A compact integrated inductor

Abstract

The present invention discloses a compact one-piece inductor, which relates to the technical field of one-piece inductors. The inductor comprises an outer shell and a partition. The outer shell is composed of a first heat sink and a firm layer covering the outer side of the first heat sink. A magnetic column is installed at a central position inside the partition. A threaded support is sleeved on the outer side of the magnetic column. A winding coil is spirally wound along a threaded groove on the outer side of the threaded support. Electrode sheets are respectively welded to the two ends of the winding coil. Through grooves for overlapping the electrode sheets are provided on two opposite sides of the outer shell. The present invention separates and supports two adjacent copper wires of the winding coil by the threaded support, thereby avoiding extrusion and adhesion between the copper wires during the hot pressing process, thereby improving the yield rate of the one-piece inductor.

Description

Technical Field

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

[0002] An integrally formed inductor (molded inductor: Molding Choke) includes a base body and a winding body. The base system is formed by embedding the winding body in metal magnetic powder and die-casting. The SMD pins are lead pins of the winding body that are directly formed on the surface of the base body. Existing integrally formed inductors are gradually developing in the direction of being light, thin, small, and high-performance. However, due to the limitation of small size, the winding coils of the integrally formed inductors are prone to extrusion and adhesion during the hot pressing process, thereby affecting the yield rate of the integrally formed inductors during the production process. In addition, the existing integrally formed inductors usually only use a very thin epoxy resin insulation layer on the outside of the metal magnetic powder. During the product patch processing, it is easy to be scratched by the machine, causing damage to the metal magnetic powder. At the same time, since the integrally formed inductor is prone to heat accumulation during use and is affected by external electromagnetic waves, the performance of the integrally formed inductor is reduced, thereby affecting other components in the circuit. Therefore, a compact integrally formed inductor is needed to solve the above problems. Summary of the Invention

[0003] The object of the present invention is to provide a compact integrally formed inductor to solve the above-mentioned defects caused by the prior art.

[0004] A compact, one-piece inductor comprises an outer shell and a partition. 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 mounted 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 threaded groove on the outside of the threaded support. Electrode sheets are welded to the two ends of the winding coil. 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, and 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. Winding a copper wire along the thread groove of the threaded support into a winding coil using a winding machine, welding electrode sheets to the two ends of the copper wire of the winding coil using a spot welding machine, and overlapping the two electrode sheets in the through groove for positional fixation, so that the winding coil and the threaded support are located inside the outer shell;

[0009] S2. Using an injection molding machine, magnetic powder is injected into the interior of the outer shell. Subsequently, the partition is buckled onto the outer shell so that the magnetic column is inserted into the hollow portion of the threaded support. The docking piece is buckled into the docking groove to complete the docking of the outer shell and the partition, so that the first heat sink and the second heat sink form a heat dissipation unit.

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

[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 heat generated by the inductor during use is quickly released to the outside world and the PCB through the first heat sink and the second heat sink, respectively, 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, improving the overall anti-electromagnetic capability of the inductor.

[0013] The outer shell protects the metal magnetic powder, preventing it from being scratched by the machine during use. The reinforcing ribs on the first heat sink increase the heat dissipation area while strengthening the structure of the outer shell, 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 structural diagram of the present invention as a whole.

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

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

[0017] Figure 4 This 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 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 plate; 9-through groove; 10-second heat sink; 11-docking groove; 12-docking plate; 13-reinforcement rib. DETAILED DESCRIPTION

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

[0022] like Figures 1 to 6 As shown, a compact one-piece molded 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 are provided on two opposite sides of the outer shell 1 for overlapping the electrode sheets 8. The through grooves 9 limit the electrode sheets 8 and play a role in limiting and fixing 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 is installed on the inner wall of the first heat sink 3 for use with the docking groove 11. 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 is abutted against the inside of the docking groove 11 by the action of elastic force, while stably connecting the partition 2, so that the first heat sink 3 and the second heat sink 10 form the entire 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 on the outside of the partition 2 and in contact with the PCB board, the partition 2 and the second heat sink 10 are coated with a high-temperature resistant insulating layer on the contact side with the PCB board, and when the present invention is soldered 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 shape of the reinforcing rib 13 is hollow, and the insulating material of the outer shell 1 can fully fill the hollow portion 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. Use a winding machine to wind the copper wire along the thread groove direction of the threaded support member 6 to form a winding coil 7, and use a spot welding machine to weld electrode sheets 8 to the two ends of the copper wire of the winding coil 7. The two electrode sheets 8 are overlapped and fixed in the through groove 9 so that the winding coil 7 and the threaded support member 6 are located inside the outer shell 1.

[0027] S2. Use 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. Then, buckle the docking piece 12 into the docking groove 11 to complete the docking of the outer shell 1 and the partition 2. Thus, the first heat sink 3 and the second heat sink 10 form a heat dissipation unit.

[0028] S3 , performing heat pressing operation on the outer shell 1 and the partition 2 by using a heat press, 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 world and the PCB board through the first heat sink 3 and the second heat sink 10, 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.

[0031] The outer shell 1 is used to wrap and protect the metal magnetic powder to prevent it from being scratched by the machine during use, 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 improving the service life of the inductor.

[0032] It is understood from common technical knowledge that the present invention may be implemented by other embodiments that do not depart from its spirit or essential features. Therefore, the embodiments disclosed above are, in all respects, merely illustrative and not exclusive. All modifications within the scope of the present invention or equivalent to the scope of the present invention are intended to be encompassed by the present invention.

Claims

1. A method for manufacturing an injection molded inductor, characterized by: The inductor 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 at a central position inside the partition (2), 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 welded to the two 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); Second heat sinks (10) are installed on both sides of the partition (2); a docking groove (11) is provided at one end of the second heat sink (10) located on the inner side of the outer shell (1); and an elastic docking piece (12) for use with the docking groove (11) is installed on the inner side wall of the first heat sink (3); Trapezoidal reinforcing ribs (13) are provided on the outer side of the first heat sink (3); The method comprises the following steps: 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, and 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. Inject the magnetic powder into the interior of the outer shell (1) through an injection molding machine, 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. Using a hot press, the outer shell (1) and the partition (2) are hot-pressed, and the two electrode sheets (8) are bent into the mounting grooves on the partition (2).

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