Novel Hcore inductor manufacturing method

Abstract

The invention relates to a novel Hcore inductor manufacturing method, which comprises the following steps of: calculating and marking a flattening distance, a flattening position and a flattening thickness required by a copper wire coil part and a tail wire part so as to carry out accurate flattening control on a copper wire; flattening the coil part of the copper wire to enable the thickness of the coil part to be 90%-70% of the diameter of the original copper wire; flattening the tail wire part of the copper wire to enable the thickness of the tail wire part to be 60%-40% of the diameter of the original copper wire; the coil part is wound and formed in a spiral horizontal winding mode; and embedding the magnetic core, turning the line, bending and forming. According to the invention, the current path length and resistance are effectively reduced, the DCR is further reduced, the energy conversion efficiency of the power inductor is improved, and heat is reduced.

Description

[0001] Technology Neighborhood This invention relates to the field of electronic component technology, and particularly to a method for manufacturing magnetic core inductors. Background Technology

[0002] In today's rapidly evolving technological landscape, modern electronic fields such as 5G communication, the Internet of Things, and AI servers are transforming people's lives and work at an unprecedented pace. Within these fields, power inductors, as key electronic components, play an indispensable role. DC resistance (DCR) is a crucial indicator for evaluating the performance of power inductors, profoundly impacting their energy loss, heat generation, and the overall efficiency and stability of the equipment.

[0003] Existing technologies involve first winding the copper wire into a coil shape, and then flattening it. This process has a drawback: when current flows through the power inductor, the presence of DCR (Displacement Reduction) generates Ic. 2 The energy loss of R is represented by I, where I is the current and R is the current-to-temperature ratio (DCR). This energy loss is dissipated as heat, causing the power inductor to heat up. The larger the DCR, the more heat is generated for the same current. Excessive heat will raise the temperature of the power inductor, which in turn will affect the performance of its internal materials, such as reducing the permeability, causing a change in the inductance value, and affecting the normal operation of the circuit.

[0004] In applications such as switching power supplies, the energy conversion efficiency of a power inductor is closely related to its resistance coefficient (DCR). A high DCR results in more electrical energy being converted into heat and lost, reducing the power supply's conversion efficiency. For example, in a DC-DC converter, if the power inductor has a high DCR, a significant proportion of electrical energy will be wasted in the inductor's resistance during the input-to-output voltage conversion process, leading to reduced output power and decreased power supply efficiency. This not only increases energy consumption but may also affect the device's battery life or necessitate a higher-power power supply, increasing equipment cost and size.

[0005] Furthermore, DCR can also affect the stability of equipment. In some circuits with high requirements for power supply stability, such as precision analog circuits and radio frequency circuits, voltage fluctuations and energy losses caused by DCR may introduce noise, interfere with signal transmission and processing, lead to a decrease in equipment performance, or even failure. Summary of the Invention

[0006] The purpose of this invention is to address the shortcomings of existing technologies by designing an integrated molding technology. Through a unique design of the winding method and core structure, the current path length and resistance are effectively reduced, thereby reducing DCR, improving the energy conversion efficiency of the power inductor, and reducing heat generation.

[0007] The objective of this invention can be achieved through the following technical solution: a novel Hcore inductor manufacturing method, the method comprising: 1) Calculate and mark the required flattening spacing, flattening position and flattening thickness of the copper wire coil and tail wire parts in order to accurately control the flattening of the copper wire; 2) Use a flattening device to flatten the coil portion of the copper wire, making its thickness 90%-70% of the original copper wire diameter; 3) Use a flattening device to flatten the tail section of the copper wire, making its thickness 60%-40% of the original copper wire diameter; 4) The coil part of the copper wire is wound into shape using a spiral horizontal winding method; 5) According to design requirements, the tail wire part is shaped by inserting a magnetic core and bending the wire.

[0008] Furthermore, in the novel Hcore inductor manufacturing method, the calculation and marking of the copper wire coil portion and the tail wire portion involves the installation of a CCD to precisely control the flattening spacing, flattening position, and flattening thickness.

[0009] The advancement of this technology lies in its ability to significantly reduce DCR, significantly improve the energy conversion efficiency of power inductors, reduce heat generation, and enhance the stability and lifespan of equipment. Furthermore, the winding method of first flattening the wire, then winding it around the coil, and finally inserting the magnetic core to form the wire shape significantly reduces the bending force required for the copper wire at the bend corner, thereby reducing the strength requirements of the magnetic core. Attached Figure Description

[0010] Figure 1 This is a schematic diagram of the three-dimensional structure of the copper wire after it has been flattened according to the present invention; Figure 2 This is a three-dimensional structural diagram of the coil section of the present invention being wound and formed; Figure 3 This is a three-dimensional structural diagram of the coil winding of the present invention, in which the magnetic core tail wire is inserted and formed by twisting the wire. Detailed Implementation

[0011] This invention employs a winding method that involves first flattening the copper wire, then winding the coil section into shape, and finally inserting it into the magnetic core for wire flipping. This significantly reduces the bending force required for the copper wire at the bend corner, thereby reducing the strength requirements of the magnetic core. This can significantly reduce the DCR, significantly improve the energy conversion efficiency of the power inductor, reduce heat generation, and improve the stability and lifespan of the equipment.

[0012] like Figure 1As shown, first calculate and mark the required flattening spacing, flattening position, flattening thickness H of coil part 2, and flattening thickness h of tail part 3 located at both ends of coil part 2 on the copper wire; input the above data into the flattening machine to enable the flattening machine to precisely control the flattening of the copper wire; flatten the copper wire to obtain the desired result. Figure 1 The flattened copper wire shown.

[0013] like Figure 2 As shown, the coil portion of the flattened copper wire is wound into shape according to the set number of turns and diameter; resulting in... Figure 2 The structure shown is formed by winding the coil portion.

[0014] like Figure 3 As shown, the copper wire is wound around the coil part and the bottom of the coil is attached to the magnetic core 4. The tail wire parts 3 at both ends of the coil part 1 are bent into shape as needed to obtain the finished product.

Claims

1. A novel method for manufacturing Hcore inductors, characterized in that, The method includes: 1) Calculate and mark the required flattening spacing, flattening position and flattening thickness of the copper wire coil and tail wire parts in order to accurately control the flattening of the copper wire; 2) Use a flattening device to flatten the coil portion of the copper wire, making its thickness 90%-70% of the original copper wire diameter; 3) Use a flattening device to flatten the tail section of the copper wire, making its thickness 60%-40% of the original copper wire diameter; 4) The coil part of the copper wire is wound into shape using a spiral horizontal winding method; 5) According to design requirements, the tail wire part is shaped by inserting a magnetic core and bending the wire.

2. The novel Hcore inductor manufacturing method according to claim 1, characterized in that, The calculation and marking of the copper wire coil and tail wire parts are achieved by installing a CCD to precisely control the flattening spacing, flattening position, and flattening thickness.

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