Coil element

Abstract

The utility model relates to the technical field of magnetic devices, and discloses a coil element which comprises a first magnetic core, a second magnetic core, a coil composed of at least one wire and a metal terminal, the first magnetic core comprises a middle column and end polar plates connected to the two ends of the middle column, the coil is wound on the middle column according to a preset rule, and the metal terminal is arranged on the middle column. Each wire is provided with a metal lead wire body, the second magnetic core is arranged on one side of the first magnetic core and is connected with the end polar plate, the side, away from the middle column, of the end polar plate is connected with the metal terminals which are oppositely arranged at certain intervals, one side of each metal terminal is integrally connected with a first functional pin, and the other side of each metal terminal is integrally connected with a second functional pin. The first functional pin is provided with a welding part, and the metal lead wire body crosses the end pole plate and then is electrically connected with the welding part of the first functional pin. The structural reliability of the coil element is improved, and the comprehensive performance of the coil element is optimized.

Description

Technical Field

[0001] The present application relates to the technical field of magnetic devices, and in particular to a coil element. Background Art

[0002] Coil components are usually widely used in the automotive field to deal with problems related to electromagnetic compatibility and power supply filtering. They help reduce common-mode noise in power supply lines and ensure the normal operation of electronic equipment in automobiles. They are also effectively reduced by using them in automotive cables and signal lines to help automotive systems meet electromagnetic compatibility standards. Automobiles have a long service life. The national "Motor Vehicle Mandatory Scrapping Standard" stipulates that the mandatory scrapping life of passenger cars is more than 500,000 kilometers, and the safety and reliability requirements are strict. In the actual operating conditions of the automobile, the working environment is harsh, accompanied by mechanical vibration, uncertain mechanical shock, operating temperature in the range of -50℃ to +150℃, and various humidity conditions, salt spray conditions and altitudes, etc., which bring great challenges to the reliability of coil components in related technologies. In order to better meet the requirements of the vehicle environment for coil components, it is necessary to design a coil component with excellent reliability. Utility Model Content

[0003] In view of this, the present application provides a coil element to solve the above problems.

[0004] To achieve the above objectives, the technical solutions adopted are:

[0005] A coil element comprises a first magnetic core, a second magnetic core, a coil consisting of at least one conductive wire and a metal terminal, wherein the first magnetic core comprises a middle column and end plates connected to both ends of the middle column, the coil is wound on the middle column according to a preset rule, each conductive wire has a metal lead body, the second magnetic core is arranged on one side of the first magnetic core and is respectively connected to the end plates, the side of the end plates facing away from the middle column is connected to the metal terminals which are arranged opposite to each other and maintained at a certain interval, one side of the metal terminal is integrally connected with a first functional pin, the first functional pin is provided with a welding portion, and the metal lead body is electrically connected to the welding portion of the first functional pin after passing over the end plates.

[0006] The present application is further configured as follows: a first functional groove is symmetrically opened on one side of the end plate away from the second magnetic core, the metal lead body corresponds one-to-one to the first functional groove, the metal lead body is electrically connected to the welding part of the first functional pin through the first functional groove, and the welding part corresponds to the first functional groove in position.

[0007] The present application is further configured as follows: a second functional groove is symmetrically opened on the side of the end plate away from the second magnetic core, a second functional pin is integrally connected to one side of the metal terminal, and the second functional pin is buckled on the second functional groove and protrudes from the outer surface of the end plate.

[0008] The present application is further configured as follows: the first functional grooves symmetrically arranged on the same end plate are located between the second functional pins symmetrically arranged.

[0009] The present application is further configured as follows: the second functional pins symmetrically arranged on the same end plate are located between the first functional grooves symmetrically arranged.

[0010] The present application is further configured as follows: a certain distance is maintained between the symmetrically arranged first functional grooves, and a certain distance is maintained between the symmetrically arranged second functional feet.

[0011] The present application is further configured as follows: a third functional groove is opened on a side of the end plate away from the middle column, the metal terminal is connected in the third functional groove, and the third functional groove is connected and communicated with the first functional groove and the second functional groove.

[0012] The present application is further configured as follows: a first adhesive layer is provided in the third functional groove, and the first adhesive layer is adhesively fixed to the metal terminal in the third functional groove.

[0013] The present application is further configured as follows: a fourth functional groove is opened on the side of the end plate away from the middle column, the fourth functional groove is respectively connected and communicated with the first functional groove and the third functional groove, and the fourth functional groove gradually expands from the first functional groove toward the third functional groove.

[0014] The present application is further configured as follows: a second adhesive layer is provided on the side of the second magnetic core facing the end plate, the second adhesive layer respectively adheres and fixes the second magnetic core and the first magnetic core, and the second magnetic core and the side wall of the end plate are located in the same plane.

[0015] In summary, compared with the prior art, the present application discloses a coil element, wherein a coil composed of at least one conductor is wound on the middle column of a first magnetic core, each conductor has a metal lead body, and end plates at both ends of the middle column are connected to the second magnetic core to form a closed magnetic circuit, wherein a metal terminal is connected to the side of the end plate facing away from the middle column, and a first functional pin having a welding portion is integrally connected to one side of the metal terminal, and the metal lead body is electrically connected to the welding portion of the first functional pin after passing over the end plate, that is, through the above arrangement, the connection position of the metal terminal is limited, and the connection point between the metal lead body and the welding portion of the first functional pin and the coil is ensured to have sufficient physical isolation space through the end plate, thereby improving the structural reliability of the coil element and optimizing the comprehensive performance of the coil element. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present application. For those skilled in the art, other drawings can be obtained based on these drawings without creative work.

[0017] Figure 1 is a schematic diagram of the three-dimensional structure of the coil element of this embodiment;

[0018] Figure 2 is a schematic diagram of the three-dimensional structure of the first magnetic core of the coil element of this embodiment;

[0019] Figure 3 is a schematic side view of the coil element of this embodiment;

[0020] Figure 4 It is a schematic diagram of the three-dimensional structure of another coil element of this embodiment. DETAILED DESCRIPTION

[0021] Here, exemplary embodiments will be described in detail, examples of which are shown in the accompanying drawings. When the following description refers to the drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements. The implementations described in the following exemplary embodiments do not represent all implementations consistent with the present application. Instead, they are only examples of devices and methods consistent with some aspects of the present application as detailed in the attached claims.

[0022] It should be noted that, in this article, the terms "include", "comprises" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also includes other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, an element defined by the sentence "includes a ..." does not exclude the existence of other identical elements in the process, method, article or device including the element. In addition, components, features, and elements with the same name in different embodiments of the present application may have the same meaning or different meanings, and their specific meanings need to be determined by their explanation in the specific embodiment or further combined with the context of the specific embodiment.

[0023] It should be understood that the specific embodiments described herein are only used to explain the present application and are not used to limit the present application.

[0024] In the subsequent description, the suffixes such as "module", "component" or "unit" used to represent elements are only used to facilitate the description of the present application, and have no specific meanings. Therefore, "module", "component" or "unit" can be used in a mixed manner.

[0025] In the description of the present application, it should be noted that the terms "upper", "lower", "left", "right", "inner", "outer", etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present application. In addition, the terms "first", "second", and "third" are used for descriptive purposes only, and cannot be understood as indicating or implying relative importance.

[0026] The technical solutions shown in this application will be described in detail below through specific embodiments. It should be noted that the description order of the following embodiments is not intended to limit the priority order of the embodiments.

[0027] As described in the background technology, coil components in the prior art are widely used in the automotive field. However, in the actual operating conditions of the automobile, there are mechanical vibrations, uncertain mechanical shocks, operating temperatures ranging from -50°C to +150°C, various humidity conditions, salt spray conditions, and altitudes. The coil components in the related technology do not have the reliability to be suitable therefor, and thus cannot guarantee their good working life. Based on this, the present embodiment discloses a coil component.

[0028] Please refer to Figure 1 , Figure 2 as well as Figure 3The coil element of this embodiment may include a first magnetic core 1 , a coil 2 composed of at least one wire 22 , a second magnetic core 3 , and a metal terminal 5 .

[0029] Specifically, the first magnetic core 1 includes a middle column 11 and end plates 4 connected to both ends of the middle column 11. The coil 2 is wound on the middle column 11 according to a preset rule, and each wire 22 has a metal lead body 21. The metal lead body 21 can be led out from both ends of the wire 22. The metal terminals 5 are arranged relatively and at a certain interval on the side of the end plate 4 away from the middle column 11. The metal lead body 21 is electrically connected to the metal terminals 5. The second magnetic core 3 is arranged on one side of the first magnetic core 1 and is respectively connected to the end plates 4, so as to form a closed magnetic circuit with the first magnetic core 1.

[0030] Among them, a first functional pin 51 is integrally connected to one side of the metal terminal 5, and a welding portion 53 is provided on the first functional pin 51. The metal lead body 21 is electrically connected to the welding portion 53 after passing over the end plate 4, so that the end plate 4 is used to provide sufficient physical isolation space for the connection between the metal lead body 21 and the welding portion 53, thereby improving the structural reliability of the coil element.

[0031] In the specific implementation process, the first functional groove 41 is symmetrically opened on one side of the end plate 4 facing away from the second magnetic core 3, and the metal lead body 21 can correspond one-to-one to the first functional groove 41, and the metal lead body 21 can be electrically connected to the metal terminal 5 through the first functional groove 41, that is, the metal lead body 21 can be electrically connected to the welding portion 53 of the first functional pin 51 through the first functional groove 41, and through the one-to-one corresponding metal lead body 21 and the first functional groove 41, the metal lead body 21 of each coil 2 can be matched with a first functional groove 41 at the same end, thereby ensuring that the outlet of the metal lead body 21 is guided through the first functional groove 41 and providing a safe space for the metal lead body 21.

[0032] Furthermore, the metal lead body 21 of the present embodiment is electrically connected to the metal terminal 5 via the welding portion 53. The connection can be achieved by welding. In order to facilitate and quickly perform welding, the welding portion 53 can be designed as an oblate spheroid structure. The oblate spheroid structure is filled with solder, and the welding portion 53 corresponds to the first functional groove 41 in position, so that after the metal lead body 21 is led out of the first functional groove 41, it can be directly connected to the welding portion 53, thereby saving the auxiliary hanging wire or blocking wire structure of the coil element in the related art.

[0033] It should be noted that, based on the structural design that the metal terminal 5 is located on the side of the end plate 4 away from the center column 11, it can be ensured that there is sufficient physical isolation space between the connection point between the metal lead body 21 and the metal terminal 5 and the coil 2, thereby avoiding the risk of the coil 2 being melted due to high temperature when the metal lead body 21 and the metal terminal 5 are fixed by welding, and can also prevent foreign matter from contaminating the coil 2 during the welding process, thereby improving the structural reliability of the coil element.

[0034] The first functional slot 41 may be parallel to the extension direction of the second magnetic core 3 , so as to facilitate the routing of the metal lead body 21 .

[0035] The side walls of the second magnetic core 3 and the end plate 4 may be located in the same plane, so as to facilitate multi-angle installation of the coil element during actual application.

[0036] The groove body depth of the first functional groove 41 of the present embodiment is greater than the wire diameter of the metal lead wire body 21, so that the first functional groove 41 can better accommodate and guide the metal lead wire body 21. The groove body shape of the first functional groove 41 can be arc-shaped, triangular, U-shaped, trapezoidal or rectangular, so as to better guide the metal lead wire body 21 and ensure that it is correctly fitted on the metal lead wire body 21. It can also provide additional mechanical stability, help fix the metal lead wire body 21 and reduce its vibration or displacement.

[0037] In this embodiment, a second functional groove 42 can be symmetrically opened on the side of the end plate 4 facing away from the second magnetic core 3, and a second functional pin 52 is integrally connected to one side of the metal terminal 5. The second functional pin 52 is buckled on the second functional groove 42 and protrudes from the outer surface of the end plate 4, so that the coil element can be externally connected through the second functional pin 52.

[0038] In some embodiments, the second functional pin 52 can be relatively perpendicular to the metal terminal 5, that is, the second functional pin 52 can maintain a 90° bending angle with the metal terminal 5. At the same time, the second functional pin 52 can also be parallel to the first functional groove 41 on the end plate 4, so as to facilitate the overall structure of the coil element to be neat, and can also optimize the structural processing of the coil element and improve the cost performance of the coil element.

[0039] It should be noted that, in the coil element of the present embodiment, the symmetrically arranged first functional slots 41 on the same end plate 4 are located between the symmetrically arranged second functional pins 52, that is, when the coil element is connected to the external system through the second functional pins 52, the first functional slots 41 can provide sufficient safety space for the routing of the metal lead body 21, and can prevent the metal lead body 21 from excessive contact with the outside world, thereby reducing the risk of accidentally scratching the metal lead body 21, thereby improving the operating safety of the coil element.

[0040] In some embodiments, reference Figure 4 The second functional feet 52 of the coil elements symmetrically arranged on the same end plate 4 can also be located between the first functional slots 41 symmetrically arranged.

[0041] In the specific implementation process, in order to optimize the arrangement space of the metal lead body 21 electrically connected to the welding part 53 of the first functional pin 51 after being led out from the coil 2, a certain distance is maintained between the symmetrically arranged first functional grooves 41, and a certain distance is maintained between the symmetrically arranged second functional pins 52.

[0042] It should be noted that a third functional groove 43 is also provided on the side of the end plate 4 facing away from the center column 11, and the metal terminal 5 is connected in the third functional groove 43 to improve the fixed connection relationship between the metal terminal 5 and the end plate 4, wherein the third functional groove 43 is connected and communicated with the first functional groove 41 and the second functional groove 42 to facilitate the overall processing of the first magnetic core 1.

[0043] A first adhesive layer 6 is disposed in the third functional groove 43 , and the first adhesive layer 6 is used to bond and fix the metal terminal 5 in the third functional groove 43 .

[0044] On the other hand, based on the structural design that the third functional groove 43 is connected and communicated with the first functional groove 41 and the second functional groove 42, the first adhesive layer 6 can also extend into the first functional groove 41 and the second functional groove 42, thereby improving the fixed connection between the second functional pin 52 and the end plate 4, and the metal lead body 21 and the end plate 4, thereby ensuring the structural reliability of the coil element as a whole and optimizing the performance of the coil element.

[0045] In the specific implementation process, a fourth functional groove 44 is opened on the side of the end plate 4 away from the center column 11, and the fourth functional groove 44 is respectively connected to and communicates with the first functional groove 41 and the third functional groove 43, and the fourth functional groove 44 gradually expands from the first functional groove 41 toward the third functional groove 43, that is, the fourth functional groove 44 can be designed in a trumpet-mouth structure, so that the metal lead body 21 can be smoothly connected to the welding part 53 after being led out from the first functional groove 41, avoiding excessive hard contact with the groove wall of the first functional groove 41, thereby ensuring the quality of the metal lead body 21.

[0046] In this embodiment, a second adhesive layer 7 is provided on the side of the second magnetic core 3 facing the end plate 4 , and the second adhesive layer 7 respectively adheres and fixes the second magnetic core 3 and the first magnetic core 1 to improve the fixed connection relationship between the second magnetic core 3 and the first magnetic core 1 .

[0047] The metal lead bodies 21 of the present embodiment are correspondingly led out from both ends of the coil 2. Taking the coil 2 with two stacked wires 22 as an example, the coil 2 at the same end can correspond to two metal lead bodies 21 of different layers. These two metal lead bodies 21 can be connected to the welding part 53 after passing through the first functional groove 41 respectively, so as to facilitate the welding fixation in the subsequent process and the construction of the coil loop.

[0048] It can be understood that the metal terminals 5 on the end plate 4 are relatively arranged and maintained at a certain interval to avoid accidental contact between adjacent metal terminals 5, and the coil 2 is wound according to a preset rule. The preset rule here can be to select several coils 2 with the same winding direction, or to adopt an alternating direction design to reduce leakage inductance; or to specify the number of layers of the coil 2, the winding density of the coil 2, and the wire material used for the coil 2.

[0049] Among them, the integrally connected middle column 11 and the end pole plate 4 can form an I-shaped structure or a drum-shaped structure, and the part of the end pole plate 4 protruding from the middle column 11 constitutes a side leg wall 8. The height of the side leg wall 8 relative to the middle column 11 is greater than the height of the coil 2 relative to the middle column 11, so as to facilitate the winding of the coil 2 and also facilitate the construction of a closed magnetic circuit between the second magnetic core 3 and the first magnetic core 1.

[0050] Furthermore, the second functional foot 52 of the present embodiment can be extended to be flush with the side leg wall 8. Based on the structural design of the side leg wall 8, the coil element of the present embodiment can prevent magnetic field loss and reduce magnetic leakage of the first magnetic core 1, thereby reducing the impact on surrounding electromagnetic sensitive devices during actual operation, thereby improving the comprehensive performance of the coil element.

[0051] The first magnetic core 1 and the second magnetic core 3 of the present embodiment are both made of magnetic materials, and the magnetic materials here may include one or more of ferrite materials, magnetic metal alloy materials, iron-silicon alloy materials or soft magnetic materials to meet the working requirements of the magnetic device.

[0052] The center column 11 of this embodiment can be designed as a rectangular structure to facilitate the stacking of the coil 2, that is, to provide more winding space, and the edges and corners of the rectangular body can also be used to adjust the magnetic field distribution of the magnetic device, which helps to optimize the performance of the inductor device and is easier to process and manufacture in the production process.

[0053] The conductor 22 of this embodiment can be made of copper enameled wire material. It can be understood that metallic copper is an excellent conductive material with low resistance characteristics. Using copper enameled wire as the coil 2 can reduce the resistance of the inductor element and improve the current transmission efficiency. Copper has good thermal conductivity and can effectively conduct heat away from the coil 2 to avoid degradation or damage of the inductor performance due to excessive temperature. On the other hand, copper enameled wire can usually withstand higher temperatures and is suitable for applications in some high-temperature environments. This is very important for coil elements that need to work under high temperature conditions. Copper enameled wire has high corrosion resistance and can resist the erosion of some chemical substances, thereby extending the service life of the coil element.

[0054] The present embodiment discloses a coil element, in which a coil 2 composed of at least one wire 22 is wound on a middle column 11 of a first magnetic core 1, each wire 22 has a metal lead body 21, and end plates 4 at both ends of the middle column 11 are connected to a second magnetic core 3 to form a closed magnetic circuit, wherein a metal terminal 5 is connected to a side of the end plate 4 away from the middle column 11, and a first functional pin 51 is integrally connected to one side of the metal terminal 5, and a welding portion 53 is provided on the first functional pin 51, and a first functional groove 41 is symmetrically opened on a side of the end plate 4 away from the second magnetic core 3, and the metal lead body 21 is electrically connected to the welding portion 53 through the first functional groove 41, thereby guiding the outlet of the metal lead body 21 through the first functional groove 41 and providing a safe space for the metal lead body 21, ensuring that there is sufficient physical isolation space between the connection point between the metal lead body 21 and the metal terminal 5 and the coil 2, thereby improving the structural reliability of the coil element and optimizing the comprehensive performance of the coil element.

[0055] The above is a detailed introduction to the present application. Specific examples are used in this article to illustrate the principles and implementation methods of the present application. The description of the above embodiments is only used to help understand the core idea of ​​the present application. At the same time, for technical personnel in this field, according to the idea of ​​the present application, there will be changes in the specific implementation methods and application scope. In summary, the content of this specification should not be understood as a limitation on the present application.

Claims

1. A coil element, characterized in that: It includes a first magnetic core, a second magnetic core, a coil composed of at least one wire and a metal terminal. The first magnetic core includes a middle column and end plates connected to both ends of the middle column. The coil is wound on the middle column according to a preset rule. Each of the wires has a metal lead body. The second magnetic core is arranged on one side of the first magnetic core and is respectively connected to the end plates. The side of the end plates facing away from the middle column is connected to the metal terminals that are relatively arranged and maintained at a certain interval. One side of the metal terminal is integrally connected with a first functional pin. The first functional pin is provided with a welding portion. The metal lead body is electrically connected to the welding portion of the first functional pin after passing over the end plates.

2. The coil component according to claim 1, wherein: A first functional groove is symmetrically opened on one side of the end plate away from the second magnetic core, and the metal lead body corresponds to the first functional groove one by one. The metal lead body is electrically connected to the welding part of the first functional pin through the first functional groove, and the welding part corresponds to the first functional groove in position.

3. The coil component according to claim 2, wherein: A second functional groove is symmetrically formed on one side of the end plate away from the second magnetic core, and a second functional pin is integrally connected to one side of the metal terminal. The second functional pin is buckled on the second functional groove and protrudes from the outer surface of the end plate.

4. The coil component according to claim 3, characterized in that The first functional grooves symmetrically arranged on the same end plate are located between the second functional pins symmetrically arranged.

5. The coil component according to claim 3, characterized in that The second functional pins symmetrically arranged on the same end plate are located between the first functional grooves symmetrically arranged.

6. The coil component according to claim 3, wherein: A certain distance is maintained between the symmetrically arranged first functional grooves, and a certain distance is maintained between the symmetrically arranged second functional feet.

7. The coil component according to claim 3, wherein: A third functional groove is formed on a side of the end plate away from the center column, the metal terminal is connected in the third functional groove, and the third functional groove is connected and communicated with the first functional groove and the second functional groove.

8. The coil component according to claim 7, wherein: A first adhesive layer is disposed in the third functional groove, and the first adhesive layer is adhesively fixed to the metal terminal in the third functional groove.

9. The coil component according to claim 7, wherein: A fourth functional groove is formed on one side of the end plate away from the middle column. The fourth functional groove is respectively connected to and communicates with the first functional groove and the third functional groove, and the fourth functional groove gradually expands from the first functional groove toward the third functional groove.

10. The coil component according to any one of claims 1 to 9, characterized in that: A second adhesive layer is provided on the side of the second magnetic core facing the end plate, and the second adhesive layer respectively adheres and fixes the second magnetic core and the first magnetic core, and the second magnetic core and the side wall of the end plate are located in the same plane.

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