounting hole being open, the mounting part being inserted into the mounting hole and passing through the support protrusion through the mounting hole.

[0012] In an optional embodiment, the base is provided with a partition member that protrudes from the second side, the magnetic frame is fitted around the periphery of the partition member, and the two winding coils are respectively located on both sides of the partition member.

[0013] In an optional embodiment, two positioning grooves are further provided on the second side, the two positioning grooves being located on both sides of the separating component, the positioning grooves being used to accommodate the winding coil and to position the common mode magnetic core assembly.

[0014] In one alternative embodiment, the winding coil is formed by winding a flat wire with a rectangular cross-section. After winding, the thickness of the flat wire is set along the axial direction of the winding coil, and the width of the flat wire is set along the radial direction of the winding coil. The winding coil has a single-layer structure in the radial direction.

[0015] In one optional embodiment, the connecting conductive element is a plate-like structure, which is formed by bending to create the mounting portion and the attachment portion.

[0016] Secondly, a method for fabricating an open common-mode inductor is provided, comprising the following steps:

[0017] A base, a flat wire, and a plurality of conductive connecting components are provided. The base has a first side and a second side disposed opposite to each other, and the conductive connecting components have a mounting portion and a mounting portion.

[0018] A magnetic frame is obtained by compacting magnetic materials into a predetermined shape and then sintering them.

[0019] The flat wires are wound around two different regions of the magnetic frame to form a common-mode magnetic core assembly;

[0020] The mounting portion of the conductive connector is connected to the base, and the mounting portion of the conductive connector abuts against the first side of the base, and the common mode magnetic core assembly is attached to the first side of the base.

[0021] The connection terminals of the winding coil are soldered to the corresponding conductive components.

[0022] The technical advantages of this invention compared to existing technologies are as follows: Two winding coils are wound around different positions on a magnetic frame to form a common-mode magnetic core assembly, which is then fixed to the second side of a base. Multiple conductive connecting elements are provided on the base. Each conductive connecting element has a mounting portion and a surface mounting portion. The mounting portion connects to the base, and the surface mounting portion abuts against the first side. The side of the surface mounting portion facing away from the base is the surface mounting surface. Simultaneously, the connecting ends of the winding coils are electrically connected to the conductive connecting elements one by one. Compared to existing common-mode inductors, during installation, the surface mounting surface of the conductive connecting element can be placed against the pads on the circuit board, and then the surface mounting portion of the conductive connecting element is soldered to the pads. This achieves surface mounting of the entire common-mode inductor, making inductor installation more convenient and faster. The surface mounting surface also increases the contact area between the conductive connecting element and the pads, resulting in a more secure soldering and thus a more robust installation of the common-mode inductor.

[0023] It is understandable that the beneficial effects of the second aspect mentioned above can be found in the relevant descriptions in the first aspect mentioned above, and will not be repeated here. Attached Figure Description

[0024] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments of the present invention or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 This is a schematic diagram of the structure of the open common-mode inductor provided in an embodiment of the present invention. Figure 1 ;

[0026] Figure 2 This is a schematic diagram of the structure of the open common-mode inductor provided in an embodiment of the present invention. Figure 2 ;

[0027] Figure 3 This is a schematic diagram of the base structure used in an embodiment of the present invention. Figure 1 ;

[0028] Figure 4 This is a schematic diagram of the base structure used in an embodiment of the present invention. Figure 2 ;

[0029] Figure 5 yes Figure 4 Enlarged structural diagram at point A;

[0030] Figure 6 This is a schematic diagram of the structure of the conductive connecting element used in an embodiment of the present invention.

[0031] Explanation of reference numerals in the attached figures:

[0032] 1. Base; 11. First side; 12. Second side; 13. Support protrusion; 131. Pressing support surface; 14. Mounting structure; 141. Mounting socket; 15. Separating component; 16. Receiving groove; 17. Pressing rib; 18. Positioning groove; 2. Connecting conductive component; 21. Mounting part; 22. Mounting part; 221. Mounting surface; 3. Common mode magnetic core assembly; 31. Magnetic frame; 32. Winding coil; 33. Connecting end. Detailed Implementation

[0033] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0034] In the description of this invention, it should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0035] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0036] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0037] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments.

[0038] Please refer to Figures 1 to 4 As shown, in an embodiment of the present invention, in a first aspect, an open-type common-mode inductor is provided. The open-type common-mode inductor includes a base 1, connecting conductive elements 2, and a common-mode magnetic core assembly 3. The base 1 has a first side 11 and a second side 12 disposed opposite to each other. Multiple connecting conductive elements 2 are provided, each having a mounting portion 21 and a mounting portion 22. The mounting portion 21 is used to connect to the base 1, and the mounting portion 22 abuts against the first side 11. The side of the mounting portion 22 facing away from the base 1 is a mounting surface 221, which is used to contact a pad on a circuit board. The common-mode magnetic core assembly 3 is fixed on the second side 12 and includes a magnetic frame 31 and two winding coils 32. The two winding coils 32 are wound at different positions on the magnetic frame 31. Each winding coil 32 has two connecting ends 33, which correspond one-to-one with the connecting conductive elements 2 and are electrically connected to them.

[0039] Specifically, base 1 refers to a component with a certain volume. Base 1 is usually made of insulating material, such as PPS (Polyphenylene Sulfide) or bakelite, giving it good insulation properties as well as good high-temperature resistance and structural strength. Base 1 can be manufactured by injection molding or machining. Connecting conductive component 2 refers to a conductor component with a certain volume, such as a metal with good conductivity like gold, silver, or copper. Connecting conductive component 2 can be block-shaped, plate-shaped, or column-shaped, and can also be a combination of various shapes. Magnetic frame 31 refers to a structural component that plays a key supporting and magnetic guiding role in electromagnetic equipment. It is mainly used to fix the coil winding and provide a low magnetic resistance path for magnetic flux, allowing the magnetic field to be more effectively concentrated and guided, thereby enhancing the performance of the electromagnetic equipment. The overall shape of magnetic frame 31 is usually a closed frame structure. Winding coil 32 refers to a coil structure made by winding metal wire according to certain rules and turns. The metal conductor with an insulating layer on the outside of the winding coil 32 is a core component of many electromagnetic devices. The metal conductor in the winding coil 32 can generate a magnetic field when current flows through it, and the change in the magnetic field will induce an electromotive force in the coil itself or adjacent coils. By winding the winding coil 32 around different parts of the magnetic frame 31, a common mode magnetic core assembly 3 is formed. The common mode magnetic core assembly 3 as a whole can be fixed to the second side 12 of the base 1 by means of clipping, gluing, or fastening.

[0040] The open-type common-mode inductor provided in this embodiment of the invention consists of two winding coils 32 wound at different positions on a magnetic frame 31 to form a common-mode magnetic core assembly 3, which is then fixed to the second side surface 12 of a base 1. Multiple connecting conductive elements 2 are provided on the base 1. Each connecting conductive element 2 has a mounting portion 21 and a mounting portion 22. The mounting portion 21 is used to connect to the base 1, and the mounting portion 22 abuts against the first side surface 11. The side of the mounting portion 22 facing away from the base 1 is the mounting surface 221. Simultaneously, the connecting ends 33 of the winding coils 32 are correspondingly and electrically connected to the connecting conductive elements 2 one-to-one. Compared with existing common-mode inductors, during installation, the mounting surface 221 of the connecting conductive element 2 can be placed against the pads on the circuit board, and then the mounting portion 22 of the connecting conductive element 2 can be soldered to the pads, thus achieving surface mounting of the entire common-mode inductor. This makes the installation of the inductor more convenient and faster. At the same time, the setting of the mounting surface 221 also increases the contact area between the connecting conductive element 2 and the pads, making the soldering between the connecting conductive element 2 and the pads more secure, thereby making the installation of the common-mode inductor more secure.

[0041] Furthermore, by mounting the common-mode magnetic core assembly 3, consisting of a magnetic frame 31 and two winding coils 32, on the second side 12 of the base 1, and connecting the connection ends 33 of the winding coils 32 to the connecting conductive parts 2 on the base 1, an overall open inductor structure is formed, which improves the overall heat dissipation of the inductor. At the same time, due to the small number of parts in the inductor, the overall structure of the inductor is simpler, the size of the inductor is reduced, and the production cost of the inductor is lowered.

[0042] In one embodiment, see Figure 2 After the conductive connecting element 2 is installed onto the base 1, the mounting surfaces 221 of the multiple conductive connecting elements 2 are all on the same plane. Specifically, the aforementioned plane can be set parallel to the first side 11 of the base 1. By ensuring that the mounting surfaces 221 of the multiple conductive connecting elements 2 are all on the same plane, height differences between the mounting surfaces 221 can be avoided. Furthermore, since the pads on the circuit board are generally on the same plane, when the common-mode inductor is mounted onto the circuit board via surface mounting, by ensuring that the mounting surfaces 221 of the multiple conductive connecting elements 2 are all on the same plane, when one conductive connecting element 2's mounting surface 221 contacts the pad on the circuit board, the mounting surfaces 221 of the other conductive connecting elements 2 will also contact the pad on the circuit board. This makes it easier for the entire base 1 to connect to the circuit board via surface mounting and also makes the inductor installation more stable.

[0043] In one embodiment, see Figure 4The first side surface 11 also has multiple supporting protrusions 13, each protruding from the first side surface 11. Each supporting protrusion 13 corresponds to one of the multiple conductive connecting elements 2. The end of each supporting protrusion 13 facing away from the base 1 has a pressing supporting surface 131, and the mounting part 22 abuts against the pressing supporting surface 131. Specifically, the supporting protrusion 13 refers to a protruding structure with a certain height, and can be block-shaped, column-shaped, or plate-shaped. The supporting protrusion 13 can be integrally formed with the base 1, or it can be an additional component installed on the first side surface 11 by welding, bonding, or snap-fitting. The pressing supporting surface 131 refers to a surface structure with a certain area, and can be a planar structure or a curved surface structure. In this embodiment, multiple supporting protrusions 13 are also provided on the first side surface 11, and each supporting protrusion 13 corresponds to one of the multiple conductive connecting elements 2. Furthermore, the supporting protrusion 13 has a pressing support surface 131 at the end opposite to the base 1. When installing the conductive component 2, the mounting part 21 of the conductive component 2 can be installed onto the base 1 or the supporting protrusion 13, and the mounting part 22 of the conductive component 2 can be pressed against the pressing support surface 131. The support of the supporting protrusion 13 allows the mounting part 22 to be spaced apart from the first side 11, leaving space for the soldering installation of the mounting part 22, preventing the base 1 from obstructing the connection between the mounting part 22 and the solder pads on the circuit board, making the installation of the inductor more convenient. In addition, after the conductive component 2 is installed, the mounting part 22 of the conductive component 2 can be pressed by the pressing support surface 131, making the mounting part 22 of the conductive component 2 flatter and more firmly fixed.

[0044] In an optional embodiment, please refer to Figure 4 The supporting protrusion 13 and the base 1 are integrally molded. Specifically, for example, when the base 1 is made of PPS or bakelite, the supporting protrusion 13 and the base 1 can be integrally molded by injection molding, which can make the installation of the supporting protrusion 13 more secure and reliable.

[0045] In one embodiment, see Figure 4 and Figure 5A mounting structure 14 is provided on the supporting protrusion 13, and the mounting part 21 is connected to the supporting protrusion 13 through the mounting structure 14. Specifically, the mounting structure 14 is a structure used to fix an object, and the mounting structure 14 can fix the object by means of snap-fit, plug-in, or fastener connection. In this embodiment, when the conductive component 2 is installed, the mounting part 21 of the conductive component 2 can be connected to the supporting protrusion 13 through the mounting structure 14. Firstly, since the volume of the supporting protrusion 13 is smaller than the volume of the base 1, by setting the mounting structure 14 on the supporting protrusion 13, the processing difficulty of the mounting structure 14 can be reduced, thereby reducing the overall manufacturing cost of the base 1. Secondly, the mounting structure 14 is set on the support protrusion 13 so that the mounting structure 14 can be closer to the pressing support surface 131 on the support protrusion 13. At this time, when the mounting part 21 is fixed by the mounting structure 14 and the mounting part 22 abuts against the pressing support surface 131, setting the mounting structure 14 close to the pressing support surface 131 can reduce the distance between the mounting part 21 and the mounting part 22 of the conductive component 2, thereby reducing the overall volume of the conductive component 2.

[0046] In one embodiment, see Figure 5 The mounting structure 14 includes a mounting hole 141 disposed on the support protrusion 13. Both ends of the mounting hole 141 are open, and the mounting part 21 is inserted into the mounting hole 141, penetrating the support protrusion 13 through the mounting hole 141. Specifically, the mounting hole 141 refers to a hole structure with a certain depth, and its open ends form a through-hole structure penetrating the entire support protrusion 13. In this embodiment, the mounting hole 141 can be arranged in a direction parallel to the pressing support surface 131. When installing the conductive component 2, the mounting part 21 of the conductive component 2 can be inserted into the mounting hole 141 from one open end and protrude from the other open end, forming a connection end 33 connected to the winding coil 32. At this time, the mounting part 22 of the conductive component 2 can simultaneously abut against the pressing support surface 131, making the installation of the conductive component 2 more convenient.

[0047] In an optional embodiment, please refer to Figure 5 The inner wall of the mounting hole 141 is also provided with a pressure rib 17, which is arranged along the axial direction of the mounting hole 141. Specifically, the pressure rib 17 refers to a protruding structure of a certain length, which protrudes from the inner wall of the mounting hole 141. After the mounting part 21 of the conductive component 2 is inserted into the mounting hole 141, the pressure rib 17 abuts against the side of the conductive component 2, making the conductive component 2 more firmly and reliably inserted into the mounting hole 141, thereby improving the safety of the inductor.

[0048] Based on the aforementioned characteristic anti-compression rib 17, please refer to Figure 5 The number of pressure ribs 17 is multiple, and the multiple pressure ribs 17 are spaced apart. Specifically, by providing multiple spaced pressure ribs 17 on the inner wall of the mounting hole 141, a receiving gap is formed between the connecting conductive member 2 and the mounting hole 141 after the connecting conductive member 2 is inserted into the mounting hole 141. The receiving gap can be used to accommodate adhesive, so that the connecting conductive member 2 and the supporting protrusion 13 can be fixed by adhesive, making the connecting conductive member 2 more firmly installed.

[0049] In one embodiment, see Figure 1 The common-mode magnetic core assembly 3 is glued and fixed to the second side 12 of the base 1 using adhesive. Specifically, adhesive refers to a substance that can bond two or more objects together through surface adhesion. The adhesive can be epoxy resin. By gluing and fixing the common-mode magnetic core assembly 3, installation is made more convenient while ensuring a firm fixation.

[0050] In one embodiment, see Figure 1 and Figure 3 A partition component 15 is provided on the base 1, protruding from the second side 12. A magnetic frame 31 is fitted around the partition component 15, and two winding coils 32 are located on both sides of the partition component 15. Specifically, the partition component 15 refers to a component with a certain height. The partition component 15 can be integrally formed with the base 1, or it can be installed on the second side 12 by means of gluing, welding, or snap-fit ​​connection. By providing a partition component 15 protruding from the second side 12 of the base 1, when the common-mode magnetic core assembly 3 is installed on the second side 12 of the base 1, the magnetic frame 31 is fitted around the partition component 15, and the two winding coils 32 are located on both sides of the partition component 15. The two sides of the partition component 15 can abut against the two winding coils 32, and the two ends of the partition component 15 can abut against the inner wall of the magnetic frame 31. Thus, the partition component 15 limits the common-mode magnetic core assembly 3 in a direction parallel to the second side 12, making the common-mode magnetic core assembly 3 more securely installed.

[0051] In an optional embodiment, please refer to Figure 3 The separating component 15 is a separating plate. Specifically, the separating plate refers to a plate-like structure with a certain thickness, and one side of the separating plate is connected to the first side 11 of the base 1. The two sides of the separating plate abut against the two winding coils 32 respectively, where the two sides refer to the two sides with the largest area on the separating plate. At the same time, the two ends of the separating plate abut against the inner wall of the magnetic frame 31 respectively. This allows for the positioning of the common-mode magnetic core assembly 3 while making the overall structure of the base 1 lighter and reducing manufacturing costs.

[0052] Based on the above feature separator, please refer to Figure 3 The thickness of the separator plate gradually decreases from near to far from the second side 12 along the direction perpendicular to the second side 12. Specifically, the thickness of the separator plate refers to the distance between the two surfaces of the separator plate. By gradually decreasing the thickness of the separator plate from near to far from the second side 12 along the direction perpendicular to the second side 12, the contact between the surface of the separator plate and the winding coil 32 will become closer and closer as the common-mode magnetic core assembly 3 moves towards the second side 12, rather than being close from the beginning, making the installation of the common-mode magnetic core assembly 3 more convenient.

[0053] In one embodiment, see Figure 3 Two positioning grooves 18 are also provided on the second side surface 12. The two positioning grooves 18 are located on both sides of the separating component 15. The positioning grooves 18 are used to accommodate the winding coil 32 and to position the common mode magnetic core assembly 3. Specifically, the positioning groove 18 refers to a groove structure with a certain depth. Since the winding coil 32 on the common mode magnetic core assembly 3 is generally in contact with the second side surface 12 during installation, the bottom shape of the positioning groove 18 can match the shape of the winding coil 32, for example, it can be arc-shaped. In this embodiment, by providing positioning grooves 18 on the second side surface 12, on the one hand, the installation position of the common mode magnetic core assembly 3 can be positioned, making the installation position of the common mode magnetic core assembly 3 more accurate. On the other hand, by providing positioning grooves 18, the contact area between the winding coil 32 and the base 1 is increased, making the adhesion between the winding coil 32 and the base 1 more firm.

[0054] In an optional embodiment, please refer to Figure 3 A receiving groove 16 is provided on the side of the base 1 to accommodate the connection end 33 of the winding coil 32. Specifically, the receiving groove 16 refers to a groove structure with a certain depth. By providing the receiving groove 16 on the side of the base 1, when the connection end 33 of the winding coil 32 is welded to the connecting conductive part 2, the connection end 33 of the winding coil 32 can be placed in the receiving groove 16, avoiding the connection end 33 of the winding coil 32 from protruding from the base 1, thereby making the overall appearance of the common mode inductor neater.

[0055] In one embodiment, see Figure 1The winding coil 32 is formed by winding flat wire. The flat wire has a rectangular cross-section. After winding, the thickness of the flat wire is set along the axial direction of the winding coil 32, and the width of the flat wire is set along the radial direction of the winding coil 32. The winding coil 32 has a single-layer structure in the radial direction. Specifically, flat wire, also known as flat cable or flat wire, is a conductive material with a flat shape. Compared with traditional round wire, it has a larger width and a smaller thickness. The main body of the flat wire is usually made of metal, and the outside of the flat wire is usually provided with an insulating layer. The insulating layer can be made of polyesterimide enameled film, which can give the flat wire better insulation and extend its service life. In this embodiment, by using flat wire to wind the winding coil 32, and setting the thickness of the flat wire along the axial direction of the winding coil 32 and the width of the flat wire along the radial direction of the winding coil 32, more turns can be wound per unit length, allowing the inductor to have a larger operating power. In addition, the winding coil 32 formed by winding flat wire can make the effective cross-sectional area of ​​the common mode inductor larger and the skin effect at high frequencies smaller. Furthermore, the winding coil 32 has a single-layer structure in the radial direction, which can effectively avoid the interlayer proximity effect of the winding coil 32, reduce the influence of the inductor's parasitic capacitance, and thus improve the overall performance of the common-mode inductor.

[0056] In one embodiment, see Figure 2 and Figure 6 The conductive connector 2 has a plate-like structure, which is bent to form the mounting portion 21 and the mounting portion 22. Specifically, by making the conductive connector 2 into a plate-like structure and bending it to form the mounting portion 21 and the mounting portion 22, the overall structure of the conductive connector 2 can be made more robust and reliable, and the manufacturing of the conductive connector 2 can be made simpler and more convenient.

[0057] Secondly, a method for fabricating an open common-mode inductor is provided, comprising the following steps:

[0058] The system provides a base 1, a flat wire, and multiple conductive connectors 2. The base 1 has a first side 11 and a second side 12 that are disposed opposite to each other. The conductive connectors 2 have a mounting portion 21 and a mounting portion 22.

[0059] Specifically, the base 1 is generally made of insulating material. The material of the base 1 can be PPS (polyphenylene sulfide), with a melting point of 285℃~300℃. The base 1 can also be made of bakelite, which also has good mechanical properties and heat resistance. The first side 11 and the second side 12 refer to the two larger sides of the base 1. The first side 11 can be the bottom surface of the base 1, and the second side 12 can be the top surface of the base 1. A flat conductor is a conductive material with a flat shape. Compared with traditional round conductors, it has a larger width and a smaller thickness. The connecting conductive component 2 can be formed by cutting and bending a metal sheet to create the mounting part 21 and the mounting part 22.

[0060] The magnetic frame 31 is obtained by sintering after the magnetic material is compacted according to a preset shape.

[0061] Specifically, the magnetic material and dopant are mixed in a certain ratio, the mixture is then compacted using a mold, and finally sintered at high temperature. The magnetic material can be selected based on its high saturation magnetic induction, high Curie temperature, and high power. The mixing ratio of the magnetic material and dopant is well known to those skilled in the art and will not be elaborated upon here.

[0062] A common-mode magnetic core assembly 3 is fabricated by winding flat wires around two different regions of a magnetic frame 31.

[0063] Specifically, flat wires can be wound around two different areas of the magnetic frame 31 using a winding device to form two winding coils 32. The two winding coils 32 and the magnetic frame 31 together form a common-mode magnetic core assembly 3.

[0064] The mounting part 21 of the conductive component 2 is connected to the base 1, and the mounting part 22 of the conductive component 2 abuts against the first side 11 of the base 1, and the common mode magnetic core assembly 3 is attached to the first side 11 of the base 1.

[0065] Specifically, the common mode magnetic core assembly 3 can be fixed to the base 1 by adhesive bonding, and the connecting conductive component 2 can also be fixed to the base 1 by adhesive bonding, using epoxy resin adhesive.

[0066] The connection end 33 of the winding coil 32 is soldered to the corresponding conductive component 2.

[0067] Specifically, the connection end 33 of the winding coil 32 can be directly connected to the connecting conductive element 2, or a lead-out end can be provided between the connection end 33 of the winding coil 32 and the connecting conductive element 2 for connection to the connecting conductive element 2. The lead-out end is generally made of conductive material, such as tin bronze. The lead-out end can also be glued to the side of the base 1 with adhesive, thereby making the lead-out end setting more stable and reliable.

[0068] The above are merely preferred embodiments of the present invention, and only specifically describe the technical principles of the present invention. These descriptions are only for explaining the principles of the present invention and should not be construed as limiting the scope of protection of the present invention in any way. Based on this explanation, any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention, as well as other specific embodiments of the present invention that can be conceived by those skilled in the art without creative effort, should be included within the scope of protection of the present invention.

Claims

1. An open-type common-mode inductor, characterized in that, include; The base has a first side and a second side that are positioned opposite to each other. Multiple conductive connectors are provided, each having a mounting portion and a mounting portion. The mounting portion is connected to the base, and the mounting portion abuts against the first side surface. The side of the mounting portion facing away from the base is a mounting surface, which is used to contact pads on the circuit board. A common-mode magnetic core assembly is fixed on the second side surface and includes a magnetic frame and two winding coils. The two winding coils are wound at different positions on the magnetic frame. Each winding coil has two connection ends, which correspond one-to-one with the connecting conductive element and are electrically connected to the connecting conductive element. After the conductive connector is installed on the base, the mounting surfaces of the multiple conductive connectors are all on the same plane. The first side also has multiple support protrusions, which protrude from the first side. Each of the multiple support protrusions corresponds to one of the multiple conductive connectors. The end of each support protrusion facing away from the base has a pressing support surface, and the mounting part abuts against the pressing support surface. The support protrusion is provided with a mounting structure, and the mounting part is connected to the support protrusion through the mounting structure. The mounting structure includes a mounting hole provided on the support protrusion. Both ends of the mounting hole are open, and the mounting part is inserted into the mounting hole. The mounting part passes through the support protrusion through the mounting hole. The axis of the mounting hole is parallel to the clamping support surface. The inner wall of the mounting hole is also provided with a pressure rib, and the pressure rib is arranged along the axis of the mounting hole.

2. The open-type common-mode inductor as described in claim 1, characterized in that, The base is provided with a partition component, which protrudes from the second side. The magnetic frame is fitted around the partition component, and the two winding coils are located on both sides of the partition component.

3. The open-type common-mode inductor as described in claim 2, characterized in that, The second side is also provided with two positioning grooves, which are located on both sides of the separator. The positioning grooves are used to accommodate the winding coil and to position the common mode magnetic core assembly.

4. The open-type common-mode inductor as described in claim 1, characterized in that, The winding coil is formed by winding a flat wire with a rectangular cross-section. After winding, the thickness of the flat wire is set along the axial direction of the winding coil, and the width of the flat wire is set along the radial direction of the winding coil. The winding coil has a single-layer structure in the radial direction.

5. The open-type common-mode inductor as described in claim 1, characterized in that, The connecting conductive component is a plate-shaped structure, and the plate-shaped structure is bent to form the mounting part and the attachment part.

6. A method for fabricating an open common-mode inductor, used to manufacture the open common-mode inductor as described in any one of claims 1 to 5, characterized in that, Includes the following steps: A base, a flat wire, and a plurality of conductive connecting components are provided. The base has a first side and a second side disposed opposite to each other, and the conductive connecting components have a mounting portion and a mounting portion. A magnetic frame is obtained by compacting magnetic materials into a predetermined shape and then sintering them. The flat wires are wound around two different regions of the magnetic frame to form a common-mode magnetic core assembly; The mounting portion of the conductive connector is connected to the base, and the mounting portion of the conductive connector abuts against the first side of the base, and the common mode magnetic core assembly is attached to the first side of the base. The connection terminals of the winding coil are soldered to the corresponding conductive components.

Images