A winding coil manufacturing process and structure with good insulation effect and high precision

Abstract

This invention relates to a manufacturing process and structure for a winding coil with good insulation and high precision, belonging to the field of power supply accessory technology. The manufacturing process includes: preparing a high-temperature resistant, heat-fusible FR-4 material substrate; forming a winding coil receiving cavity by CNC machining a single-layer substrate, or forming a substrate by stacking multiple layers of FR-4 plates and simultaneously machining the receiving cavity and winding coil hole plug by CNC machining; installing the winding coil in the receiving cavity; covering the winding coil pin ends with Teflon sleeves or wrapping them with high-temperature resistant tin foil to form an insulating layer; setting FR-4 / ceramic / aluminum panels on the upper and lower surfaces of the substrate, and stacking FR-4 fusible panels according to the thickness requirements of the finished product; after fixing the assembly, performing hot pressing fusion to integrate the materials of each layer; and performing CNC precision machining on the winding holes after cooling. This winding coil manufacturing process and structure utilizes FR-4 material to wrap the winding coil internally, resulting in good voltage resistance and insulation performance. The thickness of the finished product can be customized according to the application scenario or different equipment, and the minimum encapsulation thickness is 0.01 mm thick copper wire or copper sheet.

Description

Technical Field

[0001] This invention relates to the field of power supply accessories technology, specifically to a winding coil manufacturing process and structure with good insulation and high precision. Background Technology

[0002] The winding coils in motors, inductors, voltage regulators, and transformers are one of the main electrical components. Winding coils are coil structures made of wires, and their function is to transfer and convert energy through the principle of electromagnetic induction. In transformers, winding coils transmit electrical energy from one circuit to another through electromagnetic induction. In motors, winding coils convert electrical energy into mechanical energy through the interaction of the magnetic field generated by the current and mechanical energy. In voltage regulators and some types of transformers, winding coils are used to regulate voltage and ensure the stability of the output voltage. Winding coils are an indispensable component of electrical equipment, and their performance directly affects the overall operation and safety of the equipment.

[0003] Traditional winding coil manufacturing processes have limitations in several aspects, making it difficult to meet the demands of modern electronic devices for high performance, high reliability, and diverse application scenarios. First, the insulation treatment of traditional winding coils often involves simply wrapping or impregnating them with insulating materials, which can be damaged during use, leading to a decrease in insulation performance and affecting the safety and stability of the equipment. Second, the manufacturing process of traditional winding coils often results in the pins being completely enclosed inside, which limits the application of winding coils in certain specific scenarios. Finally, the processing of traditional winding coils often involves manual or simple mechanical processing methods, which suffer from low processing accuracy and poor dimensional consistency. The processing of winding holes is no exception; traditional processes often fail to guarantee the accuracy and dimensional consistency of winding holes, which affects the electromagnetic performance and efficiency of the winding coils.

[0004] Therefore, a winding coil manufacturing process and structure with good insulation and high precision are proposed to solve the technical problems of poor safety and stability of the aforementioned winding coils. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a winding coil manufacturing process and structure with good insulation and high precision, which has the advantages of high safety and stability of the winding coil, and solves the problem that damage during use leads to a decrease in insulation performance, affecting safety and stability.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a winding coil manufacturing process with good insulation effect and high precision, S1, substrate preparation: prepare a high temperature resistant and heat-fusible FR-4 material substrate, use a single-layer substrate to form a winding coil receiving cavity by CNC machining, or use multi-layer FR-4 plates stacked to form a substrate and simultaneously machine the receiving cavity and winding coil hole plug by CNC machining.

[0007] S2. Winding installation: Install the winding coil in the receiving cavity. When using a multilayer substrate process, the hole plug needs to be inserted into the winding coil hole.

[0008] S3, Pin treatment: Teflon sleeves or high-temperature resistant tin foil are put on the winding coil pin ends to form an isolation layer (if the pin length needs to be reserved by 2cm, then the length of the isolation layer is also set to 2cm).

[0009] S4. Panel Assembly: FR-4 / ceramic / aluminum panels are set on the upper and lower surfaces of the substrate, and FR-4 soluble panels are stacked according to the thickness requirements of the finished product.

[0010] S5. Hot pressing curing: After the assembly is fixed with screws or rivets, hot pressing is performed to fuse the materials of each layer together.

[0011] S6, CNC precision finishing: After cooling, the shape and holes of the winding are precision machined by CNC to form the finished product.

[0012] Furthermore, in step S1, the cross-sectional shape of the plug matches the hole of the winding coil, and its height is not less than the thickness of the winding coil. The plug is fixed to the hole of the winding coil by interference fit or screw.

[0013] Furthermore, the winding coil in step S3 is made of copper or aluminum with high conductivity and low loss to improve the efficiency of the winding coil.

[0014] Furthermore, during the pin processing in step S3, the wrapping of the Teflon sleeve or high-temperature resistant tin foil must be uniform and tight to prevent the pin ends from failing to isolate due to loosening or external factors during use.

[0015] Furthermore, in step S4, the thickness of the FR-4 / ceramic / aluminum panel is 0.05-0.15cm. When using the FR-4 / ceramic or aluminum panel, its surface is processed with heat dissipation fins or model markings (S-PH / S-1H). During the panel assembly process, the selection of the FR-4 / ceramic / aluminum panel needs to take into account the operating environment and heat dissipation performance of the winding coil to ensure that the winding coil can operate stably under various conditions.

[0016] Furthermore, in step S5, the hot-pressing fusion temperature is 180-220℃, the pressure is 5-8MPa, the hot-pressing fusion duration is 30-60 minutes, and the hot-pressing fusion needs to be carried out in an inert gas protective environment.

[0017] Furthermore, in step S4, the number N of soluble panels stacked satisfies: N = (T_finished product - T_substrate - 2 × T_panel) / 0.05

[0018] (T is the unit of thickness in cm, and the thickness of a single layer of soluble panel is 0.05 cm).

[0019] This application also proposes a winding coil with good insulation effect and high precision, which is manufactured using the winding coil manufacturing process with good insulation effect and high precision as described above, including a winding coil, an FR-4 insulating shell, a multilayer substrate, a heat dissipation panel, and a soluble panel.

[0020] The winding coil has a hole and a pin passes through it;

[0021] The FR-4 insulating shell is wrapped around the winding coil by hot pressing and fusion, and the interior of the FR-4 insulating shell is fitted with a plug.

[0022] The multilayer substrate is composed of 2-4 layers of FR-4 substrate laminated together;

[0023] The heat dissipation panel covers the upper and lower surfaces of the multilayer substrate.

[0024] The soluble panel is stacked on the outside of the heat dissipation panel.

[0025] Furthermore, the winding coil is made of either copper or aluminum, and the surface of the winding coil is coated with insulating varnish. The wall thickness of the FR-4 insulating shell is 1 / 5 to 1 / 3 of the diameter of the winding coil.

[0026] Furthermore, the heat dissipation panel is made of any one of FR-4, ceramic, or aluminum.

[0027] Compared with the prior art, the technical solution of this application has the following beneficial effects:

[0028] 1. The manufacturing process and structure of this high-precision winding coil with good insulation utilize FR-4 material to wrap the winding coil internally, providing excellent withstand voltage insulation performance. The thickness of the finished product can be customized according to the application scenario or different equipment, with a minimum encapsulation thickness of 0.01MM copper wire or copper sheet. Moreover, the coil has better sealing performance, with waterproof and scratch-resistant properties against the insulating paint covering the coil surface, resulting in higher stability. This makes the inside of the coil less susceptible to corrosion from external factors such as moisture and dust, further improving the service life of the coil winding.

[0029] 2. The manufacturing process and structure of this winding coil, which has good insulation and high precision, allows the pins of the winding coil to be exposed, effectively improving the application scenarios of the finished product.

[0030] 3. The winding coil manufacturing process and structure, which features good insulation and high precision, utilize CNC machining to process the winding holes, resulting in higher precision, improved electromagnetic performance and efficiency, and reduced problems caused by machining errors. Attached Figure Description

[0031] Figure 1 This is a flowchart illustrating the manufacturing process of a winding coil with good insulation and high precision according to the present invention.

[0032] Figure 2 This is a schematic diagram of the structure of a winding coil with good insulation and high precision according to the present invention;

[0033] Figure 3 This is a schematic diagram of the winding coil structure in this invention;

[0034] Figure 4 This is an overall schematic diagram of a winding coil with good insulation and high precision according to the present invention;

[0035] Figure 5 This is a schematic diagram of the connection structure of the multilayer substrate, heat dissipation panel, and soluble panel in this invention.

[0036] In the diagram: 100, winding coil; 200, FR-4 insulating housing; 300, multilayer substrate; 400, heat dissipation panel; 500, soluble panel; 101, hole; 102, pin; 201, hole plug. Detailed Implementation

[0037] 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.

[0038] Example 1:

[0039] Please see Figure 1-5 The manufacturing process of a winding coil with good insulation and high precision in this embodiment includes the following steps:

[0040] S1. Substrate preparation: Prepare a high-temperature resistant and heat-fusible FR-4 material substrate, and use a single-layer substrate to form a winding coil receiving cavity through CNC machining;

[0041] S2. Winding installation: Install the winding coil inside the receiving cavity;

[0042] S3, Pin treatment: Teflon sleeves or high-temperature resistant tin foil are put on the winding coil pin ends to form an isolation layer (if the pin length needs to be reserved by 2cm, then the length of the isolation layer is also set to 2cm).

[0043] S4. Panel Assembly: FR-4 / ceramic / aluminum panels are set on the upper and lower surfaces of the substrate, and FR-4 soluble panels are stacked according to the thickness requirements of the finished product.

[0044] S5. Hot pressing curing: After the assembly is fixed with screws or rivets, hot pressing is performed to fuse the materials of each layer together.

[0045] S6, CNC precision finishing: After cooling, the shape and holes of the winding are precision machined by CNC to form the finished product.

[0046] In this embodiment, the cross-sectional shape of the plug in step S1 matches the hole of the winding coil, and its height is not less than the thickness of the winding coil. The plug is fixed to the hole of the winding coil by interference fit or screw.

[0047] The winding coil in step S3 is made of copper or aluminum with high conductivity and low loss in order to improve the efficiency of the winding coil.

[0048] Preferably, the winding coil in step S3 is made of copper material with high conductivity and low loss.

[0049] During the pin processing in step S3, the wrapping of the Teflon sleeve or high-temperature resistant tin foil must be uniform and tight to prevent the pin end from failing to isolate due to loosening or external factors during use.

[0050] It should be noted that the leads of the winding coil are exposed after being fitted with Teflon sleeves or wrapped with high-temperature resistant tin foil to form an insulating layer. This design makes the winding coil more applicable in different application scenarios, especially in scenarios where the leads need to be exposed to connect to external circuits.

[0051] Furthermore, by sleeved with Teflon tubing or wrapped with high-temperature resistant tin foil to form an isolation layer at the pin end, not only is the pin protected, but insulation and safety during soldering are also ensured. After the isolation layer is processed, the exposed part of the pin can be soldered. During soldering, the isolation layer can prevent the heat generated during the soldering process from damaging the pin, while maintaining good insulation between the pin and the external circuit. This step is to isolate the exposed pin. After encapsulation, the isolation layer can be quickly formed for the processing of the exposed pin.

[0052] In step S4, the thickness of the FR-4 / ceramic / aluminum panel is 0.05-0.15cm. When using FR-4 / ceramic or aluminum panels, their surfaces are processed with heat dissipation fins or model markings (S-PH / S-1H). During panel assembly, the selection of FR-4 / ceramic / aluminum panels must take into account the operating environment and heat dissipation performance of the winding coil to ensure that the winding coil can operate stably under various conditions.

[0053] It should be noted that, especially when using FR-4 / ceramic or aluminum panels, the surface is processed with heat dissipation fins, which further increases the heat dissipation area and improves heat dissipation efficiency.

[0054] Preferably, the thickness of the FR-4 / ceramic / aluminum panel is 0.05cm.

[0055] The hot-pressing fusion temperature in step S5 is 180-220℃, the pressure is 5-8MPa, the hot-pressing fusion duration is 30-60 minutes, and the hot-pressing fusion needs to be carried out in an inert gas protective environment.

[0056] Preferably, the hot-pressing fusion temperature is 180°C, the pressure is 5 MPa, and the hot-pressing fusion duration is 30 minutes.

[0057] In step S4, the number N of soluble panels stacked satisfies:

[0058] N = (T_finished product - T_substrate - 2 × T_panel) / 0.05

[0059] (T is the unit of thickness in cm, and the thickness of a single layer of soluble panel is 0.05 cm).

[0060] Understandably, the number of soluble panels stacked can be flexibly adjusted according to the thickness requirements of the finished product. This design makes the structure of the winding coil more flexible and can meet the needs of different thicknesses and sizes.

[0061] The winding coil with good insulation and high precision in this embodiment is manufactured using the same winding coil manufacturing process as in Embodiment 1, and includes a winding coil 100, an FR-4 insulating shell 200, a multilayer substrate 300, a heat dissipation panel 400, and a soluble panel 500.

[0062] A hole 101 is provided on the winding coil 100, and a pin 102 is passed through the winding coil 100;

[0063] The FR-4 insulating shell 200 is wrapped around the winding coil 100 by hot pressing and fusion, and the interior of the FR-4 insulating shell 200 is fitted with a plug 201;

[0064] The multilayer substrate 300 is composed of 2-4 layers of FR-4 substrate laminated together;

[0065] The heat dissipation panel 400 covers the upper and lower surfaces of the multilayer substrate 300.

[0066] The soluble panel 500 is stacked on the outside of the heat dissipation panel 400.

[0067] The winding coil 100 is made of either copper or aluminum, and the surface of the winding coil 100 is coated with insulating varnish. The insulating varnish further enhances the insulation effect, prevents current leakage and short circuit, and improves the overall stability of the winding coil. The wall thickness of the FR-4 insulating shell 200 is 1 / 5 to 1 / 3 of the diameter of the winding coil 100.

[0068] The heat dissipation panel 400 is made of any one of the following materials: FR-4, ceramic, or aluminum.

[0069] It should be noted that the heat dissipation panel 400 is made of FR-4, ceramic or aluminum, which have good thermal conductivity and help to dissipate heat quickly and keep the temperature of the winding coil stable during operation.

[0070] Preferably, the wall thickness of the FR-4 insulating housing 200 is 1 / 5 of the diameter of the winding coil 100, and the heat dissipation panel 400 is made of FR-4.

[0071] When applying, prepare at least two panels with the same shape as the substrate. The panels can be made of FR-4 material, ceramic material, or aluminum material. The two panels are set on the top and bottom surfaces of the substrate. If ceramic or aluminum material panels are used, they can be used to conduct heat generated when the winding coil is working. Another function of the panels is to fix the winding coil installed in the receiving cavity.

[0072] Calculate the thickness of the finished product, prepare several fusible panels with the same shape as the substrate, and place the fusible panels one by one on the upper surface of the panel. The fusible panels are made of FR-4 material and can be fused with the substrate after being heat-fused. If the required thickness of the finished product is 0.6CM, the back end of the substrate is 0.3CM, the thickness of the panel is 0.1CM, and the thickness of the fusible panel is set to 0.05CM, then four fusible panels need to be set, and so on.

[0073] Each panel is fixed to the substrate through the pre-set fixing holes using screws or rivets, and then placed into a hot melt machine for fusion.

[0074] After cooling, the winding coils on the substrate are CNC machined to form the finished product.

[0075] The winding coil 100 completes energy transmission and conversion through the principle of electromagnetic induction, realizing the increase or decrease of voltage. The FR-4 insulating shell 200 and the insulating varnish on the surface of the winding coil together provide excellent insulation performance to prevent current leakage and short circuit. The heat dissipation panel 400 uses a material with good thermal conductivity to quickly dissipate heat and keep the temperature of the winding coil stable during operation. At the same time, the tight bonding of each layer of materials and the integrated structure improve the overall stability and service life of the winding coil. The exposed design of the pin 102 makes the winding coil more applicable in different application scenarios, especially in scenarios where the pin 102 needs to be exposed to connect to external circuits.

[0076] Example 2:

[0077] The basic content is the same as in Example 1, except that:

[0078] Please see Figure 1-5 The manufacturing process of a winding coil with good insulation and high precision in this embodiment includes the following steps:

[0079] S1. Substrate preparation: Prepare a high-temperature resistant and heat-fusible substrate (FR-4 material). The substrate is formed by stacking multiple high-temperature resistant plates. Several receiving cavities adapted to the winding coil are machined by CNC. The winding coil hole plugs are also machined.

[0080] S2. Winding installation: Install the winding coils one by one into the receiving cavity, and then install the hole plugs into the holes of the winding coils;

[0081] S3, Pin treatment: Teflon sleeves or high-temperature resistant tin foil are put on the winding coil pin ends to form an isolation layer (if the pin length needs to be reserved by 2cm, then the length of the isolation layer is also set to 2cm).

[0082] S4. Panel Assembly: FR-4 / ceramic / aluminum panels are set on the upper and lower surfaces of the substrate, and FR-4 soluble panels are stacked according to the thickness requirements of the finished product.

[0083] S5. Hot pressing curing: After the assembly is fixed with screws or rivets, hot pressing is performed to fuse the materials of each layer together.

[0084] S6, CNC precision finishing: After cooling, the shape and holes of the winding are precision machined by CNC to form the finished product.

[0085] In this embodiment, the cross-sectional shape of the plug in step S1 matches the hole of the winding coil, and its height is not less than the thickness of the winding coil. The plug is fixed to the hole of the winding coil by interference fit or screw.

[0086] The winding coil in step S3 is made of copper or aluminum with high conductivity and low loss in order to improve the efficiency of the winding coil.

[0087] Preferably, the winding coil in step S3 is made of aluminum material with high conductivity and low loss.

[0088] During the pin processing in step S3, the wrapping of the Teflon sleeve or high-temperature resistant tin foil must be uniform and tight to prevent the pin end from failing to isolate due to loosening or external factors during use.

[0089] It should be noted that the leads of the winding coil are exposed after being fitted with Teflon sleeves or wrapped with high-temperature resistant tin foil to form an insulating layer. This design makes the winding coil more applicable in different application scenarios, especially in scenarios where the leads need to be exposed to connect to external circuits.

[0090] Furthermore, by sleeved with Teflon tubing or wrapped with high-temperature resistant tin foil to form an isolation layer at the pin end, not only is the pin protected, but insulation and safety during soldering are also ensured. After the isolation layer is processed, the exposed part of the pin can be soldered. During soldering, the isolation layer can prevent the heat generated during the soldering process from damaging the pin, while maintaining good insulation between the pin and the external circuit. This step is to isolate the exposed pin. After encapsulation, the isolation layer can be quickly formed for the processing of the exposed pin.

[0091] In step S4, the thickness of the FR-4 / ceramic / aluminum panel is 0.05-0.15cm. When using FR-4 / ceramic or aluminum panels, their surfaces are processed with heat dissipation fins or model markings (S-PH / S-1H). During panel assembly, the selection of FR-4 / ceramic / aluminum panels must take into account the operating environment and heat dissipation performance of the winding coil to ensure that the winding coil can operate stably under various conditions.

[0092] Preferably, the thickness of the FR-4 / ceramic / aluminum panel is 0.1cm.

[0093] The hot-pressing fusion temperature in step S5 is 180-220℃, the pressure is 5-8MPa, the hot-pressing fusion duration is 30-60 minutes, and the hot-pressing fusion needs to be carried out in an inert gas protective environment.

[0094] Preferably, the hot-pressing fusion temperature is 200°C, the pressure is 6.5 MPa, and the hot-pressing fusion duration is 45 minutes.

[0095] In step S4, the number N of soluble panels stacked satisfies:

[0096] N = (T_finished product - T_substrate - 2 × T_panel) / 0.05

[0097] (T is the unit of thickness in cm, and the thickness of a single layer of soluble panel is 0.05 cm).

[0098] Understandably, the number of soluble panels stacked can be flexibly adjusted according to the thickness requirements of the finished product. This design makes the structure of the winding coil more flexible and can meet the needs of different thicknesses and sizes.

[0099] The winding coil with good insulation and high precision in this embodiment is manufactured using the winding coil manufacturing process with good insulation and high precision as in Embodiment 2, and includes a winding coil 100, an FR-4 insulating shell 200, a multilayer substrate 300, a heat dissipation panel 400, and a soluble panel 500.

[0100] A hole 101 is provided on the winding coil 100, and a pin 102 is passed through the winding coil 100;

[0101] The FR-4 insulating shell 200 is wrapped around the winding coil 100 by hot pressing and fusion, and the interior of the FR-4 insulating shell 200 is fitted with a plug 201;

[0102] The multilayer substrate 300 is composed of 2-4 layers of FR-4 substrate laminated together;

[0103] The heat dissipation panel 400 covers the upper and lower surfaces of the multilayer substrate 300.

[0104] The soluble panel 500 is stacked on the outside of the heat dissipation panel 400.

[0105] The winding coil 100 is made of either copper or aluminum, and the surface of the winding coil 100 is coated with insulating varnish. The insulating varnish further enhances the insulation effect, prevents current leakage and short circuit, and improves the overall stability of the winding coil. The wall thickness of the FR-4 insulating shell 200 is 1 / 5 to 1 / 3 of the diameter of the winding coil 100.

[0106] The heat dissipation panel 400 is made of any one of the following materials: FR-4, ceramic, or aluminum.

[0107] It should be noted that the heat dissipation panel 400 is made of FR-4, ceramic or aluminum, which have good thermal conductivity and help to dissipate heat quickly and keep the temperature of the winding coil stable during operation.

[0108] Preferably, the wall thickness of the FR-4 insulating housing 200 is 1 / 4 of the diameter of the winding coil 100, and the heat dissipation panel 400 is made of FR-4.

[0109] When applying, prepare a high-temperature resistant and heat-fusible substrate (FR-4 material). The substrate is formed by stacking multiple high-temperature resistant plates. Several receiving cavities adapted to the winding coil are machined by CNC. The winding coil hole plug is also machined.

[0110] Install the winding coils one by one into the receiving cavity, and then install the hole plugs into the holes of the winding coils;

[0111] Prepare a suitable Teflon sleeve or high-temperature resistant tin foil with the specified winding coil pin length. Place the Teflon sleeve on the pin end of the winding coil or wrap the high-temperature resistant tin foil around the pin of the reserved length to form an isolation effect.

[0112] Prepare at least two panels with the same shape as the substrate. The panels can be made of FR-4 material, ceramic material, or aluminum material. The two panels are set on the top and bottom surfaces of the substrate. If ceramic or aluminum material panels are used, they can be used to conduct heat generated when the winding coil is working. Another function of the panels is to fix the winding coil installed in the receiving cavity.

[0113] Calculate the thickness of the finished product, prepare several fusible panels with the same shape as the substrate, and place the fusible panels one by one on the upper surface of the panel. The fusible panels are made of FR-4 material and can be fused with the substrate after being heat-fused. If the required thickness of the finished product is 0.6CM, the back end of the substrate is 0.3CM, the thickness of the panel is 0.1CM, and the thickness of the fusible panel is set to 0.05CM, then four fusible panels need to be set, and so on.

[0114] Each panel is fixed to the substrate through the pre-set fixing holes using screws or rivets, and then placed into a hot melt machine for fusion.

[0115] After cooling, the winding coils on the substrate are CNC machined to form the finished product.

[0116] The winding coil 100 completes energy transmission and conversion through the principle of electromagnetic induction, realizing the increase or decrease of voltage. The FR-4 insulating shell 200 and the insulating varnish on the surface of the winding coil together provide excellent insulation performance to prevent current leakage and short circuit. The heat dissipation panel 400 uses a material with good thermal conductivity to quickly dissipate heat and keep the temperature of the winding coil stable during operation. At the same time, the tight bonding of each layer of materials and the integrated structure improve the overall stability and service life of the winding coil. The exposed design of the pin 102 makes the winding coil more applicable in different application scenarios, especially in scenarios where the pin 102 needs to be exposed to connect to external circuits.

[0117] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0118] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention.

Claims

1. A manufacturing process for winding coils with good insulation and high precision, characterized in that: Includes the following steps: S1. Substrate preparation: Prepare a high-temperature resistant and heat-fusible FR-4 material substrate. A single-layer substrate is used to form a winding coil receiving cavity through CNC machining, or multiple layers of FR-4 plates are stacked to form a substrate and the receiving cavity and winding coil hole plug are machined simultaneously by CNC. S2. Winding installation: Install the winding coil in the receiving cavity. When using a multilayer substrate process, the hole plug needs to be inserted into the winding coil hole. S3. Pin treatment: Teflon sleeves or high-temperature resistant tin foil are put on the winding coil pin ends to form an isolation layer (if the pin length needs to be reserved by 2cm, then the length of the isolation layer is also set to 2cm). S4. Panel Assembly: FR-4 / ceramic / aluminum panels are set on the upper and lower surfaces of the substrate, and FR-4 soluble panels are stacked according to the thickness requirements of the finished product. S5. Hot pressing curing: After the assembly is fixed with screws or rivets, hot pressing is performed to fuse the materials of each layer together. S6, CNC precision finishing: After cooling, the shape and holes of the winding are precision machined by CNC to form the finished product.

2. The manufacturing process of a winding coil with good insulation effect and high precision according to claim 1, characterized in that: In step S1, the cross-sectional shape of the plug matches the hole of the winding coil, and its height is not less than the thickness of the winding coil. The plug is fixed to the hole of the winding coil by interference fit or screw.

3. The manufacturing process for a winding coil with good insulation and high precision according to claim 1, characterized in that: The winding coil in step S3 is made of copper or aluminum with high conductivity and low loss to improve the efficiency of the winding coil.

4. The winding coil manufacturing process with good insulation effect and high precision according to claim 1, characterized in that: During the pin processing in step S3, the wrapping of the Teflon sleeve or high-temperature resistant tin foil must be uniform and tight to prevent the pin end from failing to isolate due to loosening or external factors during use.

5. The manufacturing process of a winding coil with good insulation effect and high precision according to claim 1, characterized in that: In step S4, the thickness of the FR-4 / ceramic / aluminum panel is 0.05-0.15cm. When using FR-4 / ceramic or aluminum panels, their surfaces are processed with heat dissipation fins or model markings (S-PH / S-1H). During panel assembly, the selection of FR-4 / ceramic / aluminum panels must take into account the operating environment and heat dissipation performance of the winding coil to ensure that the winding coil can operate stably under various conditions.

6. The manufacturing process for a winding coil with good insulation and high precision according to claim 1, characterized in that: The hot-pressing fusion temperature in step S5 is 180-220℃, the pressure is 5-8MPa, the hot-pressing fusion duration is 30-60 minutes, and the hot-pressing fusion needs to be carried out in an inert gas protective environment.

7. The manufacturing process for a winding coil with good insulation and high precision according to claim 1, characterized in that: In step S4, the number N of soluble panels stacked satisfies: N = (T finished product - T substrate - 2 × T panel) / 0.05 (T is the thickness unit cm, and the thickness of a single layer of soluble panel is 0.05 cm).

8. A winding coil structure with good insulation effect and high precision, manufactured by any one of the processes of claims 1-7, characterized in that: It includes a winding coil (100), an FR-4 insulating shell (200), a multilayer substrate (300), a heat dissipation panel (400), and a soluble panel (500). The winding coil (100) has a hole (101) and a pin (102) passes through the winding coil (100). The FR-4 insulating shell (200) is wrapped with the winding coil (100) by hot pressing and fusion, and the interior of the FR-4 insulating shell (200) is fitted with a plug (201). The multilayer substrate (300) is composed of 2-4 layers of FR-4 substrate laminated together; The heat dissipation panel (400) covers the upper and lower surfaces of the substrate multilayer substrate (300); The soluble panel (500) is stacked on the outside of the heat dissipation panel (400).

9. The winding coil structure with good insulation effect and high precision according to claim 8, characterized in that: The winding coil (100) is made of either copper or aluminum, and the surface of the winding coil (100) is coated with insulating varnish. The wall thickness of the FR-4 insulating shell (200) is 1 / 5 to 1 / 3 of the diameter of the winding coil (100).

10. A winding coil structure with good insulation effect and high precision according to claim 8, characterized in that: The heat dissipation panel (400) is made of any one of FR-4, ceramic, or aluminum.

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