Ultrathin inductor and high-volume-ratio flat wire winding method thereof

Abstract

The invention discloses an ultrathin inductor and a high-volume-ratio flat wire winding method thereof. Relates to the technical field of inductors. Comprising a base and a boss which are integrally formed, the boss is arranged on the front face of the base, a coil is wound on the outer wall of the boss, two pins of the coil are folded to the back face of the base, and the two pins of the coil are half embedded in the back face of the base. The winding device has the advantage that the problem that the coil is prone to falling off after winding is completed can be solved.

Description

Technical Field

[0001] The present application relates to the technical field of inductors, and in particular to an ultra-thin inductor and a method for winding a high-occupancy flat wire thereof. Background Art

[0002] Ultra-thin inductors are thin-walled inductors, typically between 0.4 mm and 1.0 mm thick, making them suitable for space-constrained applications. Ultra-thin inductors typically have extremely low DC resistance, which helps reduce energy loss and improve efficiency. They are widely used in various electronic devices, particularly portable electronics, networking equipment, industrial automation, smart homes, and consumer electronics.

[0003] A fully automatic ring-braided inductor winding machine is disclosed in a Chinese patent document with publication number CN222338075U, and specifically discloses a frame, a main control unit, a magnetic ring feeding mechanism, a manipulator mechanism, a wire feeding and clamping magnetic ring mechanism for clamping magnetic rings and feeding wires, a winding mechanism for storing and winding wires, a loading mechanism for placing magnetic rings from the magnetic ring feeding mechanism on the wire feeding and clamping magnetic ring mechanism, a unloading mechanism for taking magnetic rings out of the wire feeding and clamping magnetic ring mechanism to a preset position, a wire straightening mechanism for arranging and tightening the wire ends of processed magnetic rings, and a cutting mechanism for cutting the wire ends; the main control unit is electrically connected to the magnetic ring feeding mechanism, the manipulator mechanism, the wire feeding and clamping magnetic ring mechanism, the winding mechanism, the loading mechanism, the unloading mechanism, the wire straightening mechanism and the cutting mechanism; the machine realizes the automation of magnetic ring feeding, loading, wire feeding and clamping magnetic rings, winding, unloading, wire straightening and wire cutting, replaces the manual operation part, reduces the manual labor, and greatly improves the processing efficiency and quality of the inductor coil.

[0004] In the above patent, after the winding mechanism winds the coil on the inductor, the coil needs to be grabbed by a robot and transferred to the wire straightening mechanism for folding and sorting. During the transfer process, the overall length of the wire end to be cut off is relatively long, which can easily cause the coil to fall off, affecting the success rate of winding. Summary of the Invention

[0005] In order to overcome the problem that the coil is easy to fall off after winding, the present application provides an ultra-thin inductor and a method for winding the inductor with a high-occupancy flat wire.

[0006] The present application is implemented using the following technical solution: an ultra-thin inductor, comprising an integrally formed base and a boss, the boss being arranged on the front side of the base, a coil being wound around the outer wall of the boss, the two pins of the coil being folded to the back side of the base, and the two pins of the coil being half-embedded in the back side of the base.

[0007] A method for winding a high-octane rectangular wire, for winding the coil on an ultra-thin inductor, comprises the following steps:

[0008] S1, the wire is transported to the winding mechanism through the tensioner, and the base is adsorbed to the winding mechanism through the suction rod;

[0009] S2, the winding mechanism winds the wire around the boss of the base to form a coil with two pins;

[0010] S3. The winding mechanism folds the two pins so that the two pins fit into the base. This is done.

[0011] Optionally, the winding mechanism includes a support seat, a wire pulling clamp, a lower flying fork and a material suction rod, the lower flying fork is arranged on a turntable, the support seat is passed through the inner side of the turntable, the turntable is used to drive the lower flying fork to rotate around the support seat, the material suction rod is used to suck the base, the support seat is used to cooperate with the material suction rod to form a clamp on the base, and the wire pulling clamp is used to pull the wire.

[0012] Optionally, an air hole is provided at the bottom of the suction rod, a negative pressure joint is provided at the top of the suction rod, an air channel is provided inside the suction rod, the negative pressure joint is inserted at one end of the air channel, the other end of the air channel is connected to the air hole, and a sealing ring is provided at the bottom of the suction rod, and the sealing ring is located outside the end of the air hole;

[0013] When the air pump is connected to the negative pressure connector and starts to pump air, a negative pressure that can absorb the base is formed at the end of the air hole.

[0014] Optionally, the wire pulling clamp can move freely in a horizontal plane, and the wire pulling clamp pulls the wire from one side of the support seat to the other side of the support seat, and the initial position of the lower flying fork is located on the other side of the support seat.

[0015] Optionally, a piston is provided at the upper inner portion of the air hole, and a push rod is provided at the bottom of the piston, and the piston and the push rod can slide up and down in the air hole;

[0016] A sinking groove is provided on the top of the support seat, a support plate is adapted to be provided at the notch of the sinking groove, the top of the support plate contacts the bottom of the boss, and a spring is provided between the support plate and the bottom of the sinking groove;

[0017] When the push rod moves downward, the base and the boss can move to the inner side of the sinking groove.

[0018] Optionally, the outer wall of the piston fits into the inner wall of the air hole, the outer wall of the push rod is separated from the inner wall of the air hole, and the distance between the side wall of the base and the inner wall of the sinking groove is not less than the thickness of the wire.

[0019] Optionally, the turntable is further provided with a cylinder, a push rod of the cylinder is detachably provided with a telescopic rod, and the telescopic rod and the lower flying fork are symmetrically arranged on both sides of the support seat;

[0020] A pressure plate is provided on the side of the telescopic rod facing the support seat, and a first groove and two second grooves are provided on the side of the pressure plate facing the support seat, wherein the first groove is provided in the middle of the side wall of the pressure plate, and the two second grooves are symmetrically provided on both sides of the first groove;

[0021] When the telescopic rod is extended, the first groove is sleeved on the outer side of the push rod, and the second groove is sleeved on the outer side of the pin of the coil.

[0022] Optionally, the length of the first groove is greater than the length of the second groove.

[0023] Compared with the existing technology, the present application directly folds the pins through the winding mechanism, thereby preventing the robot from grabbing the transfer coil and preventing the coil from falling due to the long wire end to be cut, thereby improving the winding success rate. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 This is the structure of this application Figure 1 ;

[0025] Figure 2 This is the structure of this application Figure 2 ;

[0026] Figure 3 It is the reference for the assembly status of the winding mechanism and tensioner Figure 1 ;

[0027] Figure 4 It is the reference for the assembly status of the winding mechanism and tensioner Figure 2 ;

[0028] Figure 5 This is a reference diagram of the assembly status of the support seat and the suction rod;

[0029] Figure 6 This is a cross-sectional view of the internal structure of the support seat and the suction rod;

[0030] Figure 7 This is a reference diagram of the assembly status of the pressure plate and the cylinder;

[0031] In the figure: 1. base; 2. boss; 3. coil; 30. pin; 4. tensioner; 5. winding mechanism; 51. support seat; 511. sinking groove; 512. support plate; 513. spring; 52. wire clamp; 53. lower flying fork; 54. suction rod; 541. air hole; 542. negative pressure joint; 543. air duct; 544. piston; 545. push rod; 55. turntable; 56. cylinder; 560. telescopic rod; 57. pressure plate; 571. first groove; 572. second groove; 6. wire. DETAILED DESCRIPTION

[0032] Below, the present application is further described in conjunction with the accompanying drawings and specific implementation methods. It should be noted that, under the premise of no conflict, the various embodiments or technical features described below can be arbitrarily combined to form new embodiments.

[0033] This application mainly winds the wire 6 on the boss 2 integrally formed with the base 1 and folds the pin 30 to achieve reliable winding of the coil 3, thereby achieving the effect of improving the success rate and stability of the inductor winding. The following is a further detailed description of this application.

[0034] Example 1

[0035] like Figure 1-2 As shown, an embodiment of the present application provides an ultra-thin inductor, including an integrally formed base 1 and a boss 2, wherein the boss 2 is arranged on the front side of the base 1. The integral formation of the boss 2 and the base 1 ensures the stability of the structure, provides a stable foundation for the operation of winding the wire 6 into the coil 3, and ultimately makes the inductor as a whole more firm and reliable.

[0036] Specifically, the base 1 and boss 2 are compacted from magnetic powder, resulting in a small size and light weight, effectively meeting the requirements for portability and compactness in modern circuits. The base 1 can be designed in various shapes, such as rectangular and circular, to accommodate various applications. The boss 2 protrudes upward from the front of the base 1. The outer wall of the boss 2 is smooth, facilitating the winding of the wire 6. The height and diameter of the boss 2 can be adjusted to accommodate coils 3 with varying numbers of turns and wire diameters.

[0037] The wound coil 3 has two pins 30, and these two pins 30 will be folded to the back of the base 1. After the folding is completed, the two pins 30 of the coil 3 are effectively fitted with the back of the base 1. Moreover, the two pins 30 are half-embedded in the back of the base 1. The half-embedded method can increase the contact area and connection stability between the pins 30 and the base 1, and prevent the pins 30 from loosening or falling off. In order to achieve the effect of the pins 30 being half-embedded in the base 1, a shallow groove can be pre-opened on the back of the base 1, and the width of the shallow groove can be slightly smaller than the outer diameter of the pins 30. In this way, after the pins 30 are folded and fall into the shallow groove, an interference fit can be formed between the pins 30 and the shallow groove, ensuring that the pins 30 can be reliably fixed in the shallow groove. Furthermore, glue can be dripped into the shallow groove after the pins 30 are folded, so as to maximize the fixing effect of the pins 30.

[0038] The working principle of this embodiment is as follows: This one-piece structural design improves the overall quality and reliability of the inductor and effectively reduces its overall size. Furthermore, the pins 30 of the coil 3 are partially embedded in the back of the base 1, which enhances the fixing effect of the pins 30 and avoids problems such as poor contact caused by loose pins 30 during subsequent processing and use, thereby improving the performance and service life of the inductor.

[0039] Example 2

[0040] like Figure 3-7 As shown, an embodiment of the present application provides a method for winding a high-octane flat wire, which is used to wind a coil 3 on an ultra-thin inductor, comprising the following steps:

[0041] S1, the wire 6 is transported to the winding mechanism 5 through the tensioner 4, and the base 1 is adsorbed to the winding mechanism 5 through the suction rod 54;

[0042] S2, the winding mechanism 5 winds the wire 6 around the boss 2 of the base 1 to form a coil 3 with two pins 30;

[0043] S3. The winding mechanism 5 folds the two pins 30 so that the two pins 30 fit in contact with the base 1. This is completed.

[0044] The winding mechanism 5 comprises a support base 51, a wire clamp 52, a lower flyer 53, and a suction rod 54. The lower flyer 53 is mounted on a turntable 55. The support base 51 is inserted into the inner side of the turntable 55. The turntable 55 drives the lower flyer 53 to rotate around the support base 51. The suction rod 54 is used to draw in the base 1. The support base 51 cooperates with the suction rod 54 to clamp the base 1. The wire clamp 52 is used to pull the wire 6. After the suction rod 54 draws in the base 1, it cooperates with the support base 51 to clamp the base 1, ensuring the stability of the base 1 during the winding process. The wire clamp 52 is freely movable in the horizontal plane and pulls the wire 6 from one side of the support base 51 to the other side. The lower flyer 53 is initially located on the other side of the support base 51. As the lower flyer 53 rotates with the turntable 55, it is driven by the wire 6 and winds turns around the outer wall of the boss 2, ultimately forming a coil 3 with two pins 30.

[0045] An air hole 541 is provided at the bottom of the suction rod 54, a negative pressure joint 542 is provided at the top of the suction rod 54, an air channel 543 is provided inside the suction rod 54, the negative pressure joint 542 is inserted at one end of the air channel 543, and the other end of the air channel 543 is connected to the air hole 541. A sealing ring is provided at the bottom of the suction rod 54, and the sealing ring is located outside the end of the air hole 541; when the air pump is connected to the negative pressure joint 542 and starts to pump air, a negative pressure is formed at the end of the air hole 541 that can absorb the base 1. The setting of the sealing ring improves the adsorption effect of the suction rod 54 on the base 1, and prevents the base 1 from falling during the movement of the suction rod 54.

[0046] The wire clamp 52 can move freely in the horizontal plane. The wire clamp 52 pulls the wire 6 from one side of the support base 51 to the other side of the support base 51. The initial position of the lower fork 53 is located on the other side of the support base 51. After the wire clamp 52 pulls the wire 6 to the position of the lower fork 53, the lower fork 53 will clamp the wire 6, and the wire clamp 52 will relax and move to the side of the support base 51 again. In this way, when the lower fork 53 rotates around the support base 51 and is wound, the lower fork 53 and the wire clamp 52 bracket will not collide. When the lower fork 53 is wound, the lower fork 53 and the wire clamp 52 are both located on one side of the support base 51. At this time, the wire 6 is cut (a shearing mechanism with the same principle as scissors can be installed on the wire clamp 52), and a coil 3 with two pins 30 will be obtained.

[0047] A piston 544 is provided on the upper inner portion of the air hole 541, and a push rod 545 is provided on the bottom of the piston 544. The piston 544 and the push rod 545 can slide up and down in the air hole 541. A sinking groove 511 is provided on the top of the support base 51, and a support plate 512 is adapted to be provided at the notch of the sinking groove 511. The top of the support plate 512 contacts the bottom of the boss 2, and a spring 513 is provided between the support plate 512 and the bottom of the sinking groove 511. When the push rod 545 moves downward, the base 1 and the boss 2 can move to the inner side of the sinking groove 511. The outer wall of the piston 544 fits with the inner wall of the air hole 541, the outer wall of the push rod 545 is separated from the inner wall of the air hole 541, and the distance between the side wall of the base 1 and the inner wall of the sinking groove 511 is not less than the thickness of the wire 6.

[0048] There is a distance between the piston 544 and the top of the air hole 541, and an air pipe is provided at the top of the suction rod 54. When the air pump delivers gas to the air hole 541 through the air pipe, the piston 544 will move downward, thereby pushing the ejector pin 545 to the outside of the air hole 541. When the air pump extracts air outward through the air pipe, the piston 544 will move upward. After the winding is completed and the wire 6 is cut, the piston 544 can move downward. At this time, the ejector pin 545 will form a pushing effect on the base 1. When the base 1 moves toward the sinking groove 511 under the pushing of the ejector pin, since the pin extends in the horizontal direction and is relatively long, the pin cannot enter the sinking groove 511 in a horizontal state. That is to say, as the support plate 512 and the base 1 move downward, the pin 30 will interfere with the notch of the sinking groove 511, thereby causing the pin 30 to be squeezed from a horizontal state to a vertical state.

[0049] The turntable 55 is also equipped with a cylinder 56. A telescopic rod 560 is detachably mounted on the push rod of the cylinder 56. The telescopic rods 560 are symmetrically arranged on either side of the support base 51, along with the lower fork 53. A pressure plate 57 is provided on the side of the telescopic rod 560 facing the support base 51. The pressure plate 57 has a first groove 571 and two second grooves 572 on the side facing the support base 51. The first groove 571 is located in the middle of the sidewall of the pressure plate 57, and the two second grooves 572 are symmetrically arranged on either side of the first groove 571. When the telescopic rod 560 is extended, the first groove 571 fits over the outer side of the push rod 545, while the second groove 572 fits over the outer side of the pin 30 of the coil 3. The length of the first groove 571 is greater than that of the second groove 572.

[0050] After the two pins 30 of the coil 3 are tilted from a horizontal position to a vertical position, the piston 544 and the push rod 545 return to their original position. The push rod of the cylinder 56 then pushes the telescopic rod 560 upward until the bottom plane of the telescopic rod 560 is higher than the top plane of the base 1, and the distance between the two planes is equal to or close to the outer diameter of the wire 6. Once the telescopic rod 560 has been vertically displaced into position, it extends toward the support base 51. As a result, the vertically extending pins 30 and the push rod 545 engage with the corresponding second grooves 572 and first grooves 571. The insertion of the ejector pin 545 into the first groove 571 ensures that there is no interference between the ejector pin 545 and the pressure plate 57. The insertion of the pin 30 into the second groove 572 folds the pin 30. That is, when the pressure plate 57 is moved into position, the pin 30 can be transformed from a horizontal state to a vertical state, achieving a close fit between the pin 30 and the base 1, effectively preventing the base 1 from falling off the suction rod 54 during the transfer process. After the winding is completed, the present application can achieve the folding operation of the pin 30 of the coil 3 without moving the base 1, greatly improving the winding efficiency.

[0051] The above are all preferred embodiments of the present application, and are not intended to limit the scope of protection of the present application. Therefore, any equivalent changes made based on the structure, shape, and principle of the present application should be included in the scope of protection of the present application.

Claims

1. An ultra-thin inductor, characterized in that: The invention comprises an integrally formed base (1) and a boss (2), wherein the boss (2) is arranged on the front side of the base (1), a coil (3) is wound on the outer wall of the boss (2), two pins (30) of the coil (3) are folded to the back side of the base (1), and the two pins (30) of the coil (3) are half-embedded in the back side of the base (1).

2. A method for winding a high duty cycle flat wire, for winding the coil (3) on an ultra-thin inductor as claimed in claim 1, characterized in that: The steps include: S1, conveying the wire (6) to the winding mechanism (5) through the tensioner (4), and adsorbing the base (1) to the winding mechanism (5) through the suction rod (54); S2, the winding mechanism (5) winds the wire (6) around the boss (2) of the base (1) to form a coil (3) with two pins (30); S3, the winding mechanism (5) folds the two pins (30) so that the two pins (30) are in contact with the base (1), and the process is completed.

3. The method for winding a high duty cycle rectangular wire according to claim 2, wherein: The winding mechanism (5) comprises a support seat (51), a wire drawing clamp (52), a lower flying fork (53) and a material suction rod (54); the lower flying fork (53) is arranged on a turntable (55); the support seat (51) is passed through the inner side of the turntable (55); the turntable (55) is used to drive the lower flying fork (53) to rotate around the support seat (51); the material suction rod (54) is used to suck the base (1); the support seat (51) is used to cooperate with the material suction rod (54) to form a clamp for the base (1); and the wire drawing clamp (52) is used to pull the wire (6).

4. The method for winding a high duty cycle rectangular wire according to claim 2, wherein: The bottom of the suction rod (54) is provided with an air hole (541), the top of the suction rod (54) is provided with a negative pressure joint (542), the interior of the suction rod (54) is provided with an air channel (543), the negative pressure joint (542) is inserted into one end of the air channel (543), the other end of the air channel (543) is connected to the air hole (541), and the bottom of the suction rod (54) is provided with a sealing ring, which is located outside the end of the air hole (541); When the air pump is connected to the negative pressure connector (542) and starts to pump air, the end of the air hole (541) forms a negative pressure that can absorb the base (1).

5. The method for winding a high duty cycle flat wire according to claim 2, wherein: The wire pulling clamp (52) can move freely in a horizontal plane, and the wire pulling clamp (52) pulls the wire (6) from one side of the support seat (51) to the other side of the support seat (51), and the initial position of the lower flying fork (53) is located on the other side of the support seat (51).

6. The method for winding a high duty cycle rectangular wire according to claim 4, wherein: A piston (544) is provided on the inner upper portion of the air hole (541), and a push rod (545) is provided on the bottom of the piston (544). The piston (544) and the push rod (545) can slide up and down in the air hole (541); A sinking groove (511) is provided on the top of the support seat (51), a support plate (512) is adapted to be provided at the notch of the sinking groove (511), the top of the support plate (512) contacts the bottom of the boss (2), and a spring (513) is provided between the support plate (512) and the bottom of the sinking groove (511); When the push rod (545) moves downward, the base (1) and the boss (2) can move to the inner side of the sinking groove (511).

7. The method for winding a high duty cycle rectangular wire according to claim 6, wherein: The outer wall of the piston (544) is in contact with the inner wall of the air hole (541), the outer wall of the push rod (545) is separated from the inner wall of the air hole (541), and the distance between the side wall of the base (1) and the inner wall of the sinking groove (511) is not less than the thickness of the wire (6).

8. The method for winding a high duty cycle rectangular wire according to claim 6, wherein: The turntable (55) is further provided with a cylinder (56), and a push rod of the cylinder (56) is detachably provided with a telescopic rod (560), and the telescopic rod (560) and the lower flying fork (53) are symmetrically arranged on both sides of the support seat (51); A pressure plate (57) is provided on the side of the telescopic rod (560) facing the support seat (51), and a first groove (571) and two second grooves (572) are provided on the side of the pressure plate (57) facing the support seat (51), wherein the first groove (571) is provided in the middle of the side wall of the pressure plate (57), and the two second grooves (572) are symmetrically provided on both sides of the first groove (571); When the telescopic rod (560) is extended, the first groove (571) is sleeved on the outside of the top rod (545), and the second groove (572) is sleeved on the outside of the pin (30) of the coil (3).

9. The method for winding a high duty cycle rectangular wire according to claim 8, wherein: The length of the first groove (571) is greater than the length of the second groove (572).

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