Parallel inductor clamp set and parallel inductor forming method

Abstract

According to the parallel inductor clamp set and the parallel inductor forming method, the clamp set comprises a longitudinal clamp and a transverse clamp, the longitudinal clamp comprises two symmetrically-arranged vertical pieces and at least four supporting pieces, the number of the supporting pieces is an even number, and the multiple supporting pieces are evenly distributed on the two different vertical pieces; the supporting pieces on each vertical piece are fixedly installed on the vertical piece in a vertically spaced mode, and the vertical pieces and the trays are arranged in an aligned mode. The two supporting pieces located on the same horizontal plane are jointly connected with a small-size inductor, inductor pins of the small-size inductor are connected to the two supporting pieces arranged side by side respectively, the transverse clamp comprises clamping pieces, the longitudinal clamps are arranged side by side at the same time, and the small-size inductors on the longitudinal clamps are all arranged on the clamping pieces. A plurality of small integrated inductors with the total value far lower than the cost of a large integrated inductor can be connected in parallel and packaged into a whole for replacement; inventory can be reduced according to flexible collocation of orders; the heat dissipation effect of the inductors connected in parallel is better, and the working current can be larger.

Description

Technical Field

[0001] This invention relates to a clamp for parallel inductors, and more particularly to a clamp kit for parallel inductors and a method for forming parallel inductors. Background Technology

[0002] Molded inductors are mainly used in switching power supply modules for various chips. When the chip requires a large operating current, a molded inductor with a larger rated current and larger size is needed. Small-sized molded inductors, such as the 2016 (2.0mm × 1.6mm) and 2520 (2.5mm × 2.0mm) models, are mainly used in mobile phones and tablets, and have a large market share. Their product models are basically standardized, and there is surplus domestic production capacity. In some space-insensitive applications, there is a demand for larger-sized products. Currently, the demand for large-size, low-inductance, high-current models is increasing, but due to the small market size and much smaller usage compared to mobile phones, they are basically in a customized state, resulting in higher prices. Furthermore, the unique winding method of large molded inductors (flat wire horizontal winding) compared to small molded inductors (flat wire vertical winding) limits the degree of automation in their production, making their production efficiency far lower than that of small molded inductors. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to overcome the shortcomings of the existing technology, such as the high cost of large-size, low-inductance, high-current inductors and the lower production efficiency compared to the production of small-size inductors, and to provide a parallel inductor fixture kit and a parallel inductor forming method.

[0004] The technical solution adopted by the present invention to solve its technical problem is a parallel inductor clamp kit and a parallel inductor forming method, including a longitudinal clamp, the longitudinal clamp including two symmetrically arranged upright pieces and at least four support pieces, the number of support pieces is even, and the multiple support pieces are evenly distributed on two different upright pieces, the support pieces on each upright piece are fixedly installed on the upright piece at intervals, and the upright pieces and support pieces are aligned; two support pieces on the same horizontal plane are connected together to a small-sized inductor, and the inductor pins of the small-sized inductor are respectively connected to the two parallel support pieces.

[0005] Furthermore, both the support plate and the tray are L-shaped to support small-sized inductors.

[0006] Furthermore, the stand has a U-shaped groove to allow observation of small-sized inductors on the support plate.

[0007] Furthermore, it also includes a lateral clamp, which includes a clamping piece, and multiple longitudinal clamps are arranged side by side, with small-sized inductors on the longitudinal clamps all mounted on the clamping piece.

[0008] Furthermore, the longitudinal clamps are arranged side by side along the width of the vertical piece, and the clamps extend along the direction of the longitudinal clamps to accommodate multiple small-sized inductors within the clamps.

[0009] Furthermore, the clip has the same number of wide holes as the small-sized inductors to provide heat dissipation gaps and to observe whether there are any empty inductor slots.

[0010] Furthermore, the lateral clamp also includes a U-shaped spacer, and the presence of multiple wide holes forms a snap-fit ​​crossbar on the spacer. The U-shaped spacer engages with the snap-fit ​​crossbar to separate multiple small-sized inductors.

[0011] Furthermore, the longitudinal clamp is energized, while the transverse clamp is not energized.

[0012] A further solution to the technical problem of the present invention is a method for forming parallel inductors using a jig assembly, comprising the following steps:

[0013] S1. Small-sized inductor products with an inductance tolerance of ±30% after preliminary electrical and visual inspection and sorting are used as components for assembly;

[0014] S2. Divide all inductors into inductance value ranges, and divide the inductance values ​​into 6 equally spaced ranges according to the center value range of the specifications;

[0015] S3. Take one inductor from interval 1, and correspondingly take one inductor from interval 6; take one inductor from interval 2, and correspondingly take one inductor from interval 5; take one inductor from interval 3, and correspondingly take one inductor from interval 4. Continue taking inductors symmetrically from the edge inwards until N inductors are taken. If the edge intervals are exhausted, take inductors from the adjacent unexhausted intervals. If the adjacent intervals are also exhausted, remove the outermost interval and start taking inductors again from the first one according to the rules.

[0016] S4. Using N inductors as a group in parallel, based on the R of N inductors... DC The DC resistance value is used for screening, R DC The N / 2 inductors with the lowest values ​​are arranged in a horizontal row, held together by clips and U-shaped spacers, R DC The N / 2 inductors with higher values ​​are also arranged in a horizontal row, clamped together by another set of clips and U-shaped spacers.

[0017] S5, R fixed by a transverse clamp DC The low-value inductor pin is connected to the tray of the lower layer in the vertical clamp, and R is fixed by another set of horizontal clamps. DC The high-value inductor pin is connected to the tray of the upper layer in the vertical fixture.

[0018] Furthermore, in step S2, the specification center values ​​of the 6 intervals are -30%~-20%, -20%~-10%, -10%~0, 0~10%, 10%~20%, and 20%~30% from left to right, and are numbered 1-6 from left to right.

[0019] In summary, the present invention has the following beneficial technical effects:

[0020] Several small integrated inductors, with a total value far lower than that of large-size integrated inductors, can be packaged in parallel to replace them; and inventory can be reduced by flexibly matching according to orders; the inductors connected in parallel have better heat dissipation due to the presence of U-shaped slots and wide holes, allowing for a larger operating current; some products with minor surface defects that do not affect use (missing corners, damage, micro-cracks) will be covered to a certain extent by the parallel fixtures, and will not be discarded or downgraded as defective products as when sold separately.

[0021] By adopting a parallel inductor forming method and selecting inductors by sorting and combining them in sections, the inductance value of the final formed parallel inductor is closer to the original design standard than that of a single inductor. This means that the inductance value of the parallel inductor is as close as possible to the design specifications, which improves the accuracy of the inductance value. With lower cost and a value closer to the standard value, the parallel inductor becomes more competitive. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of a small-sized inductor according to an embodiment of the parallel inductor clamping kit of the present invention;

[0023] Figure 2 This is a schematic diagram of the stand and support structure of an embodiment of a parallel inductor clamp kit according to the present invention;

[0024] Figure 3 This is a schematic diagram of the longitudinal clamp structure of an embodiment of the parallel inductor clamp kit of the present invention;

[0025] Figure 4 This is a longitudinal side view of a parallel inductor clamping fixture assembly according to an embodiment of the present invention;

[0026] Figure 5 This is a schematic diagram of the clamping plate structure of an embodiment of the parallel inductor clamping kit of the present invention;

[0027] Figure 6 This is a schematic diagram of the U-shaped spacer structure of an embodiment of the parallel inductor clamp kit of the present invention;

[0028] Figure 7 This is a schematic diagram of the transverse clamp structure of an embodiment of the parallel inductor clamp kit of the present invention;

[0029] Figure 8 This is a schematic diagram of the clamping structure for placing inductors according to an embodiment of the parallel inductor clamping kit of the present invention;

[0030] Figure 9 This is a schematic diagram of the overall structure of a clamping kit according to an embodiment of the parallel inductor clamping kit of the present invention;

[0031] Figure 10 This is an exploded structural diagram of a parallel inductor clamp kit according to an embodiment of the present invention.

[0032] Explanation of reference numerals in the attached figures:

[0033] 1. Longitudinal clamp; 11. Vertical piece; 111. U-shaped groove; 12. Support piece; 2. Lateral clamp; 21. Clamping piece; 211. Wide hole; 212. Snap-fit ​​crossbar; 22. U-shaped spacer; 221. Inner clip; 3. Small-size inductor; 31. Inductor lead. Detailed Implementation

[0034] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments.

[0035] Reference Figure 9 and Figure 10 The parallel inductor fixture kit of this embodiment includes a longitudinal fixture 1 and a transverse fixture 2, and a fixture kit contains multiple longitudinal fixtures 1 and multiple transverse fixtures 2. The multiple longitudinal fixtures 1 and multiple transverse fixtures 2 are connected together to multiple small-sized inductors 3 to form a complete parallel inductor.

[0036] Reference Figure 1 It should be noted that the small-sized inductor 3 in this embodiment is a standard molded inductor model 2016 (2.0mm×1.6mm) or 2520 (2.5mm×2.0mm), which is mainly used in mobile phones and tablets; correspondingly, the vertical clamp 1 and the horizontal clamp 2 are designed to match the model of the inductor, and their overall size is also adapted to the size of the product.

[0037] Reference Figure 2 , Figure 3 and Figure 4The longitudinal clamp 1 includes a vertical piece 11 and a support piece 12. The support piece 12 is welded to the vertical piece 11. Two identical vertical pieces 11 are provided, arranged symmetrically opposite each other. Two support pieces 12 are connected to each vertical piece 11 at a vertical distance. The two support pieces 12 at the same height are connected to a small inductor 3, thus enabling the longitudinal clamp 1 to connect two inductors. Specifically, both the vertical piece 11 and the support piece 12 are L-shaped, with the long side of the L-shape perpendicular to the ground and the short sides facing each other. This provides space between the two vertical pieces 11 for connecting multiple support pieces 12, and also provides a position for installing the small inductor 3 between the two support pieces 12 at the same height. Furthermore, a U-shaped groove 111 is provided on the long side of the L-shape of the vertical piece 11. The U-shaped groove 111 saves materials and allows for inspection of any missing products after the clamp assembly is completed.

[0038] It should be noted that the inductor pin 31 is soldered to the "L"-shaped short side of the tray 12. At the same time, the "L"-shaped short side of the stand 11 is usually the position to be soldered to the circuit board. This is why the next layer tray 12 does not overlap with the stand 11 on the "L"-shaped short side, so as to avoid affecting the tray 12 during soldering.

[0039] It should also be noted that a fixture kit contains multiple vertical fixtures 1, which are arranged side by side on the same horizontal plane. The direction of the side arrangement is the width extension direction of the upright piece 11 or the support piece 12. This makes it possible to see multiple upright pieces 11 side by side when viewed from the side, and a single vertical fixture 1 connected to a small-sized inductor 3 when viewed from the front.

[0040] Reference Figure 5 , Figure 6 , Figure 7 and Figure 8The transverse clamp 2 includes a clamping piece 21 and a U-shaped spacer 22. In fact, the clamping piece 21 is approximately "U" shaped. Multiple small-sized inductors 3 are placed side by side on the clamping piece 21, and the direction of the side by side is the width extension direction of the vertical piece 11 or the support piece 12. Moreover, the number of small-sized inductors 3 on the clamping piece 21 corresponds one-to-one with the number of longitudinal clamps 1, and the size of the "U" shaped opening of the clamping piece 21 is determined by the small-sized inductors 3. Specifically, the clip 21 has the same number of wide holes 211 as the small-sized inductor 3. When the small-sized inductor 3 is placed on the clip 21, it is aligned with the wide holes 211. At the same time, the presence of multiple wide holes 211 also forms a snap-fit ​​crossbar 212 on the clip 21. The U-shaped spacer 22 is interlocked with the snap-fit ​​crossbar 212, so that the small-sized inductor 3 is snapped and restricted between the side wall of the clip 21 and the U-shaped spacer 22 or between two U-shaped spacers 22. The U-shaped spacer 22 is designed in a U-shape to provide a certain elasticity for tightening and to provide a heat dissipation gap. The wide holes 211 of the clip 21 serve three purposes: first, to save raw materials; second, to eliminate the impact of the Lenz effect on the inductance of the product; and third, to observe whether there are any empty spaces in the inductor product.

[0041] In addition, the opening of the U-shaped spacer 22 has a relative inward buckle 221. Due to the elasticity of the U-shaped spacer 22 and the presence of the inward buckle 221, the opening of the U-shaped spacer 22 needs to be slightly opened to place the snap-fit ​​crossbar 212 inside the U-shaped spacer 22, and then it is fixed by welding.

[0042] It should be noted that the longitudinal clamp 1 and the transverse clamp 2 are made of tin-plated copper sheet or copper alloy sheet, and the entire longitudinal clamp 1 is electrically conductive, while the transverse clamp 2 is not conductive.

[0043] An embodiment of the present invention discloses a method for forming parallel inductors using a clamp assembly, comprising the following steps:

[0044] S1. Use 2520, 2016 or other sizes of inductor products with an inductance tolerance of ±30% after preliminary electrical and visual inspection and sorting as components for assembly.

[0045] S2. Divide all inductors into inductance value ranges. Divide the inductance values ​​into 6 equally spaced ranges according to the center value range of the specifications. The center values ​​of the specifications of the 6 ranges from left to right are -30%~-20%, -20%~-10%, -10%~0, 0~10%, 10%~20%, and 20%~30%, and the corresponding numbers from left to right are 1-6.

[0046] S3. Take one inductor from interval 1, and correspondingly take one inductor from interval 6; take one inductor from interval 2, and correspondingly take one inductor from interval 5; take one inductor from interval 3, and correspondingly take one inductor from interval 4. Continue taking inductors symmetrically from the edge inwards until N inductors are taken (the number of inductors to be connected in parallel is usually even, and the purpose of designing an even number is to reduce the tolerance of the final product). If the edge intervals are exhausted, take inductors from the adjacent unexhausted intervals. If the adjacent intervals are also exhausted, remove one of the outermost intervals and start taking inductors again from the first one according to the rules.

[0047] S4. Using N inductors as a group in parallel, based on the R of N inductors... DC The DC resistance value is used for screening, R DC The N / 2 inductors with the lowest (DC resistance) values ​​are arranged in a horizontal row, clamped together by clip 21 and U-shaped spacer 22. DC The N / 2 inductors with the highest (DC resistance) values ​​are arranged in a horizontal row and clamped together by another set of clips 21 and U-shaped spacers 22.

[0048] S5, R fixed by transverse clamp 2 DC The low-value inductor pin 31 is connected to the tray 12 of the lower layer in the vertical clamp 1, and R is fixed by another set of transverse clamps 2. DC The high-value inductor pin 31 is connected to the tray 12 of the upper layer in the longitudinal clamp 1.

[0049] It should be noted that in step S5, since the longitudinal clamp 1 and the transverse clamp 2 themselves have a certain resistance, the part with the lower DC resistance value is placed on the next layer, that is, closer to the end of the circuit, so as to balance the resistance and make the resistance value of the entire parallel inductor more uniform. At the same time, when multiple small-sized inductors 3 are connected in parallel, several inductors are clamped with the clamping piece 21 of the transverse clamp 2, and then the inductor pins 31 of the small-sized inductors 3 on the clamping piece 21 are soldered to the support piece 12.

[0050] Taking an inductor with a design sensitivity of 125nH as an example:

[0051] S1, an inductor with a size of 2520 and an inductance of 1.0μH (R DC The raw materials are 38mΩ (average saturation current 4.5A). The product sorting has a relative tolerance of 1.0μH ±30%, and the product distribution is approximately normal.

[0052] S2. Divide all inductors into inductance value ranges, which are then divided into 6 equidistant ranges based on the center value range of the specification (numbered 1-6 from left to right for the center value of the specification: -30%~-20%, -20%~-10%, -10%~0%, 0~10%, 10%~20%, 20%~30%). Specifically, the inductance value ranges are: Zone 1 (0.70-0.79μH), Zone 2 (0.80-0.89μH), Zone 3 (0.90-0.99μH), Zone 4 (1.00-1.09μH), Zone 5 (1.10-1.19μH), and Zone 6 (1.20-1.29μH).

[0053] S3. Take one stone from interval 1, then take one stone from interval 6, then one stone from interval 2, then one stone from interval 5, then one stone from interval 3, then one stone from interval 4, then one stone from interval 1 again, then one stone from interval 6, until you have 8 stones. Then, based on the R of 8 stones... DC The (DC resistance) value is used for screening, R DC The four with lower values ​​are arranged in a horizontal row, clamped by clip 21 and U-shaped spacer 22, and placed on the lower layer of tray 12 in the vertical clamp 1. DC The four with higher values ​​are placed on the upper layer of the tray 12 in the longitudinal fixture 1;

[0054] S4. Use a 2-unit longitudinal clamp 1 and a 4-unit transverse clamp 2. The clamps are made of 0.2mm copper-iron-phosphorus alloy. The longitudinal clamp 1 is tin-plated, while the transverse clamp 2 is not tin-plated.

[0055] S5. Assemble the product and reflow it at 260℃.

[0056] The final product sensitivity value was 124nH, with a sensitivity tolerance of -5% to 3%, and R... DC The average current is 4.8mΩ, and the average saturation current is 36A.

[0057] The differences in tolerances between random material selection and material selection for other different design specifications are shown in Table 1.

[0058] Table 1 Parallel Inductance Tolerances (based on raw materials with a tolerance of 1.0μH ± 30%)

[0059]

[0060] As can be seen from Table 1, the material tolerance using this method is basically within ±20%, which is one level smaller than the tolerance of a single component.

[0061] The above are all preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Identical components are represented by the same reference numerals. It should be noted that the terms "front," "rear," "left," "right," "up," and "down" used in the following description refer to directions in the accompanying drawings, while the terms "inner" and "outer" refer to directions toward or away from the geometric center of a specific component. Therefore, all equivalent changes made to the structure, shape, and principle of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A parallel inductor clamp kit, characterized in that, The system includes a longitudinal clamp (1), which includes two symmetrically arranged upright pieces (11) and at least four support pieces (12). The number of support pieces (12) is even, and the multiple support pieces (12) are evenly distributed on two different upright pieces (11). The support pieces (12) on each upright piece (11) are fixedly installed on the upright piece (11) at intervals, and the upright pieces (11) and support pieces (12) are aligned. The two support pieces (12) on the same horizontal plane are connected to a small inductor (3), and the inductor pins (31) of the small inductor (3) are respectively connected to the two side-by-side support pieces (12).

2. The parallel inductor clamp kit according to claim 1, characterized in that, Both the stand plate (11) and the support plate (12) are L-shaped to support the small-sized inductor (3).

3. A parallel inductor clamp kit according to claim 1, characterized in that, The stand (11) has a U-shaped groove (111) for observing the small inductor (3) on the support plate (12).

4. A parallel inductor clamp kit according to claim 1, characterized in that, It also includes a transverse clamp (2), which includes a clamping piece (21). The longitudinal clamp (1) is provided with multiple clamps arranged side by side, and small-sized inductors (3) on the longitudinal clamp (1) are all arranged on the clamping piece (21).

5. A parallel inductor clamp kit according to claim 4, characterized in that, The longitudinal clamp (1) is arranged side by side along the direction of the width of the upright piece (11), and the clamp piece (21) extends along the direction of the longitudinal clamp (1) to accommodate a plurality of small-sized inductors (3) within the clamp piece (21).

6. A parallel inductor clamp kit according to claim 4, characterized in that, The clip (21) has the same number of wide holes (211) as the small-sized inductor (3) to provide heat dissipation gaps and to observe whether there are any inductor vacancies.

7. A parallel inductor clamp kit according to claim 6, characterized in that, The transverse clamp (2) further includes a U-shaped spacer (22), and a plurality of the plurality of wide holes (211) are present such that a snap-fit ​​crossbar (212) is formed on the clamp (21), the U-shaped spacer engaging with the snap-fit ​​crossbar (212) to separate the plurality of small-sized inductors (3).

8. A parallel inductor clamp kit according to claim 7, characterized in that, The longitudinal clamp (1) is energized, while the transverse clamp (2) is not energized.

9. A method for forming parallel inductors using the parallel inductor fixture assembly as described in claim 8, characterized in that, Includes the following steps: S1. Small-sized inductors (3) with an inductance tolerance of ±30% after preliminary electrical and appearance inspection and sorting are used as components for assembly; S2. Divide all inductors into inductance value ranges, and divide the inductor values ​​into 6 equally spaced ranges according to the center value range of the specifications; S3. Take one inductor from interval 1, and correspondingly take one inductor from interval 6; take one inductor from interval 2, and correspondingly take one inductor from interval 5; take one inductor from interval 3, and correspondingly take one inductor from interval 4. Continue taking inductors symmetrically from the edge inwards until N inductors are taken. If the edge intervals are exhausted, take inductors from the adjacent unexhausted intervals. If the adjacent intervals are also exhausted, remove the outermost interval and start taking inductors again from the first one according to the rules. S4. Take N inductors as a group of parallel inductors, and sieve them according to the DC resistance value of N inductors. The N / 2 inductors with low DC resistance values ​​are placed in a horizontal row and clamped by the clip (21) and the U-shaped spacer (22). The N / 2 inductors with high DC resistance values ​​are also placed in a horizontal row and clamped by another set of clips (21) and the U-shaped spacer (22). S5. The inductor pin (31) with low DC resistance value fixed by the transverse clamp (2) is connected to the tray (12) of the lower layer in the longitudinal clamp (1), and the inductor pin (31) with high DC resistance value fixed by another set of transverse clamps (2) is connected to the tray (12) of the upper layer in the longitudinal clamp (1).

10. The method for forming parallel inductors in a parallel inductor fixture set according to claim 9, characterized in that, In step S2, the specification center values ​​of the 6 intervals are -30%~-20%, -20%~-10%, -10%~0, 0~10%, 10%~20%, and 20%~30% from left to right, and are numbered 1-6 from left to right.

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