A coreless inductor and its fabrication method

Abstract

This invention belongs to the field of inductor technology and discloses a coreless inductor and its preparation method. The preparation method includes the following steps: assembly of coil and conductive sheet: a coil is installed into the corresponding coil positioning slot of a welding positioning module, and pairs of conductive sheets are respectively installed into the conductive sheet positioning slots of the welding positioning module; the two conductive sheets are located on the left and right sides of the coil, respectively; connection of coil and conductive sheet: the first end of the coil in the welding positioning module is electrically connected to the first pin of the first conductive sheet on one side, and the second end of the coil is electrically connected to the second pin of the second conductive sheet on the other side; forming of package: a package is formed to cover the pins of the coil and conductive sheet, and the exposed part of the conductive sheet is located outside the package. The preparation method simplifies the process, saves materials, effectively shortens the production cycle of the inductor, and improves the production efficiency of the inductor.

Description

Technical Field

[0001] This invention relates to the field of inductor technology, and more particularly to a coreless inductor and its fabrication method. Background Technology

[0002] Inductors are important electronic components widely used in various circuits and installed in various electronic products. An inductor is essentially a passive electronic component that stores electrical energy in the form of magnetic flux. It has a certain inductance and only impedes changes in current. In circuits, it mainly plays roles such as filtering, oscillation, delay, and notch filtering, as well as signal screening, noise filtering, current stabilization, and suppression of electromagnetic interference.

[0003] Existing inductors can be classified into coreless inductors and cored inductors based on whether they have a magnetic core. Cored inductors mainly consist of a coil winding, a magnetic core mounted at the center of the coil winding, auxiliary support structures, and external encapsulation materials. Coreless inductors have a simpler structure, mainly consisting of a coil winding, conductive sheets connected to the coil winding, and an external encapsulation, eliminating the need for a magnetic core structure within the coil winding compared to cored inductors.

[0004] Current coreless inductors typically employ a multi-conductor architecture where multiple inductors are fabricated simultaneously on a conductor frame composed of interconnected conductive sheets. For example, patent application CN108133809A describes an inductor package structure with an array of conductive supports, comprising: a conductor frame 1, multiple inductor units 2, and multiple packaging units 3. The conductor frame 1 includes multiple arrayed conductive supports 10 and a connecting frame 11 connected to the conductive supports 10. Each conductive support 10 includes a first conductive pin 100 connected to the connecting frame 11 and a second conductive pin 101 (i.e., a pair of conductive sheets) connected to the connecting frame 11 and spaced a predetermined distance from the first conductive pin 100. Multiple inductor units 2 are respectively disposed on each conductive support 10, wherein each inductor unit 2 includes a coil 20, and the coil 20 has a first end 200 electrically connected to the first conductive pin 100 and a second end 201 electrically connected to the second conductive pin 101. Multiple packaging units 3 respectively encapsulate each inductor unit 2. The method for fabricating the inductor packaging structure is as follows:

[0005] S1: A wire structure component 1 is provided, wherein the wire structure component 1 includes a plurality of arrayed conductive supports 10 and a connecting frame 11 connected to the conductive supports 10, and the conductive supports 10 include a first conductive pin 100 connected to the connecting frame 11 and a second conductive pin 101 connected to the connecting frame 11 and spaced apart from the first conductive pin 100 by a predetermined distance.

[0006] S2: Multiple inductor units 2 (coils 20) are respectively disposed on each conductive support 10, and the first end 200 and the second end 201 of the coil 20 are respectively soldered to the first conductive pin 100 and the second conductive pin 101.

[0007] S3: Multiple packaging units 3 are formed to respectively encapsulate each inductor unit 2. In this embodiment, the packaging unit 3 is a regular quadrilateral and its material is a magnetic material.

[0008] S4: Separate each first conductive pin 100 and second conductive pin 101 from their respective corresponding connecting portions 111 by cutting.

[0009] S5: Bend the first exposed portion 100B and the second exposed portion 101B so that the first exposed portion 100B and the second exposed portion are attached to the packaging unit 3 to form a single inductor packaging structure.

[0010] The existing inductor manufacturing methods described above are not only complex and time-consuming, but also costly because they are fabricated on wire structure components and require a large amount of raw materials for conductive sheets.

[0011] Therefore, existing technologies need further improvement. Summary of the Invention

[0012] To address the aforementioned problems, this invention provides a method for preparing a coreless inductor and a coreless inductor prepared using this method. This preparation method simplifies the process, requires less material, effectively shortens the preparation cycle, and improves preparation efficiency.

[0013] To address the above problems, this application provides the following technical solution:

[0014] In a first aspect, this application provides a method for fabricating a coreless inductor, which includes the following steps:

[0015] Assembly of coil and conductive sheet: Install a coil into the corresponding coil positioning slot of the welding positioning module, and install the pair of conductive sheets into the conductive sheet positioning slots of the welding positioning module respectively; the two conductive sheets are located on the left and right sides of the coil respectively;

[0016] Connection between coil and conductive sheet: The first end of the coil in the welding positioning module is electrically connected to the first pin of the first conductive sheet on one side, and the second end of the coil is electrically connected to the second pin of the second conductive sheet on the other side;

[0017] Package forming: Forming a package to cover the leads of the coil and conductive sheet, and ensuring that the exposed portion of the conductive sheet is outside the package.

[0018] Optionally, in the method for preparing the coreless inductor, the following steps are included before the assembly step of the coil and conductive sheet:

[0019] Preparation of conductive sheets: Cut out each of the closely arranged conductive sheets from the conductive sheet strip; one end of the conductive sheet forms a pin for connecting the coil, and the other end of the conductive sheet is the exposed part.

[0020] Optionally, in the method for preparing the coreless inductor, after the step of forming the package, the method further includes the following step: bending the exposed portions on the left and right sides of the package body and fitting them to the package body.

[0021] Optionally, in the method for preparing the coreless inductor, the processing method of the package is hot pressing, cold pressing, or a combination of both.

[0022] Optionally, in the method for preparing the coreless inductor, the step of preparing the coil is further included before the installation step of the coil and conductive sheet: coil preparation, wherein the coil preparation method is as follows:

[0023] The wire is wound into a coil on a winding machine; the enamel is stripped from the pin connection parts at both ends of the coil, which are used for electrical connection with the pins.

[0024] Optionally, in the method for preparing the coreless inductor, two conductive sheet positioning grooves extend horizontally and converge to form an inductor receiving groove covering the area of ​​the coil positioning groove, and the coil positioning groove is formed by a recess in the center of the bottom wall of the inductor receiving groove.

[0025] Optionally, in the method for preparing the coreless inductor, in the welding positioning module, the first end of the coil installed in place overlaps with the first pin portion of the first conductive sheet on one side, and the second end of the coil overlaps with the second pin portion of the second conductive sheet.

[0026] Optionally, in the method for preparing the coreless inductor, a first positioning hole is provided on the conductive sheet, and a first positioning post for inserting into the first positioning hole is provided in the positioning groove of the conductive sheet of the welding positioning module.

[0027] Optionally, in the method for preparing the coreless inductor, a coil positioning post is provided on the bottom wall of the coil positioning groove, and the cross-section of the coil positioning post is consistent with the inner diameter of the coil.

[0028] Optionally, in the method for preparing the coreless inductor, the depth of the coil positioning groove is less than the height of the coil, and the top surface of the welding positioning module is recessed to form coil end positioning grooves for positioning the first and second ends of the coil.

[0029] Optionally, in the method for preparing the coreless inductor, in the step of connecting the coil and the conductive sheet, after the end of the coil is soldered to the pin of the corresponding conductive sheet, the end of the coil located outside the solder joint is melted off or removed; the welding positioning module is provided with a clearance slot at the position corresponding to the solder joint.

[0030] Secondly, this application provides a coreless inductor, characterized in that it is prepared by the above-described method.

[0031] The present invention has the following beneficial effects:

[0032] 1. Compared with existing processes, the preparation method of the coreless inductor provided by this invention simplifies the steps. This method directly uses pre-cut conductive sheets and coils for precise positioning and welding in the welding positioning module, eliminating the subsequent cutting process. The raw materials can be pre-prepared conductive sheets and coils, which greatly improves processing efficiency and shortens the processing cycle. It also saves conductive sheet materials and reduces the production cost of inductors.

[0033] 2. The method for preparing the coreless inductor utilizes a simple and ingeniously designed welding positioning module. This module allows for rapid and precise installation and positioning of the coil and inductor, as well as subsequent efficient welding. Furthermore, the processing of each inductor is relatively independent, allowing for immediate progress to the next step after completion. This significantly improves processing efficiency and shortens the processing cycle. Alternatively, a corresponding number of welding positioning modules can be added to the fixture as needed for batch processing.

[0034] 3. The method for fabricating the coreless inductor utilizes an array of conductive strips to prepare conductive sheets, significantly improving material utilization, increasing the yield per unit area, and substantially reducing the manufacturing cost of the inductor. The array of conductive strips is subsequently cut into individual, structurally independent conductive sheets. These sheets are then installed into corresponding positioning holes in the inductor welding and positioning module. Combined with the process described in this application, this improves the production efficiency and shortens the production cycle of the inductor unit. Attached Figure Description

[0035] Figure 1 A schematic diagram of the structure of the array-type conductive support on which inductor processing in the prior art is based;

[0036] Figure 2 This is a schematic diagram of the fabrication process for an inductor in the prior art;

[0037] Figure 3 This is one implementation of the conductive sheet / strip in Embodiment 1 of this application;

[0038] Figure 4 This is another way to realize conductive sheet material;

[0039] Figure 5 This is an exploded view of the welding positioning module and the assembled coil and conductive sheet in Example 1;

[0040] Figure 6 This is a top view of the welding positioning module in the embodiment;

[0041] Figure 7 This is a top view of the welding positioning module with the coil and conductive sheet installed in Example 1.

[0042] Figure 8 A shows the inductor structure after the package is formed; A is a top view of the structure; B is a bottom view of the structure.

[0043] Figure 9 A schematic diagram of the three-dimensional structure of the inductor used to complete the bending step;

[0044] Figure 10 A top view of a fixture assembled with multiple welding positioning modules;

[0045] Figure 11 This is a flowchart illustrating one embodiment of the method for fabricating the coreless inductor of this application;

[0046] Figure 12 This is a flowchart illustrating another embodiment of the method for fabricating the coreless inductor of this application;

[0047] Figure 13 A schematic diagram of another embodiment of the conductive sheet material for inductors;

[0048] Figure 14 A schematic diagram of another embodiment of the conductive sheet material for inductors;

[0049] The annotations in the attached figures are explained as follows:

[0050] Main body 1a, pin 1b, conductive sheet strip 01, conductive sheet 1, first conductive sheet array 011, column gap 011a, width 1b1, first conductive sheet 11, first pin 110, second conductive sheet 12, second pin 120, external exposure 13, first positioning hole 14, coil 2, first end 21, second end 22, package body 3, welding positioning module 4, conductive sheet positioning groove 41, pin positioning area 413, conductive sheet main body positioning area 412, first positioning post 411, corresponding coil positioning groove 42, coil positioning post 421, coil end positioning groove 422, inductor receiving groove 43, clearance slot hole 44, welding fixture 5, solder joint 6. Detailed Implementation

[0051] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0052] It should be noted that when an element is described as being "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 being "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 "vertical," "horizontal," "left," "right," "upper," "lower," "inner," "outer," "bottom," etc., used in this specification indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0053] 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. Furthermore, technical features involved in the different embodiments of the invention described below may be combined with each other as long as they do not conflict with each other.

[0054] like Figures 1-2 As shown, existing coreless inductors are directly processed on the whole conductor frame component 1 after the material strip is cut. First, each coil is precisely placed between the first conductive pin and the second conductor pin of each conductive bracket conductive sheet in the array. After the precise welding of the whole board is completed, the packaging unit is formed together at the corresponding position of the conductor frame component 1. Then, each inductor unit is cut off and finally, each inductor is folded.

[0055] Therefore, existing coreless inductor manufacturing processes use a single integral conductor frame component (multiple conductive sheets arranged in an array according to the welding requirements and connected together by a connecting frame) as the unit and processing object. All inductor units of a single integral conductor frame component must complete the same processing step before the whole assembly can proceed to the next processing step. Consequently, this method suffers from slow processing speed and long cycle times; furthermore, a problem in one step can affect the entire processing progress and quality. Due to the tight arrangement of the conductor frame components, precise positioning and processing speed are crucial.

[0056] To address the problems existing in the above-mentioned inductor manufacturing methods, the present invention provides a method that directly uses pre-cut conductive sheets and coils for precise positioning and connection in a welding positioning module, which greatly improves processing efficiency and shortens the processing cycle.

[0057] Example 1

[0058] This embodiment provides a method for fabricating a coreless inductor, such as... Figure 11 As shown, in order to reduce the material cost of the conductive sheet, a single conductive sheet is directly cut, and a welding positioning module is used to complete the positioning welding of each pair of conductive sheets and a coil, thereby realizing the welding processing of a single inductor.

[0059] Specifically, the method for preparing the coreless inductor includes the following steps:

[0060] Step S1: Assembly of coil and conductive sheet:

[0061] like Figure 5 As shown, a coil 2 is installed into the corresponding coil positioning slot 42 of the welding positioning module 4, and pairs of conductive pieces 1 are respectively installed into the conductive piece positioning slots 41 of the welding positioning module 4; the two conductive pieces 1 are located on the left and right sides of the coil 2, respectively. A schematic diagram of the assembled structure is shown below. Figure 7 .

[0062] To improve efficiency, this step can use multiple pre-cut and stored independent conductive sheets 1 and each pre-processed coil, which are then installed into the welding positioning module 4 to simultaneously complete the assembly and positioning of the coil and the conductive sheets on both sides.

[0063] In order to quickly and accurately position the conductive sheet 1 and the coil 2, the top surface of the welding positioning module is provided with a coil positioning groove 42 for installing the coil 2 and two conductive sheet positioning grooves 41 for horizontally oriented installation of the conductive sheet 1. The conductive sheet positioning grooves 41 are located on the left and right sides of the coil positioning groove, respectively.

[0064] Since the conductive sheet is composed of a conductive sheet body and pins extending from the tail of the conductive sheet body, the conductive sheet positioning groove 41 includes a pin positioning area 413 and a conductive sheet body positioning area 412.

[0065] To facilitate the positioning of the conductive sheet pins and the end of the coil together, the conductive sheet pin positioning area of ​​the conductive sheet positioning groove is adjacent to the outer side of the opening of the coil positioning groove. The bottom surface of the conductive sheet positioning groove is connected to the top side wall of the coil positioning groove and is in the same plane, so that the first end 21 of the coil 2 overlaps with the first pin portion of the first conductive sheet 11 on one side, and the second end 22 of the coil 2 overlaps with the second pin portion of the second conductive sheet 12.

[0066] The above arrangement allows the two ends of the installed coil to overlap with the pins of the conductive plates on both sides, making it easy for the welding equipment to directly weld the overlapping positions together, thereby achieving an electrical connection between the coil and the conductive plates.

[0067] The aforementioned welding positioning template 4, through the ingenious cooperation of the coil positioning groove 42 and the conductive sheet positioning groove 41, not only quickly realizes the installation of the coil and the conductive sheet, but also completes the precise assembly of the two in one step, improving assembly and calibration efficiency. Furthermore, since each conductive sheet is independent, the cutting step is omitted after processing, shortening the processing cycle.

[0068] In actual production, multiple inductors can be processed simultaneously by installing an appropriate number of welding positioning modules 4 on an inductor welding fixture 5, which not only improves efficiency but also makes the processing more flexible.

[0069] like Figure 10 The welding fixture 5 shown has multiple welding positioning modules 4 arranged in an array, which can be used for batch operation of the welding positioning modules 4 on the welding fixture 5 to improve the manufacturing efficiency of inductors.

[0070] Step S2: Connection of coil and conductive sheet: Connect the first end 21 of the coil 2 in the welding positioning module to the first pin 110 of the first conductive sheet 11 on one side, and connect the second end 22 of the coil to the second pin 120 of the second conductive sheet 12 on the other side.

[0071] Specifically, in this embodiment, the electrical connection between the coil end and the corresponding pin of the conductive sheet is achieved by soldering. In other embodiments, conductive adhesive can also be used to achieve the electrical connection between the coil end and the corresponding pin of the conductive sheet.

[0072] Preferably, the two conductive sheet positioning grooves 41 extend horizontally and converge to form an inductor receiving groove 43 covering the coil positioning groove area, and the coil positioning groove 42 is formed by a recess in the center of the bottom wall of the inductor receiving groove. The inductor receiving groove formed in this way has its sidewalls recessed along the outer edge of the inductor semi-finished product to be welded. This arrangement not only facilitates processing, but also facilitates the installation of parts and the removal of the internal inductor semi-finished product.

[0073] To improve the ease of coil positioning and installation accuracy, a coil positioning post 421 is provided on the bottom wall of the coil positioning groove 42, and the cross-section of the coil positioning post is consistent with the inner diameter of the coil.

[0074] Preferably, the top of the coil positioning post is a frustum or a cone. This design facilitates the quick installation of the coil onto the coil positioning post 421, improves installation efficiency, and prevents the coil from falling off due to errors.

[0075] like Figure 5 As shown, the coil includes a coil body that is arranged around the coil body and two linear ends extending from the ends of the coil body. Typically, the two ends are arranged parallel to each other and are in the same plane.

[0076] To prevent radial offset during coil installation and rotation of the coil in the slot during operation, the following settings are made: (e.g.) Figure 2 and Figure 5 As shown, the welding positioning module has two coil end positioning grooves 422 formed by the top surface of one side of the coil positioning groove. Each coil end positioning groove 422 is used to install and position the two ends of the coil.

[0077] In this embodiment, the coil end positioning grooves 422 are parallel to each other, and both ends of the coil end positioning grooves 422 are open, so that they can be used for coil ends of various lengths. The first end and the second end of the coil are located at the upper end of the coil and are perpendicular to the central axis of the coil.

[0078] In order to accurately position each conductive sheet in the welding positioning module, a first positioning hole 14 is provided on the conductive sheet, and a first positioning post 411 for inserting into the first positioning hole is provided in the conductive sheet positioning groove 41 of the welding positioning module 4.

[0079] The cooperation between the first positioning post and the first positioning hole enables the conductive sheet to be positioned quickly, preventing it from shifting left or right when it enters the conductive sheet positioning groove 41, which would affect the subsequent welding accuracy.

[0080] In this step S2, after the end of the coil is soldered to the pin of the corresponding conductive sheet, the end of the coil located outside the solder joint is melted off or melted away.

[0081] To facilitate welding operations, prevent damage to the welding positioning module, and avoid molten coil ends or debris falling onto the welding positioning module after welding, thus avoiding subsequent use and eliminating the need for cleaning, the following design is implemented: a through-hole 44 is provided in the area between the conductive sheet positioning groove 41 and the coil end positioning groove 422. Figure 7 As shown.

[0082] The area between the conductive sheet positioning groove 41 and the coil end positioning groove 422 is where the solder joint 6 of the conductive sheet pin and the coil end is located. Since the solder joint is located above the clearance slot 44, this arrangement not only avoids damage to the welding positioning module, but also facilitates the removal of impurities and debris after welding from the clearance slot 44.

[0083] In this embodiment, for ease of processing, the clearance slot 44 is a large hole corresponding to both conductive sheet positioning slots. In other embodiments, the clearance slot 44 is two independent holes corresponding to each conductive sheet positioning slot.

[0084] In addition, in order to achieve a stable connection between the welding positioning module and other structures (such as inductive welding fixtures) and improve installation convenience, the housing of the welding positioning module is symmetrically provided with mounting holes for connecting the welding positioning module and the fixture.

[0085] Step S3: Package forming: Form package 3 to cover coil 2 and the pins of conductive sheet, and make the exposed portion 13 of conductive sheet outside the package.

[0086] In this embodiment, the package is processed by hot pressing. In other embodiments, the package is processed by cold pressing.

[0087] In an optional embodiment, the entire assembly of the electrically connected coil and the left and right conductive sheets is moved to the processing position of the molding die. Partial powder is filled into the hot-pressing forming hole of the molding die, with the coil positioned within the hole. After filling the remaining powder, hot pressing is performed to form an encapsulation 3 covering the coil 2 and the leads of the conductive sheets, exposing the exposed portion 13 of the conductive sheets for easy electrical connection to an external circuit. The encapsulation can be a cuboid or other shapes.

[0088] In addition, this embodiment also provides a coreless inductor prepared using the above method.

[0089] Example 2

[0090] This embodiment provides a method for fabricating a coreless inductor, such as... Figure 12 As shown, the method for preparing the coreless inductor includes the following steps:

[0091] S1. Preparation of conductive sheets: Cut off each of the closely arranged conductive sheets 1 from the conductive sheet strip 01; one end of the conductive sheet forms a pin for connecting the coil, and the other end of the conductive sheet is the external exposed part 13.

[0092] Preparation of coil 2: The wire is wound into a coil on a winding machine; then the varnish is stripped from the pin connection parts at both ends of the coil, which are used to make electrical connections with the pins.

[0093] The fabrication of the conductive sheet and the fabrication of the coil are carried out independently and without interference, and there is no requirement for a specific order.

[0094] To improve efficiency, the conductive sheets and coils can be produced simultaneously. A sufficient quantity of conductive sheets and coils can be prepared in advance without affecting the speed of subsequent processing steps.

[0095] like Figure 3 As shown, the conductive sheet strip 01 is densely covered with a conductive sheet array consisting of multiple inductive conductive sheets 1 arranged together and a connecting part that connects the conductive sheet array into one piece. The inductive conductive sheet includes a main body 1a with a planar regular shape as the head and two separate pins 1b extending from one side of the main body as the tail. Adjacent inductive conductive sheets are arranged in parallel with their heads and tails reversed in at least one direction.

[0096] like Figure 13 In one embodiment shown, the inductive conductive sheet strip includes only a row of parallel conductive sheets and a connecting portion that connects the conductive sheets together.

[0097] like Figure 14 As shown, the conductive sheet material provided in this application includes a partially cut strip with the connecting portion completed. After all the connecting portions on the strip are cut off, individual conductive sheets are obtained.

[0098] The above-mentioned parallel arrangement of multiple conductive sheets with their ends reversed can effectively reduce the gap between adjacent conductive sheets and improve the utilization rate of the strip.

[0099] Specifically, the conductive sheet array includes at least one column of first conductive sheet arrays 011 arranged horizontally parallel to the first direction X, and each column of first conductive sheet arrays consists of conductive sheets closely arranged along the second direction Y. At least a portion of the main body 1a of each conductive sheet in each column of conductive sheet arrays arranged along the second direction has overlapping coordinates (or positions) in the first direction.

[0100] In this embodiment, preferably, the coordinates (or positions) of the main body 1a of each conductive sheet portion in each column of the conductive sheet array arranged along the second direction overlap in the first direction. Maximizing the overlap further increases the density of the conductive sheets in the conductive sheet array and improves material utilization.

[0101] Based on this, in this embodiment, there is a gap on the side of the adjacent main body of each column of the first conductive sheet array. The smaller gap between adjacent conductive sheets makes it easier to cut the conductive sheets, and the requirements for cutting accuracy can be relaxed to avoid cutting errors.

[0102] In other embodiments, the sides of adjacent conductive sheets in each column of the first conductive sheet array overlap, which makes the arrangement of each column of conductive sheets the most compact and maximizes material utilization. This arrangement requires high cutting precision.

[0103] like Figure 3 As shown, the two pins of each conductive sheet array are located at both ends of the same side. The two pins extend in opposite directions along the second direction and towards the body of the adjacent conductive sheet in the second direction. This arrangement not only effectively avoids short circuits between the two pins and facilitates soldering, but more importantly, the pins of the conductive sheets arranged in this way make full use of the gap between the bodies of the conductive sheets in the two columns of arrays. This allows the pin extension to be inserted into the narrow gap between the conductive sheets in the two columns of arrays, while ensuring sufficient pin length and improving material utilization.

[0104] Optionally, the two pins of the conductive sheet form the same angle with the side of the main body. This arrangement makes the two pins more symmetrical and the force more even in operation.

[0105] In this embodiment, two adjacent columns of first conductive sheet arrays 011 are arranged in a mirror-symmetric manner with the gap between them; the pins extending from the conductive sheets arranged in the same direction in each column occupy the gap between two adjacent columns of first conductive sheet arrays.

[0106] The width of the column gap 011a between adjacent first conductive sheet arrays is greater than or equal to twice the width 1b1 of the pin in the first direction.

[0107] Furthermore, the conductive sheet body is provided with a first positioning hole 14, either to be drilled or already drilled. The first positioning hole facilitates the subsequent positioning and installation of the cut-out individual conductive sheets at the processing location.

[0108] Preferably, on a single conductive sheet, the two pins of the first conductive sheet include a conductive pin for connection to the coil and an auxiliary pin for balancing. The width of the conductive pin along its length is greater than the width of the auxiliary pin along its length, or its thickness is greater. Since soldering in a smaller space is more difficult and requires higher precision, the above arrangement facilitates the soldering of the pin joints, improving the convenience and success rate of the soldering operation between the pin and the coil.

[0109] like Figure 4The difference between the other conductive sheet strip shown and the previous embodiment is that the two columns of pins extending from the nematic gap 011a between the first conductive sheet arrays are interlocked and staggered. The width of the nematic gap between adjacent first conductive sheet arrays is less than twice the width 1b1 of the pin in the first direction. This arrangement further reduces the gap width between adjacent columns of first conductive arrays, improves the arrangement precision of the conductive sheets, and further improves material utilization and conductive sheet yield. Furthermore, there is a gap on the outer edge of the interlocked adjacent pins. In other embodiments, the outer edges of the interlocked adjacent pins overlap to further improve material utilization.

[0110] Afterward, the cut conductive sheets are added to the flexible vibration device. By activating the working mode of the flexible vibration device, the multiple conductive sheets that have been put in batches fall into their respective positioning slots during vibration, thus separating the conductive sheets and making it easier to pick up and place the individual conductive sheets into the corresponding positions of the welding positioning module in the next step.

[0111] S2. Assembly of coils and conductive sheets: Install each coil 2 into the corresponding coil positioning slot 42 of the welding positioning module 4, and install the paired conductive sheets 1 into the conductive sheet positioning slots 41 of the welding positioning module 4 respectively; the two conductive sheets 1 are located on the left and right sides of the coil 2 respectively. See the schematic diagram of the assembled structure. Figure 7 .

[0112] S3. Connection of coil and conductive sheet: Connect the first end 21 of the coil 2 in the welding positioning module to the first pin 110 of the first conductive sheet 11 on one side, and connect the second end 22 of the coil to the second pin 120 of the second conductive sheet 12 on the other side.

[0113] S4. Package Forming: A package 3 is formed to cover the coil 2 and the leads of the conductive sheet, with the exposed portion 13 of the conductive sheet located outside the package, resulting in... Figure 8 The structure shown.

[0114] S5. Bend the exposed portions on the left and right sides of the package body and fit them to the package body.

[0115] The above steps form a more compact inductor unit, such as... Figure 9 As shown.

[0116] In addition, the following steps are also set:

[0117] S6. Inductor units are tested. If a defective inductor is detected, it is unloaded into a defective product placement fixture using a defective unloading fixture for separation. Good products are collected using a good product unloading mechanism.

[0118] Preferably, the detection includes the detection of bending, which is performed using a CCD inspection machine to inspect all six sides of the inductor.

[0119] In addition, a welding inspection step can be added after step S3: a portion of the inductors can be randomly selected or each inductor can be inspected. The inspection method is a tensile test. If the welding is found to be without problems, it will prevent the production of defective welded products in batches.

[0120] Correspondingly, this embodiment also provides a coreless inductor prepared using the above method.

[0121] It is understood that those skilled in the art can make equivalent substitutions or modifications to the technical solutions and concepts of this invention, and all such substitutions or modifications should fall within the protection scope of the appended claims.

Claims

1. A method of manufacturing a coreless inductor, characterized by, Includes the following steps: Assembly of coil and conductive sheet: Install a coil (2) into the corresponding coil positioning slot (42) of the welding positioning module (4), and install a pair of conductive sheets (1) into the conductive sheet positioning slot (41) of the welding positioning module (4); the two conductive sheets (1) are located on the left and right sides of the coil (2); one end of the conductive sheet forms a pin for connecting the coil, and the other end of the conductive sheet is an external part (13); the two conductive sheet positioning slots (41) extend horizontally and converge to form an inductor receiving slot (43) covering the area of ​​the coil positioning slot, and the coil positioning slot (42) is formed by the center of the bottom wall of the inductor receiving slot; a first positioning hole (14) is provided on the conductive sheet, and a first positioning post (411) for inserting into the first positioning hole is provided in the conductive sheet positioning slot (41) of the welding positioning module (4); Connection of coil and conductive sheet: The first end (21) of the coil (2) in the welding positioning module is electrically connected to the first pin (110) of the first conductive sheet (11) on one side, and the second end (22) of the coil is electrically connected to the second pin (120) of the second conductive sheet (12) on the other side; Package forming: A package (3) is formed to cover the coil (2) and the pins of the conductive sheet, and the exposed portion of the conductive sheet is located outside the package.

2. The method of claim 1, wherein the coreless inductor is prepared by the steps of: The following steps are included before the assembly of the coil and conductive sheet: Preparation of conductive sheets: Cut out each of the closely arranged conductive sheets (1) from the conductive sheet strip (01).

3. The method of claim 1, wherein the coreless inductor is prepared by the steps of: Before the installation of the coil and conductive sheet, the following steps are also included: preparation of the coil (2), the method for preparing the coil is as follows: The wire is wound into a coil on a winding machine; the enamel is stripped from the pin connection parts at both ends of the coil, which are used for electrical connection with the pins.

4. The method of claim 3, wherein the coreless inductor is prepared by, The steps following the forming of the package include: bending the exposed portions on the left and right sides of the package body and fitting them to the package body.

5. The method of claim 1, wherein the coreless inductor is prepared by the steps of: The packaging body is processed by hot pressing, cold pressing, or a combination of both.

6. The method for preparing a coreless inductor according to claim 2, characterized in that, In the welding positioning module, the first end (21) of the coil (2) installed in place overlaps with the first pin portion of the first conductive sheet (11) on one side, and the second end (22) of the coil (2) overlaps with the second pin portion of the second conductive sheet (12).

7. The method for preparing a coreless inductor according to claim 2, characterized in that, The bottom wall of the coil positioning groove (42) is provided with a coil positioning column (421), and the cross-section of the coil positioning column is consistent with the inner diameter of the coil.

8. The method for preparing a coreless inductor according to claim 7, characterized in that, The top surface of the welding positioning module is recessed on one side of the coil positioning groove to form a coil end positioning groove (422) for positioning the first and second ends of the coil.

9. The method for preparing a coreless inductor according to claim 1, characterized in that, In the connection steps of the coil and the conductive sheet, after the end of the coil is welded to the pin of the corresponding conductive sheet, the end of the coil located outside the solder point is melted or melted off; the welding positioning module is provided with a clearance slot (44) through the corresponding solder point (6).

10. A coreless inductor, characterized in that, It is prepared by the method according to any one of claims 1 to 9.

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