Magnetic element forming method, magnetic element and transformer
Through the mold injection molding method, the problems of waste of space, high cost and inability to achieve automated production in existing magnetic component designs are solved, and efficient and automated magnetic component production and precise assembly are achieved.
Patent Information
- Application Number
- CN202311452123.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2023-11-02
- Publication Date
- 2025-05-06
AI Technical Summary
The existing magnetic component designs have problems such as wasted space, high costs, inability to achieve automated production, unstable structural structure and poor assembly effects.
By adopting the mold injection molding method, through mold clamping and colloid injection molding of the first mold and the second mold, a plurality of conductive layers and an integrated colloid part are formed, so as to realize automated winding and integrated molding of the magnetic element.
It reduces the use of insulating tape materials, saves product space, reduces production costs, realizes automated production, and improves product accuracy and assembly effect.
Smart Images
Figure CN119943557A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of magnetic elements, and in particular to a magnetic element forming method, a magnetic element and a transformer. Background Art
[0002] At present, switching power supplies tend to be high efficiency and high power density. How to reduce labor costs and achieve automated production is an issue that magnetic component design engineers must consider.
[0003] The existing magnetic element includes a metal layer and a bobbin, and insulating tape is provided between the metal sheets in the metal layer. The bobbin is provided with bumps and clamping points. The bumps and the metal layer are manually fixed and combined to obtain a magnetic component, and then the magnetic components are combined in pairs through the clamping points to obtain a magnetic element. Furthermore, the coil is manually wound on the magnetic element and assembled on the magnetic column of the magnetic core to obtain a transformer, and finally the transformer is calibrated using a foot plate so that the transformer is finally formed and used. At present, the metal sheet and plastic combined magnetic element can achieve the advantages of high efficiency, high power density, and good heat dissipation, but the existing design and magnetic element structure have the following disadvantages:
[0004] (1) Isolation tape needs to be inserted between metal sheets. Due to process problems, the insulating tape needs to be larger than the metal sheet itself, which easily causes waste of design space.
[0005] (2) It is necessary to open multiple sets of molds for use, which is costly;
[0006] (3) During the manufacturing process of magnetic components, a lot of manpower is required and automated production cannot be achieved;
[0007] (4) Due to the combination tolerance, the magnetic component structure is unstable and can only be wound manually;
[0008] (5) Due to the combination tolerance and manufacturing tolerance of the metal layer and the winding frame, the assembly effect is poor, and the finished product often needs to be calibrated on the foot fixture before it can be finally formed and used.
[0009] Therefore, how to design a metal sheet magnetic component that can meet the requirements of high efficiency and high power density and can be produced automatically is an urgent problem that the industry needs to solve. Summary of the invention
[0010] The purpose of this application is to provide a magnetic element that can solve one or more defects of the prior art.
[0011] In order to achieve the above-mentioned purpose, the present case provides a magnetic element molding method, including providing a first sub-mold and a second sub-mold, the first sub-mold including a first positioning groove, a first positioning surface, a second positioning groove and a second positioning surface; providing a first conductive sheet and a second conductive sheet, the first conductive sheet and the second conductive sheet both including a conductive body and a conductive pin; fixing the conductive body of the first conductive sheet to the first positioning surface, fixing the conductive pin of the first conductive sheet to the first positioning groove, fixing the conductive body of the second conductive sheet to the second positioning surface, fixing the conductive pin of the second conductive sheet to the second positioning groove; placing the first sub-mold and the second sub-mold together, After the two sub-molds are combined, a first mold is obtained, and a first colloid is injected into the first mold, so that the first conductive sheet, the second conductive sheet and the first colloid form a conductive layer; a third sub-mold, a fourth sub-mold and a fifth sub-mold are provided, and the third sub-mold includes a third positioning groove; a plurality of conductive layers are prepared, and the conductive layers are fixed in the third positioning groove, and each conductive layer has a first through hole, and the fifth sub-mold is penetrated in the first through holes of the plurality of conductive layers; and after the third sub-mold, the fourth sub-mold and the fifth sub-mold are combined, a second mold is obtained, and a second colloid is injected into the second mold, and the plurality of conductive layers and the second colloid form a magnetic element.
[0012] In order to achieve the above-mentioned purpose, the present case provides a magnetic element, comprising multiple conductive layers and multiple integrally formed second colloid parts, each conductive layer comprises a first conductive sheet, a second conductive sheet and a first colloid part, arranged between the first conductive sheet and the second conductive sheet, for fixing and insulating the first conductive sheet and the second conductive sheet, each second colloid part comprises an annular outer wall, and the multiple second colloid parts are alternately arranged with the multiple conductive layers, wherein each conductive layer is injection molded by the first conductive sheet and the second conductive sheet through a first mold, and the magnetic element is injection molded by the multiple conductive layers through a second mold.
[0013] In order to achieve the above-mentioned purpose, the present case provides a transformer, including a magnetic core, the aforementioned magnetic element and a winding, wherein the magnetic core includes a magnetic column; the magnetic element is arranged on the magnetic column; the winding includes a plurality of coil parts, and the plurality of coil parts are respectively wound around a plurality of integrally formed second colloid parts.
[0014] The magnetic component molding method and magnetic component mold opening methods provided in this case are less and low in cost. The magnetic component is molded by mold injection, and the components are fixed by colloid. The components are stable and can be automatically wound. The magnetic component is made by one-piece molding, which does not require manual assembly, and the finished product does not require fixture calibration, and the product precision is also better. When using the magnetic components provided in this case to produce transformers, the conductive pin tolerances between multiple conductive layers of the magnetic component are small, the assembly effect is good, and the finished product does not require the pin fixture to be calibrated. BRIEF DESCRIPTION OF THE DRAWINGS
[0015] In order to more clearly illustrate the technical solution implemented in this case, the following is a brief introduction to the drawings required for use in the embodiments.
[0016] Figure 1 A schematic diagram of the structure of a magnetic element according to an embodiment of the present invention;
[0017] Figure 2 A schematic diagram of the structure of a conductive layer in one embodiment of the present invention;
[0018] Figure 3 for Figure 1 A flow chart of a method for forming a magnetic element as shown;
[0019] Figure 4 This is a schematic diagram of injection molding of the conductive layer in this case;
[0020] Figure 5 This is a schematic diagram of the structure of the first sub-mold in this case;
[0021] Figure 6 This is a schematic diagram of the injection molding of the magnetic component in this case;
[0022] Figure 7 A schematic diagram of fixing the conductive layer and the second mold in this case;
[0023] Figure 8 Windings wound on Figure 1 A schematic diagram of a magnetic element is shown;
[0024] Fig. 9 To include Figure 1 A schematic diagram of the structure of a transformer with magnetic elements shown;
[0025] Fig.10 To include Figure 1 Schematic diagram of the structure of the transformer with magnetic components shown.
[0026] Additional aspects and advantages of the present invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the present invention. DETAILED DESCRIPTION
[0027] Example embodiments will now be described more fully with reference to the accompanying drawings, however, the example embodiments can be implemented in many forms and should not be construed as limited to the embodiments set forth herein; on the contrary, these embodiments are provided so that the present case will be comprehensive and complete and will fully and completely convey the concept of the example embodiments to those skilled in the art.
[0028] Figure 1 This is a schematic diagram of the structure of the magnetic element 10 of this case, as shown in the figure, Figure 1Two different structures of the magnetic element 10 are shown as examples, namely structure (a) and structure (b). The magnetic element 10 may also be other structures, and the present invention is not limited thereto. Structure (a) and structure (b) have similar structures, both including multiple conductive layers 11, multiple integrally formed second colloid parts 12, and a channel C. Figure 2 Schematic diagram of the structure of the conductive layer 11 in structure (a) and structure (b). Figure 1 and Figure 2 Each conductive layer 11 includes a first conductive sheet 111, a second conductive sheet 112 and a first colloid part 113. The first colloid part 113 is disposed between the first conductive sheet 111 and the second conductive sheet 112 to fix and insulate the first conductive sheet 111 and the second conductive sheet 112. Each conductive layer 11 has a first through hole H1. Each second colloid part 12 includes an annular outer wall. A plurality of second colloid parts 12 are alternately disposed with a plurality of conductive layers 11. Each second colloid part has a second through hole. A plurality of second through holes are connected to each other to form a channel C. The first colloid part 113 and the second colloid part 12 are, for example, thermoplastic materials. Each conductive layer 11 is formed by injection molding of the first conductive sheet 111 and the second conductive sheet 112 through a first mold. The magnetic element 10 is formed by injection molding of a plurality of conductive layers 11 through a second mold.
[0029] The first conductive sheet 111 and the second conductive sheet 112 are, for example, metal sheets or PCB windings, and the conductive pin tolerance between the plurality of conductive layers 11 is less than 0.1 mm.
[0030] Figure 3 for Figure 1 The flow chart of the molding method 100 of the magnetic element 10 is shown, and the molding method 100 comprises the following steps:
[0031] S101: providing a first sub-mold and a second sub-mold, wherein the first sub-mold comprises a first positioning groove, a first positioning surface, a second positioning groove and a second positioning surface;
[0032] S102: providing a first conductive sheet and a second conductive sheet, wherein the first conductive sheet and the second conductive sheet both include a conductive body and conductive pins;
[0033] S103: fixing the conductive body of the first conductive sheet on the first positioning surface, fixing the conductive pin of the first conductive sheet on the first positioning groove, fixing the conductive body of the second conductive sheet on the second positioning surface, and fixing the conductive pin of the second conductive sheet on the second positioning groove;
[0034] S104: The first sub-mold and the second sub-mold are combined to obtain a first mold, and a first colloid is injected into the first mold, so that the first conductive sheet, the second conductive sheet and the first colloid form a conductive layer;
[0035] S105: providing a third sub-mold, a fourth sub-mold and a fifth sub-mold, wherein the third sub-mold comprises a third positioning groove;
[0036] S106: preparing a plurality of conductive layers, the conductive layers being fixed in the third positioning grooves, each conductive layer having a first through hole, and the fifth sub-mold being inserted into the first through holes of the plurality of conductive layers; and
[0037] S107: The third sub-mold, the fourth sub-mold and the fifth sub-mold are combined to obtain a second mold, and a second colloid is injected into the second mold. The plurality of conductive layers and the second colloid form a magnetic element.
[0038] According to the following Figure 4-Figure 7 The molding method, mold structure and use method of the magnetic element 10 are described in detail.
[0039] Figure 4 FIG. 1 is a schematic diagram of injection molding of the conductive layer 11. Figure 4 As shown, a first mold 21 is provided, the first mold 21 comprises a first sub-mold 211 and a second sub-mold 212, the second sub-mold 212 and the first sub-mold 211 are placed in an upper and lower form, and the conductive layer 11 injection molded by the first mold 21 is a horizontal structure.
[0040] The structure of the first sub-mold 611 is shown in FIG. Figure 5 , combined with Figure 4 and Figure 5 The first sub-mold 211 includes a first positioning groove 211a, a first positioning surface 211b, a second positioning groove 211c and a second positioning surface 211d. A first conductive sheet 111 and a second conductive sheet 112 are provided. The first conductive sheet 111 includes a conductive pin a and a conductive body b. The second conductive sheet 112 includes a conductive pin c and a conductive body d. The shapes of the conductive body b of the first conductive sheet 111 and the first positioning surface 211b match each other. The shapes of the conductive pin a of the first conductive sheet 111 and the first positioning groove 211a match each other. The shapes of the conductive pin c and the second positioning groove 211c of the second conductive sheet 112 match each other. The conductive body b of the first conductive sheet 111 is fixed to the first positioning surface 211b, the conductive pin a of the first conductive sheet 111 is fixed to the first positioning groove 211a, the conductive body d of the second conductive sheet 112 is fixed to the second positioning surface 211d, and the conductive pin c of the second conductive sheet 112 is fixed to the second positioning groove 211c.
[0041] In some embodiments of the present invention, Figure 4 As shown, the second conductive sheet 112 further includes positioning protrusions 1121 , which can be used to position and fix the adjacent coil portions 41 when the adjacent coil portions 41 of the winding 40 are bridged on the second conductive sheet 112 therebetween.
[0042] exist Figure 4 In the illustrated embodiment, the conductive pin a of the first conductive sheet 111 and the conductive pin c of the second conductive sheet 112 are located on different sides. In other embodiments, the conductive pin a of the first conductive sheet 111 and the conductive pin c of the second conductive sheet 112 may be located on the same side, and the structure of the first sub-mold is adjusted accordingly, which is not limited to the present embodiment.
[0043] After the first sub-mold 211 and the second sub-mold 212 are molded together to obtain the first mold 21, colloid is injected into the first mold 21, and the colloid is injected between the first conductive sheet 111 and the second conductive sheet 112 to form a first colloid part 113. The first conductive sheet 111 and the second conductive sheet 112 are fixed and insulated by the first colloid part 113, and the first conductive sheet 111, the second conductive sheet 112 and the first colloid part 113 form a conductive layer 11. A plurality of conductive layers 11 are prepared in the same way.
[0044] Figure 6 FIG. 1 is a schematic diagram of the injection molding of the magnetic element 10 of the present invention. Figure 6 As shown, a third sub-mold 311, a fourth sub-mold 312 and a fifth sub-mold 313 are provided, the third sub-mold 311 includes a plurality of third positioning grooves 311a, the fourth sub-mold 312 includes a plurality of fourth positioning grooves, and the plurality of fourth positioning grooves are arranged corresponding to the plurality of third positioning grooves 311a.
[0045] Figure 7 It is a schematic diagram of fixing multiple conductive layers 11 to the second mold 31. The multiple conductive layers 11 are respectively fixed to multiple third positioning grooves 311a. Each conductive layer 11 has a first through hole H1. The fifth sub-mold 313 is penetrated through the first through holes H1 of the multiple conductive layers 11. The multiple conductive layers 11 are arranged in sequence on the fifth sub-mold 313.
[0046] The third sub-mold 611 , the fourth sub-mold 612 and the fifth sub-mold 613 are combined to obtain the second mold 31 , and colloid is injected into the second mold 31 , and the plurality of conductive layers 11 and the colloid form the magnetic element 10 .
[0047] Specifically, refer to Figure 6 and Figure 7 The fifth sub-mold 313 has a first curved surface S1, and a first surface F1 is provided between two adjacent third positioning grooves 311a. Correspondingly, a second surface is provided between two adjacent fourth positioning grooves. The first surface F1 and the second surface form a second curved surface. The colloid is injected between the first curved surface S1 and the second curved surface to form a plurality of integrally formed second colloid parts 12. Each second colloid part 12 has an annular outer wall. The plurality of second colloid parts 12 and the plurality of conductive layers 11 are alternately arranged to form Figure 1 The magnetic element 10 shown. For ease of observation, Figure 6The conductive layers 11 and the second colloid parts 12 are shown separately, and a position 11a is shown between two adjacent second colloid parts 12, which corresponds to the position of the conductive layer 11. In the produced magnetic component product, only the conductive layer body is provided at the position 11a, and no colloid exists.
[0048] Corresponds to Figure 1 Two structures (a) and (b) of the magnetic element 10 are shown, Figure 8 Schematic diagrams (a') and (b') showing windings wound around the magnetic element 10. Figure 1 and Figure 8 The winding 40 includes a plurality of coil parts 41, and the plurality of coil parts 41 are respectively wound on the second colloid part 12 of the magnetic element 10. The plurality of conductive layers 11 and the plurality of coil parts 41 are staggered and insulated by the insulating layer outside the coil. The pins of the winding can be selected according to the actual situation, generally on the same side or on the opposite sides with a difference of 180°, which is not limited in this case. The magnetic element 10 wound with the winding 40 can be further assembled with the magnetic core into a transformer.
[0049] like Fig. 9 As shown, the transformer 50 includes a magnetic core 51, a magnetic element 10 and a winding 40. The magnetic core 51 includes a magnetic column corresponding to Figure 8 In the structures (a') and (b') shown in the figure, the magnetic element 10 can be matched with magnetic cores of different structures to obtain a transformer 50 having a structure such as Fig. 9 (a”) and (b”). The magnetic element 10 is arranged on the magnetic column of the magnetic core 51 through a channel, and the multiple coil parts 41 of the winding 40 are respectively wound on the second colloid part 12 of the magnetic element 10. The multiple conductive layers 51 of the magnetic element 50 are used as the secondary winding of the transformer 90, and the multiple coil parts 81 are used as the primary winding of the transformer 90. The multiple conductive layers 51 can be connected in parallel or in series, and the multiple coil parts 81 can be connected in parallel or in series.
[0050] The magnetic column in the magnetic core 51 can also be multiple columns, such as Fig.10 As shown, the transformer 60 includes a magnetic core 51 , a magnetic element 10 and a winding 40 , wherein the magnetic core 51 includes two magnetic columns, and each magnetic element 10 is correspondingly disposed on one of the magnetic columns.
[0051] In some embodiments of the present case, the magnetic core type may be E-type, U-type, P-type, etc., but the present case is not limited thereto.
[0052] The magnetic element proposed in this case has the following advantages:
[0053] (1) The conductive sheet is fixed by the positioning surface and positioning groove on the first mold, and the colloid is used for the first injection molding after the mold is closed to fix and insulate the conductive sheet and obtain a conductive layer, thereby reducing the insulating tape material and saving the overall product space;
[0054] (2) First, the conductive layer is inserted into the positioning groove of the second mold, and then the second mold is used to position the conductive layer as a whole. Then, the conductive layer is combined into a whole by a colloid to obtain a magnetic element. The magnetic element is made by an integrated molding method, which does not require manual assembly, and the finished product does not require fixture calibration, and the product precision is also better.
[0055] (3) During the injection molding process of magnetic components, fewer molds are opened, resulting in low costs;
[0056] (4) The magnetic components are molded and fixed with colloid, and the components are stable to achieve automated winding;
[0057] (5) The tolerance of the conductive pins between multiple conductive layers is small, the assembly effect is good, and the finished product does not require calibration of the pin fixture.
[0058] Although the embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and the scope of protection of the present invention shall be based on the scope defined by the appended claims.
Claims
1. A method for forming a magnetic element, characterized in that: Include: Providing a first sub-mold and a second sub-mold, wherein the first sub-mold comprises a first positioning groove, a first positioning surface, a second positioning groove and a second positioning surface; Providing a first conductive sheet and a second conductive sheet, wherein the first conductive sheet and the second conductive sheet each include a conductive body and a conductive pin; Fixing the conductive body of the first conductive sheet to the first positioning surface, fixing the conductive pin of the first conductive sheet to the first positioning groove, fixing the conductive body of the second conductive sheet to the second positioning surface, and fixing the conductive pin of the second conductive sheet to the second positioning groove; The first sub-mold and the second sub-mold are combined to obtain a first mold, and a first colloid is injected into the first mold, so that the first conductive sheet, the second conductive sheet and the first colloid form a conductive layer; Providing a third sub-mold, a fourth sub-mold and a fifth sub-mold, wherein the third sub-mold comprises a third positioning groove; Prepare a plurality of the conductive layers, the conductive layers are fixed to the third positioning grooves, each of the conductive layers has a first through hole, and the fifth sub-mold is penetrated in the first through holes of the plurality of the conductive layers; as well as The third sub-mold, the fourth sub-mold and the fifth sub-mold are combined to obtain a second mold, and a second colloid is injected into the second mold. The plurality of conductive layers and the second colloid form the magnetic element.
2. The magnetic element forming method according to claim 1, characterized in that: The first conductive sheet and the second conductive sheet are metal sheets or PCB windings.
3. The magnetic element forming method according to claim 1, characterized in that: The conductive body of the first conductive sheet and the first positioning surface match each other in shape, the conductive pin of the first conductive sheet and the first positioning groove match each other in shape, and the conductive pin of the second conductive sheet and the second positioning groove match each other in shape.
4. The magnetic element forming method according to claim 1, characterized in that: The first colloid is injected between the first conductive sheet and the second conductive sheet to form a first colloid portion, and the first conductive sheet and the second conductive sheet are fixed and insulated by the first colloid portion.
5. The magnetic element forming method according to claim 1, characterized in that: The conductive layer is a horizontal structure, and the first sub-mold and the second sub-mold are placed up and down.
6. The magnetic element forming method according to claim 1, characterized in that: The third sub-mold includes a plurality of third positioning grooves, and the fourth sub-mold includes a plurality of fourth positioning grooves arranged corresponding to the third positioning grooves.
7. The magnetic element forming method according to claim 1, characterized in that: The plurality of conductive layers are sequentially arranged at intervals on the fifth sub-mold.
8. The magnetic element forming method according to claim 1, characterized in that: The second colloid forms a plurality of integrally formed second colloid parts, each of the second colloid parts has an annular outer wall, and the plurality of second colloid parts and the plurality of conductive layers are arranged alternately.
9. The magnetic element forming method according to claim 8, characterized in that: The fifth sub-mold has a first curved surface, a first surface between adjacent third positioning grooves, a second surface between adjacent fourth positioning grooves, the first surface and the second surface form a second curved surface, and the second colloid part is formed between the first curved surface and the second curved surface.
10. The magnetic element forming method according to claim 8, characterized in that: The second colloid part has second through holes, which are connected to each other correspondingly to form a channel.
11. The magnetic element forming method according to claim 1, characterized in that: The first colloid and the second colloid are thermoplastic materials.
12. The method for forming a magnetic element according to claim 1, characterized in that: The conductive pins of the first conductive sheet and the conductive pins of the second conductive sheet are located on the same side or on different sides.
13. The magnetic element forming method according to claim 1, characterized in that: The tolerance of the conductive pins between the plurality of conductive layers is less than 0.1 mm.
14. A magnetic element, characterized in that: Include A plurality of conductive layers, each of the conductive layers comprising: a first conductive sheet; a second conductive sheet; and a first colloid part, disposed between the first conductive sheet and the second conductive sheet, for fixing and insulating the first conductive sheet and the second conductive sheet, and A plurality of integrally formed second colloid parts, each of the second colloid parts comprises an annular outer wall, the plurality of second colloid parts and the plurality of conductive layers are arranged alternately, Each of the conductive layers is formed by injection molding of the first conductive sheet and the second conductive sheet through a first mold, and the magnetic element is formed by injection molding of the plurality of conductive layers through a second mold.
15. The magnetic element according to claim 14, characterized in that: The first conductive sheet and the second conductive sheet are metal sheets or PCB windings.
16. The magnetic element according to claim 14, characterized in that Each of the conductive layers has a first through hole, and each of the second colloid parts has a second through hole, which are connected to each other to form a channel.
17. The magnetic element according to claim 14, characterized in that: The conductive pin tolerance between the plurality of conductive layers is less than 0.1 mm.
18. The magnetic element according to claim 14, characterized in that The first colloid part and the second colloid part are thermoplastic materials.
19. A transformer, characterized in that: Include: A magnetic core, including a magnetic column; The magnetic element according to any one of claims 14 to 18, arranged in the magnetic column; and The winding comprises a plurality of coil parts, and the plurality of coil parts are respectively wound around the plurality of integrally formed second colloid parts.
20. The transformer according to claim 19, characterized in that The multiple conductive layers are used as the secondary winding of the transformer, the multiple coil parts are used as the primary winding of the transformer, and the multiple conductive layers and the multiple coil parts are arranged alternately.