Winding common mode inductor and manufacturing method thereof

Abstract

The invention provides a winding common-mode inductor and a manufacturing method thereof.The winding common-mode inductor comprises a magnetic core, a first coil, a second coil and a cover plate, the magnetic core comprises a middle column and limiting plates arranged at the two ends of the middle column, mounting notches are formed in the two ends of the top of each limiting plate respectively, material sheets are connected to the limiting plates, and the first coil and the second coil are arranged in the mounting notches. The material sheet comprises a main body which abuts against the outer side face of the limiting plate in a matched mode, a connecting sheet is arranged at the top end of the main body, the connecting sheet is contained in the installation notch, a wire hanging sheet is arranged at one end of the connecting sheet in a protruding mode, and a welding area is arranged at the other end of the connecting sheet; and a lug plate is arranged at the bottom end of the main body, and is propped against and matched with the bottom surface of the limiting plate. Compared with the prior art, the winding common mode inductor is relatively simple in structure, convenient and rapid to assemble, firm in wire end connection, high in anti-seismic performance and capable of effectively preventing wire breakage and avoiding the problem of open circuit caused by deformation.

Description

Technical Field

[0001] This invention relates to the technical field of common mode inductors, and in particular to a wire-wound common mode inductor and its manufacturing method. Background Technology

[0002] A wire-wound common-mode inductor is a passive device used to suppress common-mode noise in circuits. It achieves noise suppression by generating a magnetic field between two signal lines. When a common-mode current flows through the inductor, it generates a magnetic flux through the inductor coil, creating a voltage across the inductor that cancels out common-mode noise. Wire-wound common-mode inductors typically consist of two or more coils wound in a specific manner on the same magnetic core, and are commonly used to suppress common-mode interference. The flexible winding method of wire-wound common-mode inductors allows them to adapt to different application scenarios, effectively suppressing common-mode interference and making them suitable for applications requiring high electromagnetic compatibility.

[0003] Currently, the wire ends of inductor coils are typically soldered to the bottom pins. However, these pins are located on the surface of the entire winding common-mode inductor, making them susceptible to impacts and pressure, failing to protect the wire ends and potentially causing structural deformation that could lead to an open circuit. Furthermore, directly soldering the wire ends to the pins is relatively unreliable, prone to breakage, and results in unstable soldering. Therefore, it is urgent to address these issues. Summary of the Invention

[0004] To address the aforementioned problems, this invention provides a wire-wound common-mode inductor and its manufacturing method, which features a relatively simple structure, convenient and quick assembly, reliable wire connection, high shock resistance, effective prevention of wire breakage, and avoidance of open circuit problems caused by deformation.

[0005] This invention achieves the above objective through the following technical solution: a wire-wound common-mode inductor, comprising a magnetic core, a first coil, a second coil, and a cover plate, wherein the magnetic core includes a central post and limiting plates disposed at both ends of the central post, the limiting plates having mounting notches at their top ends, and a sheet material connected to the limiting plates. The material sheet includes a main body that abuts against the outer side of the limiting plate. The top of the main body is provided with a connecting piece, which is accommodated in the installation notch. One end of the connecting piece is provided with a hanging piece, and the other end of the connecting piece is provided with a welding area. The bottom of the main body is provided with a wiring piece, which abuts against the bottom surface of the limiting plate.

[0006] Further, the bottom surface of the limiting plate is convex or concave with an electrode limiting area corresponding to the connecting piece, facilitating the rapid installation of the connecting piece to the correct position; a groove adapted to the main body is provided on the outer side surface of the limiting plate; it is convenient for the sheet to be correctly and rapidly installed in place, and also facilitates the coating of the curing glue. Moreover, the main body can be hidden inside the outer side surface of the limiting plate, avoiding collision and extrusion; a curing glue is coated between the outer side surface of the limiting plate and the main body, enabling the sheet to be reliably connected to the limiting plate.

[0007] Further, the cover plate is in a flat plate shape, and the cover plate is bonded to the top surface of the limiting plate, enabling the cover plate to be firmly connected to the limiting plate to form a circular magnetic circuit.

[0008] Further, the cover plate is in a "冂" shape, and the magnetic core, the first coil and the second coil are all accommodated inside the cover plate; the cover plate can effectively protect the internal coils and wire ends, avoiding the occurrence of open circuit accidents.

[0009] Further, bayonet openings are provided at the bottom corners of the cover plate, and limiting edges adapted to the bayonet openings are convexly provided at the bottom of the sheet; it is convenient for the installation of the cover plate and ensures the firm connection of the cover plate.

[0010] Further, an opening groove is provided at the bottom side of the cover plate, and the opening groove facilitates the potting process.

[0011] Further, flange edges are respectively provided at both ends of the bottom of the limiting plate, and the bottom surface of the cover plate abuts and cooperates with the flange edges.

[0012] Further, a closing block protruding between adjacent flange edges is provided at the bottom of the cover plate.

[0013] The present invention also provides a manufacturing method for a wound common mode inductor, and the manufacturing method includes the following steps: The first step is to process the magnetic core: prepare a块状料 meeting the processing requirements, and perform subtractive processing on the块状料 to obtain the magnetic core; The second step is to process the sheet: prepare a片状料 meeting the processing requirements, and perform cutting and bending treatments on the片状料 to obtain the sheet; The third step is to assemble the sheet: coat the curing glue on the outer side surface of the limiting plate, install the sheet on the limiting plate, make the main body abut against the outer side surface of the limiting plate, place the connecting piece in the installation notch, and make the connecting piece abut against the electrode limiting area; The fourth step is to wind and weld: layer by layer wind the first coil and the second coil on the middle column, place the wire ends on the hanging wire piece, then bend the hanging wire piece to be in contact with the connecting piece to clamp the wire ends, and weld the wire ends in the welding area; Step 5, Assemble the cover plate: Coat the top surface of the limit plate with curing glue, place the cover plate on the top surface of the limit plate, and bake and cure it to form a circular magnetic circuit; Step 6, Appearance inspection: Select defective products with poor appearance through the appearance inspection machine; Step 7, Testing and packaging: Test the product and then place the product into the packaging material.

[0014] Furthermore, in Step 2, on the processed blank, the included angle between the wire hanging piece and the connecting piece is 90 degrees to 160 degrees.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows: First, by respectively opening installation gaps at both ends of the top of the limit plate and connecting the blank on the limit plate, and the connecting piece at the top of the blank is accommodated in the installation gap, the wire ends of the coil can be hidden in the installation gap, which can protect it and avoid the deformation of the structure here caused by collision and extrusion, resulting in an open circuit; Second, by providing a wire hanging piece and a welding area on the connecting piece, the wire hanging piece can clamp the wire ends of the coil here and at the same time weld the wire ends of the coil in the welding area to achieve double fixation of the wire ends, making the connection more reliable and effectively preventing wire breakage; Third, by providing a wire hanging piece, and the wire hanging piece is located at both ends of the limit plate, it can effectively avoid the short - circuit problem caused by the relatively thick steel mesh thickness during the pasting of the board; Fourth, by connecting the wire ends through the blank instead of directly welding the wire ends at the bottom, the coating can be made more uniform and have better consistency, and the solder wetting is also more stable; Fifth, by bonding the blank to the side of the limit plate, and the main body top of the blank is bent with a connecting piece and the bottom end is bent with a wiring piece, making the blank as a whole in a "C" shape, it can be effectively clamped on the limit plate, the connection is relatively firm, and the seismic performance is higher; Sixth, by setting the cover plate in a "冂" shape, the coil can be effectively wrapped inside to protect the coil and the wire ends, thus effectively solving the technical problems in this field; Generally speaking, the winding common - mode inductor structure to be protected by the present invention is relatively simple, the assembly is convenient and fast, the wire end connection is firm, the seismic performance is high, it can effectively prevent wire breakage, and at the same time can avoid the problem of open circuit caused by deformation; the manufacturing method to be protected by it has fewer steps and is relatively simple, the processing is relatively convenient, the manufactured product has higher precision and more stable quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is the overall structure diagram of Embodiment 1 of the present invention; Figure 2 It is the exploded view of Embodiment 1 of the present invention; Figure 3This is a schematic diagram of the bottom structure of the magnetic core in Embodiment 1 of the present invention; Figure 4 This is a schematic diagram of the sheet structure in Embodiment 1 of the present invention; Figure 5 This is a schematic diagram of the overall structure of Embodiment 2 of the present invention; Figure 6 This is a schematic diagram of the magnetic core structure in Embodiment 2 of the present invention; Figure 7 This is a schematic diagram of the overall structure of Embodiment 3 of the present invention; Figure 8 This is an exploded view of Embodiment 3 of the present invention; Figure 9 This is a schematic diagram of the overall structure of Embodiment 4 of the present invention; Figure 10 This is a schematic diagram of the sheet structure in Embodiment 5 of the present invention; Figure 11 This is an exploded view of Embodiment Six of the present invention; Figure 12 This is a schematic diagram of the overall structure of Embodiment Seven of the present invention.

[0017] The reference numerals in the attached diagram are explained as follows: 1-Magnetic core; 1A-Center column; 1B-Limiting plate; 1B1-Mounting notch; 1B2-Electrical limit zone; 1B3-Groove; 1B4-Flange; 2-First coil; 3-Second coil; 4-Cover plate; 4A-Bayonet; 4B-Opening slot; 4C-Closing block; 5-Sheet; 5A-Main body; 5B-Connecting piece; 5B1-Hanging piece; 5B2-Welding area; 5C-Connecting piece; 5D-Limiting flange. Detailed Implementation

[0018] To facilitate understanding of the present invention, a more detailed description is provided below with reference to the accompanying drawings and specific embodiments. The embodiments in this specification are described in a progressive manner; similar or identical parts between embodiments can be referred to mutually. Each embodiment focuses on its differences from other embodiments. Furthermore, the division of the following embodiments is for ease of description and should not constitute any limitation on the specific implementation of this application. The embodiments can be combined with and referenced by each other without contradiction.

[0019] It should be noted that when an element is described as "fixed to" another element, it can be directly on the other element, or one or more intermediate elements may exist between them. When an element is described as "connected to" another element, it can be directly connected to the other element, or one or more intermediate elements may exist between them. The terms "upper," "lower," "left," "right," "inner," "outer," and similar expressions used in this specification are for illustrative purposes only.

[0020] Unless otherwise defined, all technical and scientific terms used in this specification have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the invention. The term "and / or" as used in this specification includes any and all combinations of one or more of the associated listed items.

[0021] Example 1 like Figures 1 to 4 As shown, a wire-wound common-mode inductor includes a magnetic core 1, a first coil 2, a second coil 3, and a cover plate 4. The magnetic core 1 includes a central post 1A and limiting plates 1B disposed at both ends of the central post 1A. Mounting notches 1B1 are respectively opened at both ends of the top of the limiting plates 1B. A sheet 5 is connected to the limiting plates 1B. The material sheet 5 includes a main body 5A that abuts against the outer side of the limiting plate 1B. The top of the main body 5A is provided with a connecting piece 5B, which is housed in the installation notch 1B1. One end of the connecting piece 5B is provided with a hanging piece 5B1, and the other end of the connecting piece 5B is provided with a welding area 5B2. The bottom of the main body 5A is provided with a wiring piece 5C, which abuts against the bottom surface of the limiting plate 1B.

[0022] Specifically, the main body 5A extends vertically, while the connecting piece 5B and the wiring piece 5C both extend horizontally. The connecting piece 5B is horizontally perpendicular to the main body 5A, and the wiring piece 5C is vertically perpendicular to the main body 5A. This makes the piece 5 form a "C" shape, allowing it to be effectively engaged with the limiting plate 1B, resulting in a relatively secure connection. (Reference) Figure 4 As shown.

[0023] The bottom surface of the limiting plate 1B has a raised electrical limit area 1B2 corresponding to the connecting piece 5C. The outer side of the limiting plate 1B has a groove 1B3 that matches the main body 5A. Curing adhesive is applied between the outer side of the limiting plate 1B and the main body 5A.

[0024] The cover plate 4 is flat and is adhered to the top surface of the limiting plate 1B. It should be noted that the side of the cover plate 4 is in the same plane as the side of the limiting plate 1B, or the side of the cover plate 4 protrudes further outward relative to the side of the limiting plate 1B; similarly, the end face of the cover plate 4 is also in the same plane as the end face of the limiting plate 1B, or the end face of the cover plate 4 protrudes further outward relative to the end face of the limiting plate 1B. This better protects the wire ends within the mounting notch 1B1 to avoid collisions and compression.

[0025] Specifically, the magnetic core 1 is in the shape of an "I". The first coil 2 is wound around the surface of the central column 1A, and the second coil 3 is wound around the outer surface of the first coil 2. A mounting notch 1B1 corresponds to a piece 5. The two ends of the first coil 2 are connected to two pieces 5 respectively, and the two ends of the second coil 3 are connected to the other two pieces 5 respectively.

[0026] This embodiment also provides a method for manufacturing the wire-wound common-mode inductor, the specific manufacturing steps of which are as follows: Step 1, Processing magnetic core 1: Prepare a block material that meets the processing requirements, and perform subtractive processing on the block material to obtain magnetic core 1; The second step is to process sheet 5: prepare sheet material that meets the processing requirements, and cut and bend the sheet material to obtain sheet 5; The third step is to assemble the sheet 5: apply curing adhesive to the outer side of the limiting plate 1B, install the sheet 5 on the limiting plate 1B, make the main body 5A abut against the outer side of the limiting plate 1B, place the connecting piece 5B in the installation notch 1B1, and make the wiring piece 5C abut against the electrical limit area 1B2. The fourth step is wire winding and welding: the first coil 2 and the second coil 3 are wound layer by layer on the central column 1A, and the wire end is placed on the hanging piece 5B1. Then the hanging piece 5B1 is bent and attached to the connecting piece 5B to clamp the wire end, and the wire end is welded to the welding area 5B2. The hanging piece 5B1 can be bent upward or downward. Fifth step, assemble cover plate 4: apply curing adhesive to the top surface of limit plate 1B, place cover plate 4 on the top surface of limit plate 1B, and bake to cure to form a ring magnetic circuit. Step 6, visual inspection: Select products with poor appearance using a visual inspection machine; Step 7, Test Packaging: Test the product and then place it inside the packaging material.

[0027] In the second step, on the finished material sheet 5, the included angle between the hanging piece 5B1 and the connecting piece 5B is 90 degrees to 160 degrees.

[0028] Example 2 refer to Figure 5 and Figure 6 As shown, compared with Embodiment 1, the bottom surface of the limiting plate 1B has an electrical limit area 1B2 corresponding to the connecting piece 5C, and the groove 1B3 is provided on the outer edge of the limiting plate 1B. Compared with Embodiment 1, the material piece 5 is more convenient and faster to assemble relative to the limiting plate 1B in this embodiment.

[0029] Example 3 refer to Figure 7 and Figure 8As shown, compared with the first embodiment, the cover plate 4 is in a "冂" shape, and the magnetic core 1, the first coil 2 and the second coil 3 are all accommodated in the cover plate 4. Clamping openings 4A are provided at the bottom corners of the cover plate 4, and a limiting edge 5D protruding from the bottom of the strip 5 is adapted to the clamping openings 4A. Compared with the first embodiment, since the magnetic core 1, the first coil 2 and the second coil 3 are all accommodated in the cover plate 4 in this embodiment, the protection effect of the cover plate 4 is better. Moreover, when bonding the cover plate 4, not only the top surface of the limiting plate 1B is coated with a curing adhesive, but also the limiting edge 5D is coated with a curing adhesive, so that both the top and bottom ends of the cover plate 4 are bonded, making the connection more reliable. Furthermore, the limiting edge 5D is integrally provided with the bottom end of the main body 5A and the connecting piece 5C.

[0030] Embodiment Four Reference Figure 9 As shown, compared with the third embodiment, an opening groove 4B is provided on the bottom side of the cover plate 4; it is more convenient and fast during the potting process.

[0031] Embodiment Five Reference Figure 10 As shown, compared with other embodiments, a wire hanging piece 5B1 is also provided on the welding area 5B2, so that there are two hanging pieces 5B1 on the connecting piece 5B. In actual application, the two hanging pieces 5B1 will be bent first to double-clamp the wire head, and then laser welding will be performed on the welding area 5B2, and the connection reliability is higher.

[0032] Embodiment Six Reference Figure 11 As shown, compared with the fourth embodiment, convex flanges 1B4 are provided at both ends of the bottom of the limiting plate 1B, and the bottom surface of the cover plate 4 is in abutting fit with the convex flanges 1B4. When bonding the cover plate 4, a curing adhesive needs to be coated on the top surface of the limiting plate 1B, and also on the convex flanges 1B4, so that both the top and bottom ends of the cover plate 4 are bonded, making the connection more reliable. And there is no need to perform a grooving process on the bottom of the cover plate 4, and the potting process can be directly performed at the notch formed between two adjacent convex flanges 1B4, which is more convenient and fast.

[0033] Embodiment Seven Reference Figure 12 As shown, compared with the sixth embodiment, a closed block 4C protruding between adjacent convex flanges 1B4 is provided at the bottom of the cover plate 4. Due to the addition of the closed block 4C, the coil can be more comprehensively wrapped, and the protection effect is better.

[0034] In summary, the technical solution of this invention can fully and effectively achieve the above-mentioned objectives. Furthermore, the structure and functional principles of this invention have been fully verified in the embodiments, achieving the expected effects and objectives. Without departing from the principles and essence of this invention, various changes or modifications can be made to the embodiments. Therefore, this invention includes all substitutions within the scope mentioned in the patent application claims, and any equivalent changes made within the scope of this patent application are within the scope of the patent application.

Claims

1. A wire-wound common-mode inductor, comprising a magnetic core (1), a first coil (2), a second coil (3), and a cover plate (4), characterized in that: The magnetic core (1) includes a central column (1A) and limiting plates (1B) provided at both ends of the central column (1A). Mounting gaps (1B1) are respectively formed at both ends of the top of the limiting plates (1B). A strip (5) is connected to the limiting plates (1B). The strip (5) includes a main body (5A) that abuts against the outer side surface of the limiting plate (1B). A connecting piece (5B) is provided at the top end of the main body (5A). The connecting piece (5B) is received in the mounting gap (1B1). A wire-hanging piece (5B1) protrudes from one end of the connecting piece (5B), and a welding area (5B2) is provided at the other end of the connecting piece (5B). A wiring piece (5C) is provided at the bottom end of the main body (5A), and the wiring piece (5C) abuts against the bottom surface of the limiting plate (1B).

2. The wire-wound common-mode inductor according to claim 1, characterized in that: An electrode limiting area (1B2) corresponding to the wiring piece (5C) protrudes or depresses on the bottom surface of the limiting plate (1B). A groove (1B3) adapted to the main body (5A) is formed on the outer side surface of the limiting plate (1B). A curing adhesive is coated between the outer side surface of the limiting plate (1B) and the main body (5A).

3. A wire-wound common-mode inductor according to claim 1, characterized in that: The cover plate (4) is in a flat plate shape, and the cover plate (4) is bonded to the top surface of the limiting plate (1B).

4. A wire-wound common-mode inductor according to claim 1, characterized in that: The cover plate (4) is in a "冂" shape, and the magnetic core (1), the first coil (2), and the second coil (3) are all received in the cover plate (4).

5. A wire-wound common-mode inductor according to claim 4, characterized in that: Bays (4A) are respectively formed at the bottom corners of the cover plate (4). A limiting edge (5D) adapted to the bays (4A) protrudes from the bottom of the strip (5).

6. A wire-wound common-mode inductor according to claim 4, characterized in that: An opening groove (4B) is provided at the bottom side of the cover plate (4).

7. A wire-wound common-mode inductor according to claim 4, characterized in that: Flanges (1B4) are respectively provided at both ends of the bottom of the limiting plate (1B), and the bottom surface of the cover plate (4) abuts against the flanges (1B4).

8. A wire-wound common-mode inductor according to claim 7, characterized in that: A closing block (4C) protruding between adjacent flanges (1B4) is provided at the bottom of the cover plate (4).

9. A method for manufacturing a wire-wound common-mode inductor according to any one of claims 1 to 8, characterized in that, The manufacturing method includes the following steps: The first step, machining the magnetic core (1): Prepare a block of material meeting the machining requirements, and perform subtractive machining on the block of material to obtain the magnetic core (1). The second step, machining the strip (5): Prepare a sheet of material meeting the machining requirements, and perform cutting and bending on the sheet of material to obtain the strip (5). The third step, assembling the strip (5): Coat a curing adhesive on the outer side surface of the limiting plate (1B), install the strip (5) on the limiting plate (1B), make the main body (5A) abut against the outer side surface of the limiting plate (1B), make the connecting piece (5B) placed in the mounting gap (1B1), and make the wiring piece (5C) abut against the electrode limiting area (1B2). The fourth step, winding and welding: Layer by layer wind the first coil (2) and the second coil (3) on the central column (1A), place the wire ends on the wire-hanging pieces (5B1), then bend and fit the wire-hanging pieces (5B1) towards the connecting piece (5B) to clamp the wire ends, and weld the wire ends to the welding area (5B2). Fifth step, assemble the cover plate (4): apply curing adhesive to the top surface of the limiting plate (1B), place the cover plate (4) on the top surface of the limiting plate (1B), and bake to cure, so as to form a ring magnetic circuit. Step 6, visual inspection: Select products with poor appearance using a visual inspection machine; Step 7, Test Packaging: Test the product and then place it inside the packaging material.

10. A method for manufacturing a wire-wound common-mode inductor according to claim 9, characterized in that: In the second step, on the finished sheet (5), the included angle between the hanging piece (5B1) and the connecting piece (5B) is 90 degrees to 160 degrees.

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