Inductor capable of improving space utilization rate and manufacturing method thereof

Abstract

The invention discloses an inductor capable of improving the space utilization rate, and belongs to the technical field of inductors, the inductor specifically structurally comprises a magnetic core, a first end pole piece and a second end pole piece, the first end pole piece and the second end pole piece are of an inverted U-shaped structure, and are symmetrically and fixedly connected to the magnetic core front and back to form two magnetic paths; two ends of the first end pole piece and the second end pole piece are respectively exposed out of two side surfaces of the magnetic core, the lower ends of the first end pole piece and the second end pole piece protrude out of the lower surface of the magnetic core to form four pins, and a first groove and a second groove which are symmetrical and parallel front and back are formed in the magnetic core to form a first air gap and a second air gap and are respectively positioned in the middle below the first end pole piece and the second end pole piece. According to the invention, the inductor is installed in a manner that the pins are suspended, and the longitudinal space at the bottom of the inductor is increased, so that a matched miniaturized product can be placed in the space at the bottom of the inductor, the product density on a PCB (Printed Circuit Board) is reduced, and meanwhile, the space utilization rate on the PCB is improved.

Description

Technical Field

[0001] The invention relates to an inductor for improving space utilization and a manufacturing method thereof, belonging to the technical field of power inductors. Background Art

[0002] Power inductors can be used in power circuits to form a low-pass filter. By reducing high-frequency signal interference, the DC output of the circuit can be more stable. At the same time, it can also limit the current in the circuit and protect other components from being damaged by overload. At present, most surface-mount power inductors on the market are reduced in size, resulting in the increasing density of electronic components on PCB boards, and it is difficult to reduce the size of the inductor. The only way is to continuously expand the PCB board horizontally to meet the use requirements. The increasing density of components on the PCB board will gradually cause accidents during the use of the product (due to the excessive density of product placement, different products will absorb heat when the components of the product circuit board are welded, resulting in poor welding and causing open circuits, or the temperature is too high due to the excessive density of the circuit board, resulting in burning).

[0003] The structure of the integrated power inductor product is as follows Figure 5-7 As shown, the coil (enameled wire) is first wound, and then the lead end is flattened or connected to a metal frame, filled with a mixture of alloy powder and epoxy resin, the magnetic powder is molded, and then the terminal is bent to form a chip inductor.

[0004] The one-piece molded inductor includes a magnetic core, a coil and a terminal. The enameled wire is wound around the magnetic core to form a magnetic path. The enameled wire magnetic path is fixed inside the magnet and wrapped by molding. The free end of the enameled wire is electrically connected to the metal terminal, and the metal terminal is bent and fixed on both sides of the bottom. The inductor wire end is welded through the metal terminal, and high-temperature tin is used for welding to avoid hidden dangers at high temperatures, thereby ensuring the product welding effect and the product's high-temperature resistance performance, which meets the product's use under high temperature conditions.

[0005] When the chip-type integrated power inductor is installed, the entire PCB board space will be filled with more and more electrical components, which cannot meet the requirements of product miniaturization. Summary of the invention

[0006] The technical problem to be solved by the present invention is to provide an inductor with improved space utilization and a manufacturing method thereof, which can effectively improve the space utilization of the product after installation.

[0007] The technical solution adopted by the present invention is: an inductor with improved space utilization, including a magnetic core, a first end pole piece and a second end pole piece, the first end pole piece and the second end pole piece are in an inverted U-shaped structure, symmetrically fixedly connected to the magnetic core front and back to form two magnetic paths, the two ends of the first end pole piece and the second end pole piece are respectively exposed on the two side surfaces of the magnetic core and the lower ends protrude from the lower surface of the magnetic core to form four pins, the magnetic core is provided with a first groove and a second groove that are symmetrically parallel to each other front and back to form a first air gap and a second air gap, and the first groove and the second groove are respectively located in the middle below the first end pole piece and the second end pole piece.

[0008] Furthermore, two through holes are arranged in the magnetic core, and the first end pole piece and the second end pole piece pass through the two through holes respectively and are bent downward at both ends.

[0009] Furthermore, the bending parts at both ends of the first end electrode piece and the second end electrode piece are respectively bonded to the embedding grooves at both ends of the two through holes by glue. Furthermore, two embedding grooves facing each through hole are arranged at both ends of the magnetic core, and the embedding grooves are inserted into the bent end portions of the first end pole piece or the second end pole piece.

[0010] A method for manufacturing an inductor with improved space utilization comprises the following steps: Step 1: The magnetic core is processed by cutting two through holes to form two magnetic paths, and a first groove and a second groove are processed to form a first air gap and a second air gap, and an inlay groove is formed by cutting at both ends of the magnetic core to obtain a magnetic core structure; Step 2: Cutting the first and second end pole pieces in the shape of long strips into specified sizes, and coating the first and second end pole pieces with a layer of matte tin to form the first and second end pole pieces; Step 3: Pass the first end pole piece and the second end pole piece through the two through holes (magnetic path) of the magnetic core, bend the two ends of the first end pole piece and the second end pole piece through a bending process, and cut the lead ends of the first end pole piece and the second end pole piece (the size of the cut foot can be changed according to customer requirements). After the bending, the first end pole piece and the second end pole piece will form an inverted U shape; Step 4: After the first end pole piece and the second end pole piece are bent into shape, the end electrodes are fixed by gluing at both ends of the magnetic core; the position of the glue is in the groove formed by cutting, and after the gluing is completed, a power inductor is obtained, making the structure more compact.

[0011] The beneficial effects of the present invention are as follows: compared with the prior art, the present invention increases the traditional single magnetic path into a double magnetic path, and the two magnetic paths can achieve the purpose of changing the inductance by changing the magnetic core at the bottom of the inductor, and the two magnetic paths are independent of each other and do not interfere with each other; the enameled wire of the traditional inductor is changed to be directly replaced by an electrode sheet, which can withstand a larger current; at the same time, because the strength of the electrode sheet is much higher than the metal terminal of an ordinary inductor, the reliability of the inductor can be improved; in order to better improve the space utilization on the PCB board, the lower end of the inductor pin is protruded from the magnetic core and is no longer bent; the inductor is installed with the pin suspended, and the longitudinal space at the bottom of the inductor is increased, so that the space at the bottom of the inductor can be placed with a matching miniaturized product, so as to reduce the product density on the product PCB and improve the space utilization on the product PCB board. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 It is a three-dimensional structural diagram of an inductor; Figure 2 This is a three-dimensional structural diagram of the inductor from another perspective; Figure 3 It is a right-side structural diagram of the inductor; Figure 4 yes Figure 3 Schematic diagram of the enlarged structure of the middle AA part; Figure 5 It is a schematic diagram of a single flux circuit; Figure 6 is a schematic diagram of a cross-sectional structure of an existing integrated inductor viewed from above; Figure 7 It is a schematic diagram of the front cross-sectional structure of an existing integrated inductor. DETAILED DESCRIPTION

[0013] The present invention is further described below in conjunction with the accompanying drawings and specific embodiments.

[0014] Example 1: Figure 1-5As shown, an inductor for improving space utilization includes a magnetic core 1, a first end pole piece 2 and a second end pole piece 3, the first end pole piece 2 and the second end pole piece 3 are in an inverted U-shaped structure, and are symmetrically fixedly connected to the magnetic core 1 to form two magnetic paths, the first end pole piece 2 and the second end pole piece 3 are exposed at both sides of the magnetic core 1 and the lower ends protrude from the lower surface of the magnetic core 1 to form four pins, the magnetic core 1 is provided with a first groove 4 and a second groove 5 symmetrically parallel to each other to form a first air gap and a second air gap, and the first groove 4 and the second groove 5 are respectively located in the middle below the first end pole piece 2 and the second end pole piece 3; the traditional single magnetic path is increased to a double magnetic path, and the two magnetic paths can pass The purpose of changing the inductor's inductance is achieved by changing the magnetic core at the bottom of the inductor. The two magnetic paths are independent of each other and do not interfere with each other. The enameled wire of the traditional inductor is replaced by a direct electrode sheet, which can withstand a larger current. At the same time, because the strength of the electrode sheet is much higher than the metal terminal of an ordinary inductor, the reliability of the inductor can be improved. In order to better improve the space utilization on the PCB board, the lower end of the inductor pin is protruded from the magnetic core and no longer bent. The inductor is installed with the pin suspended in the air, and the longitudinal space at the bottom of the inductor is increased, so that the space at the bottom of the inductor can be used to place matching miniaturized products, so as to reduce the product density on the product PCB and improve the space utilization on the product PCB board.

[0015] In order to facilitate the installation and production of the first end pole piece and the second end pole piece, two through holes 6 are set in the magnetic core 1. The first end pole piece 2 and the second end pole piece 3 pass through the two through holes 6 respectively and are bent downward at both ends. By setting the through holes to pass through the end pole pieces and then directly bending them to form pins, it is easy to install and produce, and the pole pieces are more stable after bending.

[0016] In order to achieve a stable connection between the first end pole piece 2 and the second end pole piece 3, the bending parts at both ends of the first end pole piece 2 and the second end pole piece 3 are respectively bonded to the inlay grooves at both ends of the two through holes 6 by glue. By applying glue on the front and back sides, the first end pole piece 2 and the second end pole piece 3 can be firmly connected in the through holes. In order to make the structure more compact, two embedding grooves 7 facing each through hole 6 are provided at both ends of the magnetic core 1. The embedding grooves are provided to facilitate the electrode sheets to be inserted into the embedding grooves, making the structure more compact.

[0017] The present invention utilizes the pin-type inductor to be suspended and installed, so that the vertical space at the bottom of the inductor can be used to place the surface-mount device in the space, so that the vertical space utilization rate at the bottom of the inductor is greatly improved, and the horizontal space is saved for the installation of electrical components on the PCB board, which is more conducive to product miniaturization. After the power inductor can be suspended and arranged, it effectively solves the problem that different products absorb heat when the components of the product circuit board are welded due to the excessive density of product placement, resulting in poor welding and thus causing an open circuit, or the problem that the temperature is too high due to the excessive density of the circuit board and thus burns out.

[0018] Embodiment 2: A method for manufacturing an inductor with improved space utilization comprises the following steps: Step 1: The magnetic core is processed by cutting two through holes to form two magnetic paths, and a first groove and a second groove are processed to form a first air gap and a second air gap, and an inlay groove is formed by cutting at both ends of the magnetic core to obtain a magnetic core structure; Step 2: Cutting the first and second end pole pieces in the shape of long strips into specified sizes, and coating the first and second end pole pieces with a layer of matte tin to form the first and second end pole pieces; Step 3: Pass the first end pole piece and the second end pole piece through the two through holes (magnetic path) of the magnetic core, bend the two ends of the first end pole piece and the second end pole piece through a bending process, and cut the lead ends of the first end pole piece and the second end pole piece (the size of the cut foot can be changed according to customer requirements). After the bending, the first end pole piece and the second end pole piece will form an inverted U shape; Step 4: After the first end pole piece and the second end pole piece are bent into shape, the end electrodes are fixed by gluing at both ends of the magnetic core; the position of the glue is in the groove formed by cutting, and after the gluing is completed, a power inductor is obtained, making the structure more compact.

[0019] The above description is only a specific implementation mode of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can easily think of changes or substitutions within the technical scope disclosed by the present invention, which should be included in the protection scope of the present invention. Therefore, the protection scope of the present invention should be based on the protection scope of the claims.

Claims

1. An inductor for improving space utilization, characterized in that: The invention comprises a magnetic core (1), a first end pole piece (2) and a second end pole piece (3), wherein the first end pole piece (2) and the second end pole piece (3) are in an inverted U-shaped structure and are symmetrically fixedly connected to the magnetic core (1) to form two magnetic paths, the two ends of the first end pole piece (2) and the second end pole piece (3) are respectively exposed on the two side surfaces of the magnetic core (1) and the lower ends protrude from the lower surface of the magnetic core (1) to form four pins, and the magnetic core (1) is provided with a first groove (4) and a second groove (5) which are symmetrically parallel to each other to form a first air gap and a second air gap, and the first groove (4) and the second groove (5) are respectively located in the middle below the first end pole piece (2) and the second end pole piece (3).

2. The inductor for improving space utilization according to claim 1, characterized in that: Two through holes (6) are arranged in the magnetic core (1), and the first end pole piece (2) and the second end pole piece (3) respectively pass through the two through holes (6) and are bent downward at both ends.

3. The inductor for improving space utilization according to claim 2, characterized in that: The bending parts at both ends of the first end pole piece (2) and the second end pole piece (3) are respectively bonded to the embedding grooves at both ends of the two through holes (6) by glue.

4. The inductor for improving space utilization according to claim 1, characterized in that: Two embedding grooves (7) facing each through hole (6) are provided at both ends of the magnetic core (1), and the embedding grooves (7) are inserted into the bent end of the first end pole piece (2) or the second end pole piece (3).

5. The method for manufacturing an inductor with improved space utilization according to claim 1, characterized in that: The following steps are involved: Step 1: The magnetic core is processed by cutting two through holes to form two magnetic paths, and a first groove and a second groove are processed to form a first air gap and a second air gap, and an inlay groove is formed by cutting at both ends of the magnetic core to obtain a magnetic core structure; Step 2: Cutting the first and second end pole pieces in the shape of long strips into specified sizes, and coating the first and second end pole pieces with a layer of matte tin to form the first and second end pole pieces; Step 3: Pass the first end pole piece and the second end pole piece through the two through holes of the magnetic core, bend the two ends of the first end pole piece and the second end pole piece through a bending process, and cut the lead ends of the first end pole piece and the second end pole piece. After the bending, the first end pole piece and the second end pole piece will form an inverted U shape; Step 4: After the first end pole piece and the second end pole piece are bent into shape, the end electrodes are fixed by gluing at both ends of the magnetic core; the position of the glue is in the groove formed by cutting, and the power inductor is obtained after the gluing is completed.

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