Integrally-formed inductor with compact structure

Abstract

The invention discloses an integrally-formed inductor with a compact structure, and relates to the technical field of integrally-formed inductors, the integrally-formed inductor comprises an outer shell and a partition plate, the outer shell is composed of a first cooling fin and a firm layer wrapping the outer side of the first cooling fin, a magnetic column is installed in the partition plate and located in the center, and the outer side of the magnetic column is sleeved with a threaded supporting piece; the outer side of the threaded supporting piece is spirally wound with a winding coil along a threaded groove, electrode plates are welded to the two tail ends of the winding coil respectively, and through grooves in lap joint with the electrode plates are formed in the two opposite sides of the outer shell. And the copper wires are extruded and adhered, so that the yield of the integrally formed inductor is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of integrated molded inductors, and in particular to an integrated molded inductor with a compact structure. Background Art

[0002] The one-piece molded inductor (molded inductor: Molding Choke) includes a seat body and a winding body. The seat system is formed by burying the winding body in the metal magnetic powder by die-casting. The SMD pin is the lead pin of the winding body directly formed on the surface of the seat body. The existing one-piece molded inductors are gradually developing in the direction of light, thin, small and high performance. However, due to the limitation of small size, the winding coil of the one-piece molded inductor is prone to extrusion and adhesion during the hot pressing process, thereby affecting the yield rate of the one-piece molded inductor during the production process. In addition, the existing one-piece molded inductor usually only uses a very thin epoxy resin insulation layer on the outside of the metal magnetic powder, which is easily scratched by the machine during the product patch processing, causing the metal magnetic powder to be damaged. At the same time, since the one-piece molded inductor is prone to heat accumulation during use, and the influence of external electromagnetic waves, the performance of the one-piece molded inductor is reduced, thereby affecting other components in the circuit. Therefore, a compact one-piece molded inductor is needed to solve the above problems. Summary of the invention

[0003] The object of the present invention is to provide an integrated inductor with a compact structure, which solves the above-mentioned defects caused by the prior art.

[0004] A compact one-piece inductor comprises an outer shell and a partition, wherein the outer shell is composed of a first heat sink and a firm layer covering the outside of the first heat sink, a magnetic column is installed at the center of the interior of the partition, a threaded support is sleeved on the outside of the magnetic column, a winding coil is spirally wound along a thread groove on the outside of the threaded support, electrode sheets are welded to the two ends of the winding coil, and through grooves for overlapping the electrode sheets are provided on two opposite sides of the outer shell.

[0005] Preferably, second heat sinks are installed on both sides of the partition, a docking groove is provided at one end of the second heat sink located inside the outer shell, and an elastic docking piece used in conjunction with the docking groove is installed on the inner side wall of the first heat sink.

[0006] Preferably, trapezoidal reinforcing ribs are provided on the outer side of the first heat sink.

[0007] Preferably, the method comprises the following steps:

[0008] S1. Wind the copper wire along the thread groove direction of the threaded support member into a winding coil by a winding machine, and weld the electrode sheets to the two ends of the copper wire of the winding coil by a spot welding machine, and overlap the two electrode sheets in the through groove for position fixing, so that the winding coil and the threaded support member are located inside the outer shell;

[0009] S2. Inject the magnetic powder into the interior of the outer shell by an injection molding machine, then buckle the partition on the outer shell, so that the magnetic column is inserted into the hollow part of the threaded support, and buckle the docking piece into the docking groove to complete the docking work between the outer shell and the partition, so that the first heat sink and the second heat sink form a heat dissipation whole;

[0010] S3. The outer shell and the partition are hot-pressed by a hot press, and the two electrode sheets are bent into the mounting grooves on the partition.

[0011] The advantages of the present invention are that the present invention uses a threaded support to separate and support two adjacent copper wires of the winding coil, thereby avoiding extrusion and adhesion between the copper wires during the hot pressing process, and improving the yield rate of the integrally formed inductor.

[0012] The temperature generated by the inductor during use is quickly released to the outside and the PCB board through the first heat sink and the second heat sink, respectively, thereby increasing the heat dissipation channel and preventing heat accumulation from affecting the inductor. At the same time, the first heat sink plays a role in shielding electromagnetic waves and improving the overall anti-electromagnetic capability of the inductor.

[0013] The metal magnetic powder is wrapped and protected by the outer shell to prevent the metal magnetic powder from being scratched by the machine when the patch is used, thereby preventing the metal magnetic powder from being damaged. The reinforcing ribs on the first heat sink increase the heat dissipation area while strengthening the structure of the outer shell, thereby preventing the metal magnetic powder from being broken down due to insufficient voltage resistance in a high voltage environment, thereby increasing the service life of the inductor. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 It is a schematic diagram of the overall structure of the present invention.

[0015] Figure 2 It is a schematic diagram of the structure of the inner side of the outer shell of the present invention.

[0016] Figure 3 It is a schematic diagram of the overall assembly structure of the present invention.

[0017] Figure 4 It is a schematic structural diagram of the assembly of the partition, threaded support and winding coil of the present invention.

[0018] Figure 5 It is a schematic structural diagram of the buckled connection between the first heat sink and the second heat sink of the present invention.

[0019] Figure 6It is a structural schematic diagram of the docking groove and the docking piece of the present invention.

[0020] Among them: 1-outer shell; 2-partition; 3-first heat sink; 4-firm layer; 5-magnetic column; 6-threaded support; 7-winding coil; 8-electrode sheet; 9-through groove; 10-second heat sink; 11-docking groove; 12-docking sheet; 13-reinforcement rib. DETAILED DESCRIPTION

[0021] In order to make the technical means, creative features, objectives and effects achieved by the present invention easy to understand, the present invention is further explained below in conjunction with specific implementation methods.

[0022] like Figures 1 to 6 As shown, a compact integrally formed inductor includes an outer shell 1 and a partition 2. The outer shell 1 is composed of a first heat sink 3 and a firm layer 4 covering the outside of the first heat sink 3. A magnetic column 5 is installed inside the partition 2 and at the center. A threaded support 6 is sleeved on the outside of the magnetic column 5. A winding coil 7 is spirally wound along the thread groove on the outside of the threaded support 6. Electrode sheets 8 are welded to the two ends of the winding coil 7. Through grooves 9 for overlapping the electrode sheets 8 are provided on the two opposite sides of the outer shell 1. The through grooves 9 limit the electrode sheets 8 and limit and fix the metal magnetic powder when it is injected into the inner side of the outer shell 1. The firm layer 4 is made of insulating material, and the threaded support 6 is made of insulating material. The winding coil 7 and the magnetic column 5 are separated by the threaded support 6.

[0023] In this embodiment, second heat sinks 10 are installed on both sides of the partition 2. The second heat sink 10 is located at one end inside the outer shell 1 and is provided with a docking groove 11. An elastic docking piece 12 used in conjunction with the docking groove 11 is installed on the inner wall of the first heat sink 3. The first heat sink 3 and the second heat sink 10 are both made of copper sheets, the docking groove 11 and the docking piece 12 are made of copper material, and the semi-enclosed structure of the docking piece 12 has a certain elasticity, which will cause deformation when the partition 2 is docked with the outer shell 1, and when the docking is completed, the docking piece 12 abuts against the inside of the docking groove 11 through the action of elastic force, stably connecting the partition 2 while allowing the first heat sink 3 and the second heat sink 10 to form a whole heat dissipation structure, the second heat sink 10 is built into the inner side of the partition 2, and one end of the second heat sink 10 is exposed to the outside of the partition 2 and contacts the PCB board, the partition 2 and the second heat sink 10 are integrally coated with a high temperature resistant insulating layer on the contact side with the PCB board, when the present invention is welded on the PCB board, the two solder pads will not be bridged by the second heat sink 10.

[0024] In this embodiment, a trapezoidal reinforcing rib 13 is provided on the outer side of the first heat sink 3. The trapezoidal reinforcing rib 13 is hollow, and the insulating material of the outer shell 1 can be fully filled in the hollow part of the reinforcing rib 13, so that the insulating material of the outer shell 1 and the reinforcing rib 13 form a stable integral structure.

[0025] In this embodiment, the following steps are included:

[0026] S1. Wind the copper wire along the thread groove direction of the threaded support 6 into a winding coil 7 by a winding machine, and weld the electrode sheet 8 to the two ends of the copper wire of the winding coil 7 by a spot welding machine, and overlap the two electrode sheets 8 in the through groove 9 for position fixing, so that the winding coil 7 and the threaded support 6 are located inside the outer shell 1;

[0027] S2, using an injection molding machine to inject magnetic powder into the interior of the outer shell 1, then buckle the partition 2 on the outer shell 1, so that the magnetic column 5 is inserted into the hollow part of the threaded support 6, and the docking piece 12 is buckled into the docking groove 11 to complete the docking work between the outer shell 1 and the partition 2, so that the first heat sink 3 and the second heat sink 10 form a heat dissipation whole;

[0028] S3 , performing heat pressing operation on the outer shell 1 and the partition 2 by using a heat press machine, and bending the two electrode sheets 8 into the mounting grooves on the partition 2 .

[0029] The present invention uses the threaded support member 6 to separate and support two adjacent copper wires of the winding coil 7, thereby avoiding extrusion and adhesion between the copper wires during the hot pressing process, thereby improving the yield rate of the integrally formed inductor.

[0030] The temperature generated by the inductor during use is quickly released to the outside and the PCB board through the first heat sink 3 and the second heat sink 10, respectively, to increase the heat dissipation channel and avoid the influence of heat accumulation on the inductor. At the same time, the first heat sink plays a role in shielding electromagnetic waves and improves the overall anti-electromagnetic capability of the inductor.

[0031] The outer shell 1 is used to wrap and protect the metal magnetic powder to prevent the metal magnetic powder from being scratched by the machine when the patch is used, thereby preventing the metal magnetic powder from being damaged. The reinforcing ribs 13 on the first heat sink increase the heat dissipation area while strengthening the structure of the outer shell, thereby preventing the metal magnetic powder from being broken down due to insufficient voltage resistance in a high voltage environment, thereby increasing the service life of the inductor.

[0032] It is known from common technical knowledge that the present invention can be implemented by other embodiments that do not deviate from its spirit or essential features. Therefore, the above disclosed embodiments are only illustrative in all respects and are not exclusive. All changes within the scope of the present invention or within the scope equivalent to the present invention are included in the present invention.

Claims

1. A compact one-piece inductor, characterized in that: The invention comprises an outer shell (1) and a partition (2), wherein the outer shell (1) is composed of a first heat sink (3) and a firm layer (4) covering the outer side of the first heat sink (3), a magnetic column (5) is installed inside the partition (2) and at a central position, a threaded support (6) is sleeved on the outer side of the magnetic column (5), a winding coil (7) is spirally wound along a thread groove on the outer side of the threaded support (6), electrode sheets (8) are respectively welded at both ends of the winding coil (7), and through grooves (9) for overlapping the electrode sheets (8) are provided on two opposite sides of the outer shell (1).

2. The compact one-piece molded inductor according to claim 1, characterized in that: Second heat sinks (10) are installed on both sides of the partition (2); one end of the second heat sink (10) located on the inner side of the outer shell (1) is provided with a docking groove (11); and an elastic docking piece (12) used in conjunction with the docking groove (11) is installed on the inner side wall of the first heat sink (3).

3. The compact one-piece molded inductor according to claim 1, characterized in that: Trapezoidal reinforcing ribs (13) are provided on the outer side of the first heat sink (3).

4. A method for manufacturing an injection molded inductor according to any one of claims 1 to 3, characterized in that: The steps include: S1. Winding the copper wire along the thread groove direction of the threaded support member (6) into a winding coil (7) by a winding machine, welding the electrode sheets (8) to the two ends of the copper wire of the winding coil (7) by a spot welding machine, and overlapping the two electrode sheets (8) in the through groove (9) to limit and fix them, so that the winding coil (7) and the threaded support member (6) are located inside the outer shell (1); S2. Using an injection molding machine to inject magnetic powder into the interior of the outer shell (1), then buckle the partition (2) onto the outer shell (1), so that the magnetic column (5) is inserted into the hollow part of the threaded support (6), and buckle the docking piece (12) into the docking groove (11) to complete the docking work of the outer shell (1) and the partition (2), so that the first heat sink (3) and the second heat sink (10) form a heat dissipation whole; S3. The outer shell (1) and the partition (2) are subjected to heat pressing by a heat press, and the two electrode sheets (8) are bent into the mounting grooves on the partition (2).

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