Winding, inductor and manufacturing method

Abstract

The invention discloses a winding, an inductor and a manufacturing method, and belongs to the technical field of electronic elements. The winding comprises a primary coil, an insulation structure and a secondary coil, the primary coil and the secondary coil are the same in shape, the insulation structure comprises a first insulator, the first insulator is arranged between the primary coil and the secondary coil, and the first insulator, the primary coil and the secondary coil form a combined body. The two ends of the primary coil in the first direction are a first electrode end and a second electrode end respectively, the two ends of the secondary coil in the first direction are a third electrode end and a fourth electrode end respectively, and the first electrode end and the third electrode end are the same in height and both protrude out of one end of the insulation structure. The second electrode end and the fourth electrode end are the same in height and both protrude out of the other end of the insulation structure. The manufacturing process and the assembling process of the primary coil and the secondary coil are reduced, and the assembling precision of the winding and the magnetic core of the inductor is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of electronic components, and in particular to a winding, an inductor and a manufacturing method. Background Art

[0002] As one of the most commonly used and indispensable components in electronic devices, inductors hold a crucial position in the electronics field. They are widely used in various circuits, playing a vital role in achieving a variety of key functions, including filtering, energy storage, matching, and resonance. In filtering, inductors can effectively filter out clutter and interference signals in circuits, ensuring signal purity. In energy storage, they can store energy and release it when needed, providing stable energy support for circuits. In matching circuits, inductors help achieve impedance matching between different circuits, improving signal transmission efficiency. And in resonant circuits, inductors, in combination with components such as capacitors, can produce resonance at specific frequencies, widely used in communications, radio frequency, and other fields.

[0003] The TLVR (Trans-Inductor Voltage Regulator) architecture is a newly developed VR (Voltage Regulator) power supply architecture in recent years. In related technologies, a TLVR coupled inductor typically consists of several key components: a primary coil, a secondary coil, and a magnetic core assembly. The design and fabrication of the primary coil are unique. It is formed from a square-shaped conductive metal strip, first machined into a wide U-shaped portion. During assembly, this wide U-shaped portion fits into the cavity of the U-shaped core in the magnetic core assembly. Simultaneously, the ends of the primary coil are bent outward to form the first and fourth pins. The secondary coil's structure and installation method differ from the primary coil. It is formed from a conductive metal sheet, forming a narrow U-shaped portion. During assembly, this narrow U-shaped portion fits over the protruding post of the T-shaped core in the magnetic core assembly. The ends of the secondary coil are bent around the protruding post, ultimately forming the second and third pins.

[0004] However, this TLVR coupled inductor design has some shortcomings. On the one hand, the primary and secondary coils are fixed using the U-shaped core and T-shaped core in the magnetic core assembly. This fixing method not only has a complex assembly process and requires precise positioning and assembly operations, but also has low installation position accuracy of the primary and secondary coils. Deviations in the installation position may affect key parameters such as the inductance value and coupling coefficient of the inductor, thereby affecting the performance of the entire power supply system. On the other hand, the primary and secondary coils need to be bent during the manufacturing process to form the corresponding pins (also called electrode ends), which undoubtedly increases the processing steps of the coil and increases production costs.

[0005] This section provides background information related to the present application which is not necessarily prior art. Summary of the Invention

[0006] The object of the present invention is to provide a winding, an inductor and a manufacturing method, which can reduce the processing steps and assembly steps of the primary and secondary coils and improve the assembly accuracy of the winding and the magnetic core of the inductor.

[0007] To achieve the above objectives, the following technical solutions are provided:

[0008] The winding includes a primary coil, an insulating structure and a secondary coil, wherein the primary coil and the secondary coil have the same shape, the insulating structure includes a first insulator, the first insulator is arranged between the primary coil and the secondary coil, and the first insulator, the primary coil and the secondary coil form a combination. The two ends of the primary coil along the first direction are respectively a first electrode end and a second electrode end, and the two ends of the secondary coil along the first direction are respectively a third electrode end and a fourth electrode end, the first electrode end and the third electrode end have the same height and both protrude from one end of the insulating structure, and the second electrode end and the fourth electrode end have the same height and both protrude from the other end of the insulating structure.

[0009] As an optional solution for the winding, the insulation structure further includes:

[0010] The second insulator, the first insulator and the second insulator are an integrated structure, the second insulator is located on both sides of the first insulator, and the second insulator can wrap the primary coil and the secondary coil.

[0011] As an optional solution for the winding, first accommodating grooves are provided on both sides of the primary coil along the second direction, and second accommodating grooves are provided on both sides of the secondary coil along the second direction, and the second insulators are provided in the first accommodating grooves and the second accommodating grooves.

[0012] As an optional solution for the winding, the material of the insulating structure is liquid crystal polymer.

[0013] As an optional solution for the winding, the end faces and four sides of the first electrode end, the second electrode end, the third electrode end and the fourth electrode end are plated with a conductive layer, and the material of the conductive layer is metal nickel, metal tin or metal silver.

[0014] As an optional solution for the winding, the outer wall surface of the winding is circumferentially coated with insulating paint.

[0015] An inductor, comprising a magnetic core and at least one technical solution of a winding as described in any one of the above items, wherein the magnetic core has at least one through hole, the through hole passes through the top and bottom ends of the magnetic core, the winding is inserted into the through hole along a first direction, the first electrode end and the third electrode end of the winding extend out of the top end of the magnetic core, and the second electrode end and the fourth electrode end of the winding extend out of the bottom end of the magnetic core.

[0016] As an optional solution for the inductor, the top and bottom ends of the magnetic core are both provided with glue grooves at the openings of the through hole, glue is filled in the glue grooves, and the magnetic core and the winding are both bonded to the glue.

[0017] As an optional solution for the inductor, the top of the magnetic core and / or the bottom of the magnetic core are provided with a first chamfer around them, and / or

[0018] The side edge of the magnetic core is provided with a second chamfer.

[0019] A manufacturing method for preparing a winding as described in any one of the above items, comprising the following steps:

[0020] A plurality of first injection holes are processed at intervals along a second direction on the primary copper bar, and second injection holes are processed on the secondary copper bar corresponding to the first injection holes;

[0021] The primary copper bar and the secondary copper bar are placed and fixed in a mold cavity along a third direction, wherein the mold cavity has separation protrusions at both ends along the first direction, and the separation protrusions are located between the primary copper bar and the secondary copper bar;

[0022] Injecting LCP colloid from the first injection hole and the second injection hole, the primary copper strip, the LCP colloid and the secondary copper strip form a processing strip, and removing the mold cavity;

[0023] The processing strip is cut along a dividing line of each of the first injection holes to divide the processing strip into a plurality of the windings.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] The winding provided by the present invention sandwiches the first insulator of the insulating structure between the primary coil and the secondary coil, so that the primary coil, the first insulator, and the secondary coil form a combined body. The winding can be assembled into the magnetic core at one time, and the primary coil and the secondary coil do not need to be assembled separately. This not only reduces the assembly process of the winding, but also improves the assembly accuracy of the winding and the magnetic core of the inductor. Because the first electrode end and the third electrode end are the same height and both protrude from one end of the insulating structure along the first direction, and the second electrode end and the fourth electrode end are the same height and both protrude from the other end of the insulating structure along the first direction, the protruding first electrode end, second electrode end, third electrode end, and fourth electrode end can not only be directly welded to the circuit board without the need to grind the electrode ends to make them flush, but also eliminate the need to bend the primary coil and the secondary coil, thereby reducing the processing steps of the coil and improving the assembly efficiency of the winding.

[0026] The inductor provided by the present invention directly assembles the winding including the primary coil, the insulation structure and the secondary coil into the through hole of the magnetic core as a whole along the first direction, thereby improving the assembly efficiency and precision of the inductor.

[0027] The manufacturing method provided by the present invention includes a plurality of first injection holes machined at intervals along a second direction on a primary copper bar, and second injection holes machined corresponding to the first injection holes on a secondary copper bar. The primary and secondary copper bars are placed and fixed in a mold cavity at intervals along a third direction. The interior of the mold cavity has separation protrusions at both ends along the first direction, and the separation protrusions are located between the primary and secondary copper bars. LCP colloid is injected through the first and second injection holes, and the primary copper bar, LCP colloid, and secondary copper bar form a processing strip. The mold cavity is removed, and the processing strip is cut along the dividing line of each first injection hole to divide the processing strip into a plurality of windings. By cutting the processing strip, multiple windings can be prepared at a time, and the processing accuracy and consistency of each winding are guaranteed. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for use in describing the embodiments of the present invention. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the contents of the embodiments of the present invention and these drawings without any creative work.

[0029] Figure 1 Schematic diagram of the assembly of the winding from a first perspective in an embodiment of the present invention;

[0030] Figure 2 An exploded schematic diagram of a winding from a first perspective in an embodiment of the present invention;

[0031] Figure 31. It is a schematic diagram of the assembly of the winding from a second viewing angle according to an embodiment of the present invention;

[0032] Figure 4 An exploded schematic diagram of a winding from a second perspective in an embodiment of the present invention;

[0033] Figure 5 A side view of a winding in an embodiment of the present invention;

[0034] Figure 6 Schematic diagram of the assembly of an inductor according to an embodiment of the present invention;

[0035] Figure 7 Schematic diagram of an explosion of an inductor according to an embodiment of the present invention;

[0036] Figure 8 is a top view of an inductor according to an embodiment of the present invention;

[0037] Figure 9 for Figure 8 Cross-sectional view along the AA axis;

[0038] Figure 10 A flowchart of a production method according to an embodiment of the present invention;

[0039] Figure 11 This is a schematic diagram of the structure of the processed strip after injection molding in an embodiment of the present invention (the second insulator is not shown);

[0040] Figure 12 Schematic diagram of the processed strip after being cut in an embodiment of the present invention (the second insulator is not shown).

[0041] Reference numerals:

[0042] 100, winding; 200, magnetic core; 201, through hole; 202, glue storage groove; 203, first chamfer; 204, second chamfer; 300, primary copper strip; 301, first injection hole; 302, dividing line; 400, secondary copper strip; 500, LCP colloid;

[0043] 1. Primary coil; 2. Insulation structure; 3. Secondary coil;

[0044] 11. First electrode terminal; 12. Second electrode terminal; 13. First receiving groove;

[0045] 21. First insulator; 22. Second insulator;

[0046] 31. Third electrode terminal; 32. Fourth electrode terminal; 33. Second receiving groove. DETAILED DESCRIPTION

[0047] To make the objectives, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions of the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings herein can be arranged and designed in various different configurations.

[0048] In the description of the present invention, it should be noted that the terms "upper", "lower", "left", "right", "vertical", "horizontal", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, or are the orientation or position relationship in which the product of the invention is usually placed when in use. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first", "second", "third", etc. are only used to distinguish the description and cannot be understood as indicating or implying relative importance. In the description of the present invention, unless otherwise specified, "multiple" means two or more.

[0049] In the description of the present invention, it should be noted that, unless otherwise specified or limited, the terms "disposed" and "connected" should be understood in a broad sense. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0050] The following describes embodiments of the present invention in detail. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended only to explain the present invention and are not to be construed as limiting the present invention.

[0051] In order to reduce the processing and assembly processes of the primary and secondary coils and improve the assembly accuracy of the winding and the magnetic core of the inductor, this embodiment provides a winding, an inductor and a manufacturing method. Figures 1 to 12 The specific contents of this embodiment are described in detail. It should be noted that the first direction mentioned in this embodiment is Figure 1 The Z direction in this embodiment is the second direction Figure 1 The Y direction in this embodiment is the third direction Figure 1 The X direction in .

[0052] like Figures 1 to 5As shown, the winding 100 in this embodiment includes a primary coil 1, an insulating structure 2 and a secondary coil 3. The primary coil 1 and the secondary coil 3 have the same shape. The insulating structure 2 includes a first insulator 21. The first insulator 21 is arranged between the primary coil 1 and the secondary coil 3. The first insulator 21, the primary coil 1 and the secondary coil 3 form a combination. The two ends of the primary coil 1 along the first direction are respectively a first electrode end 11 and a second electrode end 12. The two ends of the secondary coil 3 along the first direction are respectively a third electrode end 31 and a fourth electrode end 32. The first electrode end 11 and the third electrode end 31 have the same height and both protrude from one end of the insulating structure 2. The second electrode end 12 and the fourth electrode end 32 have the same height and both protrude from the other end of the insulating structure 2.

[0053] The primary coil 1 and secondary coil 3 maintain a highly consistent design in shape. This identical shape allows for high compatibility in manufacturing processes, streamlining production processes and reducing costs. For example, similar equipment and process parameters can be used during coil processing, reducing production adjustment time due to coil shape differences and improving production efficiency.

[0054] The winding 100 provided in this embodiment sandwiches the first insulator 21 of the insulating structure 2 between the primary coil 1 and the secondary coil 3, so that the primary coil 1, the first insulator 21 and the secondary coil 3 form a combined body. In the traditional winding 100 assembly process, the primary coil 1 and the secondary coil 3 usually need to be assembled into the magnetic core 200 separately and independently, which not only increases the complexity and time cost of assembly, but also makes it difficult to ensure the assembly accuracy between the coil and the magnetic core 200 due to multiple assembly operations. However, the winding structure provided in this embodiment can be assembled into the magnetic core 200 in one go because the primary coil 1, the first insulator 21 and the secondary coil 3 have already formed a stable combined body in advance. This one-time assembly method greatly reduces the assembly process of the winding 100, avoids the error accumulation that may be caused by multiple assemblies, and thus significantly improves the assembly accuracy of the winding 100 and the magnetic core 200 of the inductor. Improving assembly accuracy is crucial to the performance of the inductor. It can ensure that the inductor has a stable inductance value, low loss and good electromagnetic compatibility during operation, thereby improving the performance and reliability of the entire electronic device.

[0055] In traditional electrode end processing methods for winding 100, due to limitations in coil assembly and manufacturing processes, the electrode ends often have uneven surfaces. To achieve good welding with the circuit board, the electrode ends are typically polished to make them flush. However, polishing not only adds additional processing steps and reduces production efficiency, but can also damage the electrode ends, affecting their electrical performance. For example, polishing can cause the metal layer on the electrode end surface to become thinner, increasing resistance, thereby generating more heat in the circuit and reducing circuit efficiency. In this embodiment, since the first electrode end 11, the second electrode end 12, the third electrode end 31, and the fourth electrode end 32 all protrude from the insulating structure 2 and are at the same height, they can be directly soldered to the circuit board without the need for polishing. This not only simplifies the production process and improves production efficiency, but also avoids the adverse effects of polishing on electrode end performance, ensuring good electrical connection and mechanical stability between the electrode end and the circuit board. For example, the first insulator 21 located in the middle is generally at least 0.05 mm lower than the coil electrode end.

[0056] In addition, in the traditional winding 100 structure, in order to achieve the connection between the electrode end and the circuit board or meet specific installation requirements, it is often necessary to bend the primary coil 1 and the secondary coil 3. Bending the coil not only increases the processing steps of the coil, but also has an adverse effect on the electrical performance of the coil. During the bending process of the coil, the wire inside it will be deformed, resulting in increased resistance, changes in inductance, and may even cause quality problems such as wire breakage. In this embodiment, due to the design of the protruding insulating structure 2 of the electrode end, there is no need to bend the primary coil 1 and the secondary coil 3, thereby reducing the processing steps of the coil, reducing the risk of coil damage due to bending, and improving the assembly efficiency and overall quality of the winding 100.

[0057] In some embodiments, the insulating structure 2 further includes a second insulator 22, and the first insulator 21 and the second insulator 22 are integrally formed structures. The second insulator 22 is located on both sides of the first insulator 21, and the second insulator 22 can wrap the primary coil 1 and the secondary coil 3. The insulating structure 2 is an integrally formed structure, which can ensure the integrity and stability of the entire insulating structure 2, avoid problems such as gaps and looseness that may arise from the assembly of multiple components, and thus improve the overall performance and reliability of the insulating structure 2. By adding the second insulator 22, firstly, it can significantly increase the wrapping area of ​​the insulating structure 2 for the primary coil 1 and the secondary coil 3. Originally, the insulating structure 2 may only cover part of the surface of the coil, but the addition of the second insulator 22 allows more parts of the coil to be wrapped by the insulating material, thereby improving the reliability of the insulation. Secondly, the second insulator 22 can also enhance the wrapping force of the insulating structure 2 for the primary coil 1 and the secondary coil 3. This increased wrapping force helps ensure a tight bond between the primary coil 1 and the secondary coil 3 and the insulation structure 2, preventing them from loosening and falling even under external vibration, impact, or thermal stress. Loosening and falling of the primary coil 1 and the secondary coil 3 could degrade the electrical performance of the winding 100, or even cause serious faults such as short circuits, impacting the normal operation of the entire electronic device. By adding the second insulator 22 to enhance the bonding force, the stability and reliability of the winding 100 are effectively improved, extending its service life.

[0058] In some embodiments, as Figure 2 Combine Figure 4 As shown, a first receiving groove 13 is provided on both sides of the primary coil 1 along the second direction, and a second receiving groove 33 is provided on both sides of the secondary coil 3 along the second direction. The second insulator 22 is provided in the first receiving groove 13 and the second receiving groove 33. The addition of the first receiving groove 13 and the second receiving groove 33 helps the second insulator 22 to better creep during the filling process. Creeping refers to the phenomenon of colloid flowing and filling along a specific surface or structure. The first receiving groove 13 and the second receiving groove 33 provide a channel and space for the second insulator 22 to flow, allowing the second insulator 22 to be more evenly distributed on both sides of the primary coil 1 and the secondary coil 3. At the same time, the structure of the receiving groove also allows the second insulator 22 to buckle inward, like a "button", firmly fixing the second insulator 22 in the receiving groove, further strengthening the bonding force between the second insulator 22 and the coil. In this way, the second insulator 22 can be more conveniently and stably formed on both sides of the primary coil 1 and the secondary coil 3.

[0059] In some embodiments, the insulating structure 2 is made of liquid crystal polymer. Liquid crystal polymer (LCP) possesses a range of excellent properties, making it an ideal material for the insulating structure 2. From an electrical perspective, LCP has extremely high insulation resistance, effectively preventing current leakage and ensuring the proper function of the winding 100 within the circuit. LCP also possesses high strength and toughness. During the manufacturing, transportation, and installation of the winding 100, it is inevitably subject to certain external forces. The excellent mechanical properties of LCP ensure that the insulating structure 2 will not easily crack or deform, maintaining its complete insulation and securing functions. Furthermore, LCP exhibits excellent heat and chemical resistance. During the operation of electronic equipment, the winding 100 generates a certain amount of heat. If the insulating material cannot withstand the high temperatures, it may soften, deform, or even melt, leading to insulation failure. However, LCP maintains stable performance at relatively high temperatures, ensuring that the winding 100 can function properly even under prolonged high-temperature operating conditions. Furthermore, LCP resists chemical corrosion in environments where it may come into contact with chemical substances, extending the service life of the winding 100.

[0060] In some embodiments, the end surfaces and four sides of the first electrode terminal 11, the second electrode terminal 12, the third electrode terminal 31, and the fourth electrode terminal 32 are electroplated with a conductive layer. The top and bottom of the winding 100 are electrodes (the first electrode terminal 11, the second electrode terminal 12, the third electrode terminal 31, and the fourth electrode terminal 32, respectively), which are generally electroplated. The conductive layer can be made of metal nickel, metal tin, or metal silver. This embodiment undergoes a detailed and critical treatment of the electrode terminals of the winding 100. Specifically, the first electrode terminal 11, the second electrode terminal 12, the third electrode terminal 31, and the fourth electrode terminal 32 are all electroplated, thereby forming a conductive layer. In the winding 100 structure, the protruding portions at its top and bottom are the electrodes, namely the first electrode terminal 11, the second electrode terminal 12, the third electrode terminal 31, and the fourth electrode terminal 32 mentioned above. These electrodes bear the important task of achieving electrical connection with the external circuit, and their performance is directly related to the conductivity efficiency and stability of the entire circuit. Therefore, these electrodes are generally electroplated.

[0061] The conductive layer material used in the electroplating process is a specific choice, typically nickel, tin, or silver. Each of these metals has its own unique advantages, meeting different application requirements. Nickel offers excellent corrosion and wear resistance. After being plated onto the electrode surface, it forms a dense protective film, effectively protecting the electrode from environmental damage such as oxidation and moisture during long-term use, thereby extending the electrode's service life. Nickel also has a certain degree of conductivity, which can reduce the electrode's resistance to a certain extent. Tin is favored for its excellent solderability and low cost. In the electronics manufacturing industry, soldering is a key process step in connecting inductors to circuit boards. Electrodes plated with tin have excellent wettability, allowing them to fully blend with solder paste, forming a strong solder joint and ensuring a stable and reliable electrical connection between the electrode and the circuit board. Furthermore, tin's price is relatively low, effectively reducing costs in large-scale production. Silver has the best conductivity of these materials. When silver is plated on an electrode, its resistance is significantly reduced, greatly improving electrical conductivity.

[0062] In addition to the electroplating treatment of the end surfaces of the top and bottom electrodes, the four sides near the top and bottom electrodes (at Figure 1 (not shown) will also undergo small-scale creep plating. Creep plating refers to the phenomenon that the electroplating solution deposits a conductive layer on unexpected parts of the electrode surface under the action of an electric field, and here a certain degree of creep plating is intentionally controlled. Generally speaking, the size of the creep plating is above 0.05mm. This treatment method has significant technical effects. In the process of soldering the electrode to the PCB board (printed circuit board), the welding quality directly affects the performance and reliability of the electronic device. The small-scale creep plating layer on the four sides of the electrode increases the contact area between the electrode and the solder. When the solder melts and flows during the heating process, it can better wrap the electrode, forming a fuller and firmer solder joint. A larger contact area means stronger mechanical bonding and lower contact resistance, which can effectively reduce electrical faults caused by poor welding, such as open circuits and cold solder joints. At the same time, good welding quality can also improve the stability of electronic equipment in harsh environments such as vibration and impact, ensuring the normal operation of the circuit. In addition, creep plating can also improve the edge effect of the electrode to a certain extent. The electric field distribution at the edge of the electrode is often more complex, and phenomena such as electric field concentration are prone to occur, which may affect the electrical performance of the electrode. Through creep plating, a uniform conductive layer can be formed on the edge of the electrode, optimizing the electric field distribution, reducing the adverse effects of electric field concentration, and further improving the performance and reliability of the electrode.

[0063] In some embodiments, the primary coil 1 is made of a thicker copper sheet, and the secondary coil 3 is made of a thinner copper sheet. The primary coil 1 usually needs to withstand higher voltages and currents, so it is made of a thicker copper sheet, which can effectively reduce the resistance. Increasing the thickness of the copper sheet, that is, increasing the cross-sectional area, can significantly reduce the resistance. The reduction in resistance means that when current passes through the primary coil 1, the heat generated will be reduced, and energy loss will be reduced, thereby improving the overall efficiency of the winding 100. At the same time, the thicker copper sheet also has better current carrying capacity and can stably transmit larger currents, ensuring that the circuit will not malfunction due to coil overheating or overload under normal operating conditions. The current passing through the secondary coil 3 is relatively small. Using a thinner copper sheet to make the secondary coil 3 can save material costs and reduce the overall weight of the winding 100 while meeting the electrical performance requirements, which is conducive to the miniaturization and lightweight design of electronic equipment.

[0064] In some embodiments, to ensure electrical isolation between the winding 100 and the magnetic core 200 and prevent faults such as short circuits caused by electrical contact, the outer surface of the winding 100 is circumferentially coated with insulating varnish. Insulating varnish is a special coating with excellent insulating properties that forms a reliable insulation barrier between the winding 100 and the magnetic core 200. This layer of insulating varnish plays a crucial role after the winding 100 is assembled to the magnetic core 200. In terms of insulation performance, insulating varnish has a high insulation resistance, effectively preventing current leakage between the winding 100 and the magnetic core 200. During operation of electronic equipment, the winding 100 and the magnetic core 200 may be at different electrical potentials. Without proper insulation, current may leak through the tiny gaps or contact points between them, reducing circuit efficiency and potentially posing a safety hazard. The insulating varnish completely isolates the winding 100 and the magnetic core 200, ensuring safe and stable operation of the electrical system. The insulating varnish also has excellent heat and chemical resistance. During operation of electronic equipment, the windings 100 and magnetic core 200 may generate heat due to the passage of current and may also be corroded by chemicals in the surrounding environment. Insulating varnish maintains stable insulation properties in high-temperature environments and does not soften, decompose, or lose its insulating capacity due to rising temperatures. Furthermore, it exhibits excellent resistance to common chemicals such as acids, alkalis, and salts, preventing degradation of insulation performance due to chemical corrosion, thereby extending the service life of the windings 100 and magnetic core 200. Furthermore, the application of insulating varnish provides a certain degree of moisture and dust resistance. In humid environments, moisture may seep between the windings 100 and magnetic core 200, degrading insulation performance or even causing a short circuit. The dense film formed by the insulating varnish effectively blocks moisture intrusion, keeping the windings 100 and magnetic core 200 dry. Furthermore, it prevents dust and other impurities from adhering to the surface of the windings 100, avoiding problems such as partial discharge caused by dust accumulation, further improving the reliability and stability of the electronic equipment.

[0065] like Figures 6 to 9As shown, an inductor is also provided in this embodiment, which includes a magnetic core 200 and at least one winding 100 mentioned above, and the magnetic core 200 has at least one through-hole 201, and the through-hole 201 passes through the top and bottom ends of the magnetic core 200 to form a continuous channel. The through-hole 201 design provides precise spatial positioning for the placement of the winding 100, so that the winding 100 can be accurately installed inside the magnetic core 200. In practical applications, the number and size of the through-holes 201 of the magnetic core 200 can be flexibly designed according to the specific inductance performance requirements to meet the needs of different electronic devices. As another key component of the inductor, the winding 100 adopts the unique structure described above. The primary coil 1, the insulation structure 2 and the secondary coil 3 are closely combined and exist as a whole. During the assembly process, the winding 100 is inserted into the through-hole 201 along the first direction. First, from the perspective of assembly efficiency, the primary coil 1, the insulation structure 2, and the secondary coil 3 are pre-assembled into a whole, and then directly assembled into the through-hole 201 of the magnetic core 200 along the first direction, which greatly simplifies the assembly process. In the traditional inductor assembly process, the primary coil 1 and the secondary coil 3 usually need to be installed separately and independently into the magnetic core 200, which not only increases the assembly steps and time, but also easily leads to assembly errors. The integral assembly method of this embodiment reduces the operation steps in the assembly process and avoids multiple positioning and adjustments, thereby significantly improving the assembly efficiency of the inductor. For example, in large-scale production, this efficient assembly method can shorten the production cycle and reduce production costs. Secondly, the integral assembly method also has obvious advantages in terms of assembly accuracy. Because the winding 100 is a pre-assembled whole, when it is assembled into the through-hole 201 of the magnetic core 200, the relative position relationship between the various components is fixed, which can ensure the accurate position of the primary coil 1 and the secondary coil 3 within the magnetic core 200. This high-precision assembly ensures the inductor maintains a stable inductance value and excellent electromagnetic performance during operation. If the primary coil 1 and secondary coil 3 are assembled separately, assembly errors may cause the relative position of the coils to shift, affecting the inductor's coupling coefficient and quality factor, and reducing its performance. The integrated assembly method of this embodiment effectively avoids this problem, improving the inductor's assembly precision and product quality.

[0066] In addition, the first electrode end 11 and the third electrode end 31 of the winding 100 extend out of the top of the magnetic core 200, and the second electrode end 12 and the fourth electrode end 32 of the winding 100 extend out of the bottom of the magnetic core 200. This design greatly facilitates welding the electrode ends to the circuit board. In practical applications, inductors generally need to be electrically connected to the circuit board to perform their functions. Traditional inductor structures may have problems such as unreasonable electrode end positioning and difficulty in welding, resulting in unstable welding quality and prone to faults such as cold welding and short circuits. In this embodiment, the electrode ends extending from the top and bottom of the magnetic core 200 are clearly positioned, facilitating precise alignment and welding with the pads on the circuit board. This allows welders to operate more conveniently, improving welding efficiency and quality. At the same time, since the electrode ends extend out of the magnetic core 200, it is also convenient to perform inspection and repair after welding, reducing the maintenance cost of the electronic equipment.

[0067] In some embodiments, glue grooves 202 are provided at the top and bottom ends of the magnetic core 200 at the openings of the through-hole 201. Glue is filled in these grooves 202, and the magnetic core 200 and the winding 100 are bonded to the glue. The shape, size, and depth of the glue grooves 202 can be precisely designed based on the specific specifications of the magnetic core 200 and the winding 100, as well as actual usage requirements. During inductor assembly, glue is filled in these grooves 202, and the magnetic core 200 and the winding 100 are bonded to the glue.

[0068] The technical benefits achieved by adding the glue groove 202 to this embodiment are multifaceted and significant. First, in terms of assembly stability, the glue in the glue groove 202 can achieve both mechanical fixation and chemical bonding. Once the glue is filled into the glue groove 202, it comes into full contact with the surfaces of the magnetic core 200 and winding 100. During the glue curing process, its molecules interact with molecules on the surfaces of the magnetic core 200 and winding 100, forming strong chemical bonds that tightly bond the magnetic core 200 and winding 100 together. Furthermore, the groove structure of the glue groove 202 provides a relatively enclosed space for the glue, limiting the glue's flow range and allowing the glue to be more concentratedly distributed in the contact area between the magnetic core 200 and winding 100, thereby enhancing the bond strength. This dual effect effectively improves the assembly stability of the winding 100 and the magnetic core 200, reducing the risk of the winding 100 loosening, shifting, or even falling off due to factors such as vibration, impact, or temperature fluctuations. From the perspective of inductor performance, a secure assembly ensures stable electrical performance during operation. The fixed relative position between winding 100 and magnetic core 200 ensures stable magnetic flux transmission and maintains the accuracy of the inductance value. Any looseness between winding 100 and magnetic core 200 can alter the magnetic flux distribution, causing fluctuations in the inductance value, which in turn affects the performance of the entire circuit. For example, in high-frequency circuits, even slight changes in inductance can cause signal distortion and interference, impacting proper circuit operation. The adhesive bonding effect of glue reservoir 202 minimizes this occurrence, ensuring that the inductor can stably perform its intended function under various operating conditions. Furthermore, the design of glue reservoir 202 offers certain process advantages. Filling and curing the glue are critical steps in the inductor production process. The presence of glue reservoir 202 provides clear positioning and guidance for glue filling, allowing operators to more conveniently and accurately control the amount and placement of glue, improving production efficiency and consistent product quality. At the same time, because the glue is confined in the glue groove 202, the possibility of glue overflowing onto other parts of the magnetic core 200 and the winding 100 is reduced, avoiding problems such as electrical performance degradation or poor appearance caused by glue contamination. From the perspective of long-term reliability, the bonding of the glue groove 202 and the glue can enhance the aging resistance of the inductor. During the use of electronic equipment, it is affected by various factors such as ambient temperature, humidity, and chemical substances, which may cause the connection between the magnetic core 200 and the winding 100 to gradually loosen. However, after curing, the glue has a certain elasticity and toughness, which can buffer the influence of external factors on the connection between the magnetic core 200 and the winding 100 to a certain extent, maintaining the long-term stability of the connection. Even after long-term use, the magnetic core 200 and the winding 100 can still maintain a good bonding state, extending the service life of the inductor.

[0069] In some embodiments, a first chamfer 203 is provided around the top and / or bottom of the magnetic core 200, and / or a second chamfer 204 is provided on the side of the magnetic core 200. The magnetic core 200 is usually made of a material with a certain degree of brittleness, such as ferrite and permalloy. During the processing of the magnetic core 200, such as cutting and grinding, its edges will be subject to greater stress concentration. This is because the geometric shape at the edge suddenly changes, resulting in uneven stress distribution, which is prone to chipping when subjected to external force or slight impact during processing. After adding the first chamfer 203 and the second chamfer 204, the edge of the magnetic core 200 is transformed from a sharp right angle to a chamfer with a certain curvature or slope. This structural change makes the stress distribution on the surface of the magnetic core 200 more uniform, reducing the degree of stress concentration. When the magnetic core 200 is subjected to external force, the chamfered area can better disperse the stress, avoid excessive stress concentration at the edge, and thus effectively reduce the risk of edge chipping. Sharp edges can easily scratch the operator's hands, while chamfered sides are safer and reduce the risk of accidental injury.

[0070] like Figures 10 to 12As shown, this embodiment also provides a manufacturing method for preparing the winding 100 mentioned above, and the manufacturing method includes the following steps: a plurality of first injection holes 301 are processed at intervals along the second direction on the primary copper bar 300, and a second injection hole is processed on the secondary copper bar 400 corresponding to the first injection hole 301 (the corresponding arrangement of the first injection hole 301 and the second injection hole is to enable the LCP (liquid crystal polymer) colloid to be smoothly filled into the designated position between the primary copper bar 300 and the secondary copper bar 400 during the subsequent injection molding process, thereby forming an effective insulation and connection structure); the primary copper bar 300 and the secondary copper bar 400 are placed and fixed in the mold cavity at intervals along the third direction, and the interior of the mold cavity has a separation protrusion at both ends along the first direction, and the separation protrusion is located between the primary copper bar 300 and the secondary copper bar 400 (the separation protrusion can play a role of isolation and positioning during the injection molding process, ensuring that the primary copper bar 300 and the secondary copper bar 400 are in a stable state). 0, while limiting the flow range of the LCP colloid 500 so that the colloid is filled along a predetermined path, thereby forming a winding 100 structure that meets the design requirements); injecting the LCP colloid 500 from the first injection hole 301 and the second injection hole (the LCP colloid 500 has excellent electrical properties, mechanical properties and heat resistance, and is very suitable for insulation and fixation of the winding 100. During the injection molding process, it is necessary to accurately control parameters such as injection pressure, temperature and time to ensure that the LCP colloid 500 can fully fill the gap between the primary copper bar 300 and the secondary copper bar 400, and is tightly combined with the copper bars to form a processing strip with a stable structure). The primary copper bar 300, the LCP colloid 500 and the secondary copper bar 400 form a processing strip. After the processing strip is cooled and solidified, the mold cavity is removed; cutting the processing strip along the dividing line 302 of each first injection hole 301 to divide the processing strip into several independent windings 100.

[0071] By cutting and processing strips to produce multiple windings 100 at once, the production efficiency of windings 100 is significantly improved. Traditional production methods typically require producing windings 100 individually, which is a cumbersome and time-consuming process. This method, however, utilizes batch production, reducing production steps and operational steps, enabling the production of more windings 100 in the same amount of time, meeting the needs of large-scale production. For example, in the large-scale production of some inductors, this method can significantly shorten the production cycle of windings 100 and increase product delivery speed.

[0072] This method can effectively ensure the processing accuracy and consistency of each winding 100. During the injection molding process, the precise design of the mold cavity and the setting of the separation protrusions ensure that the gap between the primary copper bar 300 and the secondary copper bar 400 and the filling of the LCP colloid 500 are strictly controlled. Each winding 100 undergoes the same process parameters and processing environment during the production process, thereby ensuring the consistency of its size, shape and electrical performance. Such high-precision and high-consistency windings 100 are crucial for the stable performance of electronic equipment. For example, in high-frequency circuits, slight dimensional deviations of the winding 100 may lead to changes in parameters such as inductance and resistance, thereby affecting the performance of the entire circuit. The winding 100 produced by this method can minimize such deviations and improve the reliability and stability of electronic equipment.

[0073] The primary copper bar 300, the LCP colloid 500, and the secondary copper bar 400 are tightly combined together through injection molding to form a structurally stable winding 100. The LCP colloid 500 not only acts as an insulator, but also enhances the connection strength between the primary copper bar 300 and the secondary copper bar 400, so that the winding 100 can maintain its structural integrity when affected by external factors such as vibration, impact, or temperature changes. This structurally stable winding 100 can better adapt to complex working environments and extend the service life of electronic equipment. For example, in some industrial control equipment, the equipment may operate for a long time in harsh environments, and the winding 100 needs to have good vibration and impact resistance. The winding 100 produced by this method can meet these requirements and ensure the normal operation of the equipment.

[0074] Note that the above are only preferred embodiments of the present invention and the technical principles employed. Those skilled in the art will understand that the present invention is not limited to the specific embodiments described herein, and that various obvious changes, readjustments, and substitutions can be made by those skilled in the art without departing from the scope of protection of the present invention. Therefore, although the present invention has been described in detail through the above embodiments, the present invention is not limited to the above embodiments and may include many other equivalent embodiments without departing from the concept of the present invention. The scope of the present invention is determined by the scope of the appended claims.

Claims

1. Winding, characterized in that, The invention comprises a primary coil (1), an insulating structure (2) and a secondary coil (3), wherein the primary coil (1) and the secondary coil (3) have the same shape, the insulating structure (2) comprises a first insulator (21), the first insulator (21) is arranged between the primary coil (1) and the secondary coil (3), the first insulator (21), the primary coil (1) and the secondary coil (3) form a combination, the two ends of the primary coil (1) along a first direction are a first electrode end (11) and a second electrode end (12), the two ends of the secondary coil (3) along the first direction are a third electrode end (31) and a fourth electrode end (32), the first electrode end (11) and the third electrode end (31) have the same height and both protrude from one end of the insulating structure (2), the second electrode end (12) and the fourth electrode end (32) have the same height and both protrude from the other end of the insulating structure (2).

2. The winding according to claim 1, characterized in that The insulating structure (2) further comprises: A second insulator (22), wherein the first insulator (21) and the second insulator (22) are an integrated structure, the second insulator (22) is located on both sides of the first insulator (21), and the second insulator (22) is capable of wrapping the primary coil (1) and the secondary coil (3).

3. The winding according to claim 2, characterized in that A first accommodating groove (13) is provided on both sides of the primary coil (1) along the second direction, a second accommodating groove (33) is provided on both sides of the secondary coil (3) along the second direction, and the second insulator (22) is provided in the first accommodating groove (13) and the second accommodating groove (33).

4. The winding according to claim 2, characterized in that The material of the insulating structure (2) is liquid crystal polymer.

5. The winding according to claim 2, characterized in that The end faces and four sides of the first electrode end (11), the second electrode end (12), the third electrode end (31) and the fourth electrode end (32) are all electroplated with a conductive layer, and the material of the conductive layer is metal nickel, metal tin or metal silver.

6. The winding according to claim 5, characterized in that The outer wall surface of the winding (100) is circumferentially coated with insulating paint.

7. Inductor, characterized in that, The invention comprises a magnetic core (200) and at least one winding according to any one of claims 1 to 6, wherein the magnetic core (200) has at least one through hole (201), the through hole (201) passes through the top and bottom ends of the magnetic core (200), the winding (100) is inserted into the through hole (201) along a first direction, the first electrode end (11) and the third electrode end (31) of the winding (100) extend out of the top end of the magnetic core (200), and the second electrode end (12) and the fourth electrode end (32) of the winding (100) extend out of the bottom end of the magnetic core (200).

8. The inductor according to claim 7, characterized in that: Glue storage grooves (202) are provided at the top and bottom ends of the magnetic core (200) at the openings of the through hole (201), glue is filled in the glue storage grooves (202), and the magnetic core (200) and the winding (100) are both bonded to the glue.

9. The inductor according to claim 7, characterized in that: The top of the magnetic core (200) and / or the bottom of the magnetic core (200) are provided with first chamfers (203) around their periphery, and / or The side edge of the magnetic core (200) is provided with a second chamfer (204).

10. A production method, characterized in that: The method for preparing the winding according to any one of claims 1 to 6 comprises the following steps: A plurality of first injection holes (301) are processed at intervals along a second direction on the primary copper bar (300), and second injection holes are processed on the secondary copper bar (400) corresponding to the first injection holes (301); The primary copper bar (300) and the secondary copper bar (400) are placed and fixed in a mold cavity at intervals along a third direction, wherein the mold cavity has separation protrusions at both ends along the first direction, and the separation protrusions are located between the primary copper bar (300) and the secondary copper bar (400); Injecting LCP colloid (500) from the first injection hole (301) and the second injection hole, the primary copper strip (300), the LCP colloid (500) and the secondary copper strip (400) form a processing strip, and removing the mold cavity; The processing strip is cut along a dividing line (302) of each of the first injection holes (301), and the processing strip is divided into a plurality of windings (100).

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