Inductor production process

Abstract

The invention relates to the technical field of electronic components, in particular to an inductor production process which comprises the following steps: S1, winding a coil, namely winding the coil coated with an insulating layer into a winding part and a lead part extending from the winding part; s2, the lead part is bent, and the lead part is bent in the axial direction of the winding part; s3, carrying out mold pressing on a body, carrying out mold pressing on a mixture of a magnetic material around the coil, and exposing a part of the lead part for connecting an external terminal; and S4, the external terminals are arranged on the two sides of the inductor in a sleeving mode and connected with the lead wire part, the lead wire part of the coil is bent to the outside of the winding part in the direction of the winding part, the magnetic core is arranged around the coil in a mold pressing mode, the external terminals are arranged on the two sides of the inductor in a sleeving mode and connected with the lead wire end, full connection with the lead wire end is facilitated, and the shock resistance of the inductor is improved by 60 G. Inductor short circuit caused by breakage is avoided, the power of the inductor is improved, the lead end can be directly connected with an electronic element to reduce loss, and the welding range is expanded through the external terminal.

Description

Technical Field

[0001] The present invention belongs to the technical field of electronic components, and particularly relates to an inductor production process. Background Art

[0002] When an inductor is used in an automobile to achieve noise suppression or step-up / step-down functions, the reliability of the inductor will be severely tested. To enable this type of passive component to still be used in the automobile circuit architecture, generally, the lead frame is connected to the coil by welding, and then the exposed part of the lead frame is bent after the inductor body is formed. However, with the increase of automobile power, the required seismic resistance is also increasing, and the characteristics required in specific application fields have exceeded the capabilities of this structure. Therefore, there is a need to develop an inductor design with a higher reliability level, and thus an inductor production process is required to solve the above problems. Summary of the Invention

[0003] To solve the above technical problems, the present invention provides an inductor production process to solve the problems in the existing market as mentioned in the above background art.

[0004] To achieve the above object, the technical solution of the present invention is as follows:

[0005] An inductor production process includes the following steps:

[0006] S1. Winding the coil, winding the coil covered with an insulating layer into a winding part and a lead part extending from the winding part;

[0007] S2. Bending the lead part, bending the lead part along the axial direction of the winding part;

[0008] S3. Molding the body by die pressing, die pressing a mixture of magnetic materials around the coil and exposing a part of the lead part for connecting to an external terminal;

[0009] S4. External terminal, sleeving on both sides of the inductor and connecting to the lead part.

[0010] Through the above technical solution, the lead part of the coil is bent along the winding part direction to the outside of the winding part, the magnetic core is die pressed around the coil, the external terminal is sleeved on both sides of the inductor and connected to the lead end, which is convenient for fully connecting with the lead end, improving the seismic resistance of the inductor by 60G, reducing the production steps, improving the production efficiency, saving labor costs, making the connection between the lead end and the external terminal more firm, avoiding short circuit of the inductor caused by breakage, also improving the power of the inductor, enabling the lead end to be directly connected to electronic components to reduce losses, and the external terminal expanding the welding range.

[0011] As a preferred solution of the present invention, the step S1 further includes the following steps:

[0012] S11. Wind the round wire or flat wire coated with an insulating layer into a hollow cylindrical winding part;

[0013] S12. Flatten the lead part and bend it in the axial direction of the winding part;

[0014] S13. Use a laser to strip the insulating layer covering the exposed lead part;

[0015] S14. Both ends of the lead part are lead ends.

[0016] Through the above technical solution, the winding part is hollow cylindrical, the part extending from the winding part is the lead part, the lead part first extends away from the winding part on both sides of the winding part, then the lead part is bent in the axial direction of the winding part and extends to the outside of the winding part, and both ends of the lead part are lead ends.

[0017] As a preferred solution of the present invention, step S3 further includes the following steps:

[0018] S31. Manufacture a U-core by hot-pressing soft magnetic powder into a U-core with a cavity inside;

[0019] S32. Manufacture a base by hot-pressing soft magnetic powder into a base with a middle column and a slot hole on the base;

[0020] S33. Place the coil in the cavity, the coil is adapted to the cavity, and pass the lead end through the slot hole and expose it;

[0021] S34. Mount the base on the cavity;

[0022] S35. Hot-press the base and the U-core into an integral molding.

[0023] As a preferred solution of the present invention, step S2 further includes the following steps:

[0024] S31. First extend the lead part along both sides of the winding part by 0.01 - 1 cm, and the extended part does not exceed the outside of the magnetic core;

[0025] S32. Then bend the lead part in the axial direction of the winding part;

[0026] S33. Remove the excess lead part that exceeds the external terminal.

[0027] Through the above technical solution, the lead is first extended along both sides of the winding part, then bent upward and extended to the outside of the end face of the winding part. After being assembled with the external terminal, the excess part exceeding the external terminal is removed.

[0028] As a preferred solution of the present invention, step S4 further includes the following steps:

[0029] S41. Punch through holes in the sheet material;

[0030] S42. Bend the sheet into a rectangle with a cross-section adapted to both ends of the inductor.

[0031] S43. Assemble and bond the sheet to the inductor to form an external terminal.

[0032] S44. Connect the sheet to the inductor by penetration welding.

[0033] S45. Tin the outer surface of the inductor by impregnation.

[0034] Through the above technical solution, for the preliminary preparation of the sheet, punch through-holes in the cut sheet, bend the sheet into a rectangle by a bending machine, weld the two ends of the sheet together, assemble the welded sheet with the inductor, use laser penetration welding to connect the sheet to the inductor, and complete the production of the inductor by impregnating and tinning the entire outer peripheral surface of the inductor. The laser penetration welding method is simple and fast, and no extra parts will be generated.

[0035] As a preferred solution of the present invention, the through-hole in step S41 is sleeved on the outer peripheral surface of the lead end, the lead end passes through the through-hole and is exposed, and the lead end is adapted to the through-hole.

[0036] Through the above technical solution, the lead end is arranged in the through-hole and is flush with the external terminal.

[0037] As a preferred solution of the present invention, the external terminal is a lead frame, and the sheet material of the lead frame is a metal conductive material.

[0038] As a preferred solution of the present invention, the lead frame is adapted to the inductor.

[0039] As a preferred solution of the present invention, the sheet thickness of the lead frame is 0.01 - 10 mm.

[0040] An inductor is obtained by an inductor production process.

[0041] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0042] Bend the lead part of the coil along the winding part direction to the outside of the winding part, mold the magnetic core around the coil, sleeve the external terminal on both sides of the inductor and connect it to the lead end, which is convenient for fully connecting with the lead end, improving the anti-seismic ability of the inductor by 60G, reducing the production steps, improving the production efficiency, saving labor costs, making the connection between the lead end and the external terminal more firm, avoiding short circuit of the inductor caused by fracture, also improving the power of the inductor, enabling the lead end to be directly connected to electronic components to reduce losses, and expanding the welding range of the external terminal. Description of the Drawings

[0043] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for the description of the embodiments or the prior art. Obviously, the drawings in the following description are some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0044] Figure 1 Structural schematic diagram of the inductor of the present invention;

[0045] Figure 2 Of the present invention Figure 1 Structural schematic diagram of the external terminal;

[0046] Figure 3 Of the present invention Figure 1 Partial structural schematic diagram in;

[0047] 3. Coil; 31. Winding part; 32. Lead part; 33. Lead end; 1. Molded body; 2. External terminal; 21. Through hole; 22. Welding point. Specific embodiments

[0048] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, rather than all embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts belong to the scope of protection of the present invention.

[0049] The present invention provides the following embodiments:

[0050] Embodiment 1:

[0051] An inductor production process, including the following steps:

[0052] S1. Wind the coil 3, wind the coil 3 covered with an insulating layer into a winding part 31, and a lead part 32 extending from the winding part 31. Step S1 further includes the following steps:

[0053] S11. Wind the round wire or flat wire covered with an insulating layer into a hollow cylindrical winding part 31;

[0054] S12. Level the lead part 32 and bend it in the axial direction of the winding part 31;

[0055] S13. Use a laser to strip the insulating layer covering the exposed lead part 32;

[0056] S14. Both ends of the lead part 32 are lead ends 33.

[0057] The winding part 31 is in the shape of a hollow cylinder. The lead part 32 extends from the winding part 31. The lead part 32 first extends away from the winding part 31 on both sides of the winding part 31, and then bends the lead part 32 in the axial direction of the winding part 31 and extends to the outside of the winding part 31. The two ends of the lead part 32 are lead ends 33;

[0058] S2. Bend the lead part 32 and bend the lead part 32 in the axial direction of the winding part 31. As a further improvement of the present invention, step S2 further includes the following steps:

[0059] S21. Extend the lead part 32 along both sides of the winding part 31 by 0.01 - 1 cm, and the extended part does not exceed the outside of the magnetic core;

[0060] S22. Then bend the lead part 32 in the axial direction of the winding part 31;

[0061] S23. Remove the redundant lead part 32 that exceeds the external terminal 2;

[0062] First extend the lead to both sides of the winding part 31, and then bend it upward and extend it outside the end face of the winding part 31. After assembling with the external terminal 2, remove the redundant part that exceeds the external terminal 2;

[0063] S3. Molding the body 1, molding a mixture of magnetic materials around the coil 3, and exposing part of the lead part 32 for connecting to the external terminal 2. Step S3 further includes the following steps:

[0064] S31. Manufacture a U-core, hot-press soft magnetic powder into a U-core, and there is a cavity inside the U-core;

[0065] S32. Manufacture a base, hot-press soft magnetic powder into a base, there is a middle column on the base, and there are slot holes on the base;

[0066] S33. Place the coil 3 in the cavity, the coil 3 is adapted to the cavity, and pass the lead end 33 through the slot hole and expose it;

[0067] S34. Mount the base on the cavity;

[0068] S35. Hot-press the base and the U-core into an integral shape;

[0069] S4. The external terminal 2 is sleeved on both sides of the inductor and connected to the lead part 32. Step S4 further includes the following steps:

[0070] S41. Punch through holes 21 on the sheet;

[0071] S42. Bend the sheet into a rectangle with a cross-section adapted to both ends of the inductor;

[0072] S43. Assemble and bond the sheet with the inductor to form the external terminal 2;

[0073] S44. Connect the sheet with the inductor by penetration welding. There are several welding points 22 on the sheet, and it also includes the welding points 22 at both ends of the through hole 21 and / or the welding points 22 on both sides of the external terminal 2 and / or the welding points 22 on the lower end face of the external terminal 2;

[0074] S45. Impregnate the outer surface of the inductor with solder.

[0075] Bend the lead portion 32 of the coil 3 along the winding portion 31 direction to the outside of the winding portion 31, mold the magnetic core around the coil 3, and sleave the external terminal 2 on both sides of the inductor and connect it to the lead end 33. This facilitates full connection with the lead end 33, improves the seismic resistance of the inductor to 60G, reduces the production steps, improves the production efficiency, saves labor costs, makes the connection between the lead end 33 and the external terminal 2 more firm, avoids short - circuit of the inductor caused by breakage, also improves the power of the inductor, the lead end 33 can be directly connected to electronic components to reduce losses, and the external terminal 2 expands the welding range.

[0076] Step S41 also includes: preliminary preparation of the sheet. The material is metal, preferably aluminum alloy. Prepare a rectangular sheet with appropriate dimensions, punch a through hole 21 in the cut - out sheet, bend the sheet into a rectangle by a bending machine, weld the two ends of the sheet together, assemble the welded sheet with the inductor, and connect the sheet and the inductor using laser penetration welding. Impregnate the entire outer peripheral surface of the inductor with solder to complete the production of the inductor. The laser penetration welding method is simple and fast, and does not produce redundant components.

[0077] As a further improvement of the present invention, the through hole 21 in step S41 is sleaved on the outer peripheral surface of the lead end 33, the lead end 33 passes through the through hole 21 and is exposed, the lead end 33 is adapted to the through hole 21, the lead end 33 is disposed in the through hole 21, and the lead end 33 is flush with the external terminal 2.

[0078] As a further improvement of the present invention, the external terminal 2 is a lead frame, and the sheet material of the lead frame is a metal conductive material.

[0079] As a further improvement of the present invention, the lead frame is adapted to the inductor.

[0080] As a further improvement of the present invention, the sheet thickness of the lead frame is 0.01 - 10 mm.

[0081] Example 2:

[0082] An inductor is obtained by an inductor production process.

[0083] The lead portion 32 of the coil 3 is bent along the winding portion 31 direction to the outside of the winding portion 31. The magnetic core is molded around the coil 3. The external terminals 2 are sleeved on both sides of the inductor and connected to the lead end 33, which facilitates sufficient connection with the lead end 33, achieves the effect of improving the seismic resistance of the inductor to 60G, reduces the production steps, improves the production efficiency, saves labor costs, makes the connection between the lead end 33 and the external terminal 2 more firm, avoids short circuit of the inductor caused by fracture, also improves the power of the inductor, the lead end 33 can be directly connected to electronic components to reduce losses, and the external terminal 2 expands the welding range.

[0084] The above description of the disclosed embodiments enables those skilled in the art to implement or use the present invention. Various modifications to these embodiments will be obvious to those skilled in the art, and the general principles defined herein can be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to these embodiments shown herein, but rather to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An inductor production process, characterized in that , including the following steps: S1, winding the coil, winding the coil covered with an insulating layer into a winding portion and a lead portion extending from the winding portion; S2, bending the lead portion, bending the lead portion along the axial direction of the winding portion; S3, molding a body, molding a mixture of magnetic materials around the coil, and leaving a portion of the lead wire for connecting an external terminal; S4, external terminals, are sleeved on both sides of the inductor and connected to the lead part.

2. The inductor production process according to claim 1, characterized in that: The step S1 further comprises the following steps: S11, winding a round wire or a flat wire coated with an insulating layer into a hollow cylindrical winding portion; S12, flattening the lead portion and bending it in the axial direction of the winding portion; S13, using laser to remove the insulating layer covering the exposed lead part; S14. Both ends of the lead portion are lead ends.

3. The inductor production process according to claim 1, characterized in that: Step S3 also includes the following steps: S31, making a U-core, hot pressing the soft magnetic powder into a U-core, wherein a cavity is provided in the U-core; S32, manufacturing a base, hot pressing the soft magnetic powder into a base, the base is provided with a middle column, and the base is provided with a slot; S33, placing the coil in the cavity, matching the coil with the cavity, and passing the lead end through the slot to expose it; S34, installing the base on the cavity; S35, hot press the base and U-core into one piece.

4. The inductor production process according to claim 3, characterized in that: Step S2 also includes the following steps: S31, extend the lead portion along both sides of the winding portion by 0.01-1 cm, and the extended portion does not exceed the outer side of the magnetic core; S32, then bending the lead portion along the axial direction of the winding portion; S33. Remove the excess lead portion exceeding the external terminal.

5. The inductor production process according to claim 1, characterized in that: Step S4 also includes the following steps: S41, punching a through hole on the sheet; S42, bending the sheet into a rectangular cross section that matches the two ends of the inductor; S43, assembling and bonding the sheet material and the inductor to form an external terminal; S44, the welding point of the sheet is connected to the inductor by laser penetration welding; S45. Apply tin to the outer surface of the inductor.

6. The inductor production process according to claim 5, characterized in that: The through hole in step S41 is sleeved on the outer peripheral surface of the lead end, the lead end passes through the through hole and is exposed, and the lead end is matched with the through hole.

7. The inductor production process according to claim 6, characterized in that: The external terminal is a lead frame, and the sheet material of the lead frame is a metal conductive material.

8. The inductor production process according to claim 7, characterized in that: The lead frame is adapted to the inductor.

9. The inductor production process according to claim 8, characterized in that: The sheet thickness of the lead frame is 0.01-10 mm.

10. An inductor, characterized in that: The inductor is produced by the inductor production process described in claims 1-9.

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