Inductor element
Through the design of split-type winding conductor and limit structure, the problems of large inductor components and poor vibration resistance are solved, and a more stable and smaller inductor component design is achieved.
Patent Information
- Application Number
- CN202422278843.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-09-19
- Publication Date
- 2025-07-25
- Estimated Expiration
- 2034-09-19
AI Technical Summary
The existing inductor components have problems with large size and poor vibration resistance of the wire, which are mainly due to the mobility of the wire winding and the uneven gap with the core.
By designing a split-type winding conductor and limiting structure, the range of movement of the winding conductor is limited, and the gap between the winding conductor and the magnetic core is reduced. The split-type winding conductor is used to form a winding conductor, combining the limiting structure and external limiting elements to limit the range of movement of the winding conductor and enhance structural stability.
The structural stability and vibration resistance of the inductor element are improved, while reducing the overall size and space of the inductor element, enhancing the fixing effect of the winding conductor.
Smart Images
Figure CN223155758U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of inductors, and particularly to an inductor component. Background Art
[0002] An inductor component is a commonly used component in a circuit system, which can convert electrical energy into magnetic energy and store it. As Figures 1 to 6 shown, the inductor component mainly consists of a magnetic core P0 and a wire winding P1 wound around the magnetic core P0. However, some current inductor components have some problems. For example, they are relatively large in size and the wire has poor anti-vibration performance.
[0003] Therefore, an optimized design scheme for the inductor component is needed. Summary of the Invention
[0004] One advantage of this application is to provide an inductor component, wherein the winding conductor of the inductor component is formed by combining at least two winding segments, so that the shapes of the respective winding segments and the combination form between the respective winding segments are relatively flexible.
[0005] Another advantage of this application is to provide an inductor component, wherein the structure of the inductor component is relatively stable, and can enhance the anti-vibration performance to a certain extent.
[0006] Another advantage of this application is to provide an inductor component, wherein the inductor component is relatively small in volume, and can reduce the occupied space to a certain extent.
[0007] Another advantage of this application is to provide an inductor component, wherein the inductor component improves its structural stability from multiple aspects, so that its structural stability is guaranteed multiple times. For example, the movement range of the winding conductor of the inductor component is restricted by a limiting structure; on the other hand, the stability of the inductor component is further improved by reducing the gap between the winding conductor and the annular magnetic core.
[0008] Another advantage of this application is to provide an inductor component, wherein while further improving the stability of the inductor component by reducing the gap between the winding conductor and the annular magnetic core, the size of the winding conductor can also be reduced, thereby reducing the overall volume of the inductor component.
[0009] Another advantage of this application is to provide an inductor component, wherein restricting the movement range of the middle section of the winding conductor can enhance the limiting effect to a certain extent compared with restricting the movement range of the end of the winding conductor.
[0010] Another advantage of the present application lies in providing an inductive component, wherein a relatively large portion of the winding conductor of the inductive component has restricted movement. For example, the entire portion of the winding conductor extending into the annular magnetic core is restricted in its movable range by the inner restricted space, such that the overall movability of the winding conductor is small, and the structure of the inductive component is relatively stable.
[0011] Another advantage of the present application lies in providing an inductive component, wherein the inductive component reduces its size and the gap between it and the annular magnetic core by adjusting the shape of the winding conductor, and the adjustment cost is relatively low.
[0012] According to one aspect of the present application, there is provided an inductive component, comprising:
[0013] An annular magnetic core having a central through-hole; and
[0014] At least one winding conductor passing through the central through-hole of the annular magnetic core and surrounding the annular magnetic core;
[0015] Wherein, the winding conductor includes a first winding segment and a second winding segment, and the first winding segment and the second winding segment are detachably connected and combined to form the winding conductor;
[0016] The first winding segment has a U-shaped structure, and the second winding segment has an I-shaped structure; the U-shaped structure of the first winding segment has two longitudinal arms spaced from each other; one of the two longitudinal arms of the U-shaped structure passes through the central through-hole of the annular magnetic core from the first side of the annular magnetic core and extends along the set axial direction of the annular magnetic core to the second side of the annular magnetic core; the second winding segment is connected between the two longitudinal arms along the set radial direction of the annular magnetic core on the second side of the annular magnetic core; the first side of the annular magnetic core and the second side of the annular magnetic core are opposite to each other in the set axial direction of the annular magnetic core.
[0017] In an embodiment of the inductive component according to the present application, the inductive component further includes a limiting structure, and the limiting structure forms at least one limiting space; wherein, at least a portion of at least one winding conductor located on the circumferential side of the annular magnetic core passes through the limiting space, such that at least one winding conductor is limited by at least one limiting space.
[0018] In an embodiment of the inductive component according to the present application, the limiting structure includes at least one inner limiting wall; at least a portion of at least one inner limiting wall is located in the central through-hole of the annular magnetic core, and the inner limiting wall divides the space in the central through-hole into at least two inner limiting spaces; wherein, at least one winding conductor passes through the inner limiting space, such that at least one winding conductor is limited by the inner limiting space.
[0019] In an embodiment of the inductive component according to the present application, the inductive component includes a cover body, and the cover body includes an inner sleeve body, an outer sleeve body, and an end wall. Wherein, the inner sleeve body is sleeved in the central through hole of the annular magnetic core and is formed by at least one of the inner limiting walls, the outer sleeve body is sleeved outside the annular magnetic core, and the end wall extends between the inner sleeve body and the outer sleeve body and is located outside the annular magnetic core.
[0020] In an embodiment of the inductive component according to the present application, the limiting structure further includes at least one outer limiting element. The outer limiting element is located outside the annular magnetic core and has at least one outer limiting hole, and the outer limiting hole forms an outer limiting space outside the annular magnetic core; at least a part of at least one of the winding conductors is located in the outer limiting hole, so that at least one of the winding conductors is limited by the outer limiting space.
[0021] In an embodiment of the inductive component according to the present application, the limiting structure further includes at least one outer limiting element; the outer limiting element is located outside the annular magnetic core and has at least one outer limiting hole, and the outer limiting hole forms an outer limiting space outside the annular magnetic core; the outer limiting element is opposite to the cover body; the annular magnetic core is disposed between the outer limiting element and the cover body; at least one of the winding conductors passes through the inner limiting space and the outer limiting hole of the outer limiting element.
[0022] In an embodiment of the inductive component according to the present application, the annular magnetic core has opposite magnetic core inner peripheral surfaces and magnetic core outer peripheral surfaces; the winding conductor has opposite conductor inner peripheral surfaces and conductor outer peripheral surfaces; the conductor inner peripheral surface faces the magnetic core outer peripheral surface; the cross-sectional shapes of both the conductor inner peripheral surface and the magnetic core outer peripheral surface are rectangular.
[0023] In an embodiment of the inductive element according to the present application, the two longitudinal arms are respectively a first longitudinal arm and a second longitudinal arm. The first turn split body further includes a first transverse arm. The first longitudinal arm and the second longitudinal arm are spaced apart from each other. The first transverse arm extends between a first end of the first longitudinal arm and a first end of the second longitudinal arm. The first longitudinal arm, the second longitudinal arm, and the first transverse arm form a U-shaped structure. The first longitudinal arm passes through the inner limiting space from a first side of the annular magnetic core and extends to a second side of the annular magnetic core. The second longitudinal arm is located on the outer peripheral side of the annular magnetic core and is opposite to the first longitudinal arm in a set radial direction of the annular magnetic core. The second turn split body is connected between a second end of the first longitudinal arm and a second end of the second longitudinal arm. The first end of the first longitudinal arm and the first end of the second longitudinal arm are located on the first side of the annular magnetic core. The second end of the first longitudinal arm and the second end of the second longitudinal arm are located on the second side of the annular magnetic core.
[0024] In an embodiment of the inductive element according to the present application, the first turn split body and the second turn split body are connected to each other by welding.
[0025] According to one aspect of the present application, a manufacturing method of an inductive element is provided, which includes the steps of:
[0026] Mounting at least one turn conductor on an annular magnetic core, wherein the annular magnetic core has a central through hole, the turn conductor includes a first turn split body and a second turn split body, the first turn split body has a U-shaped structure, and the second turn split body has an I-shaped structure. The U-shaped structure of the first turn split body has two longitudinal arms spaced apart from each other.
[0027] Wherein, in the process of mounting at least one turn conductor on the annular magnetic core, first, one of the two longitudinal arms of the U-shaped structure passes through the central through hole of the annular magnetic core from a first side of the annular magnetic core and extends along an axial direction set by the annular magnetic core to a second side of the annular magnetic core. Then, the second turn split body is connected between the two longitudinal arms on the second side of the annular magnetic core along a radial direction set by the annular magnetic core. The first side of the annular magnetic core and the second side of the annular magnetic core are opposite to each other in the axial direction set by the annular magnetic core.
[0028] In an embodiment of the manufacturing method of the inductive element according to the present application, the manufacturing method of the inductive element further includes the step of: setting a limiting structure on the annular magnetic core. Wherein, the limiting structure forms at least one limiting space. In the process of mounting at least one turn conductor on the annular magnetic core, at least a part of at least one turn conductor located on the circumferential side of the annular magnetic core passes through the limiting space, so that at least one turn conductor is limited by at least one limiting space.
[0029] The further objects and advantages of the present application will be fully realized through the understanding of the subsequent description and the accompanying drawings.
[0030] These and other objects, features, and advantages of the present application will be fully realized through the following detailed description, the accompanying drawings, and the claims. BRIEF DESCRIPTION OF THE DRAWINGS
[0031] By describing the embodiments of the present application in more detail in conjunction with the accompanying drawings, the above and other objects, features, and advantages of the present application will become more obvious. The accompanying drawings are used to provide a further understanding of the embodiments of the present application, and constitute a part of the specification. Together with the embodiments of the present application, they are used to explain the present application, and do not constitute a limitation to the present application. In the drawings, the same reference numerals generally represent the same components or...
[0032] Figure 1 A perspective view schematic diagram of the magnetic core of an existing inductive element is illustrated.
[0033] Figure 2 A perspective view schematic diagram of the wire winding of an existing inductive element is illustrated.
[0034] Figure 3 A perspective view schematic diagram of an assembly formed by combining the magnetic core and wire winding of an existing inductive element is illustrated.
[0035] Figure 4 A process schematic diagram of installing the magnetic core and wire winding of an existing inductive element on a bottom plate is illustrated.
[0036] Figure 5 A plan view schematic diagram of an existing inductive element is illustrated.
[0037] Figure 6 A cross-sectional view schematic diagram of an existing inductive element is illustrated.
[0038] Figure 7 A perspective view schematic diagram of an inductive element according to an embodiment of the present application is illustrated.
[0039] Figure 8 Another perspective view schematic diagram of an inductive element according to an embodiment of the present application is illustrated.
[0040] Figure 9 A plan view schematic diagram of an inductive element according to an embodiment of the present application is illustrated.
[0041] Figure 10 A cross-sectional view schematic diagram of an inductive element according to an embodiment of the present application is illustrated.
[0042] Figure 11 An exploded view schematic diagram of an inductive element according to an embodiment of the present application is illustrated.
[0043] Figure 12 One of the process diagrams illustrating the manufacturing process of an inductive element according to an embodiment of the present application.
[0044] Figure 13 Another process diagram illustrating the manufacturing process of an inductive element according to an embodiment of the present application.
[0045] Figure 14 A third process diagram illustrating the manufacturing process of an inductive element according to an embodiment of the present application. Detailed Description of the Embodiment
[0046] Hereinafter, exemplary embodiments according to the present application will be described in detail with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all of the embodiments of the present application. It should be understood that the present application is not limited by the exemplary embodiments described herein.
[0047] It can be understood that the term "a" should be understood as "at least one" or "one or more". That is, in one embodiment, the number of an element can be one, while in other embodiments, the number of the element can be multiple. The term "a" should not be construed as a limitation on the number. "Multiple" means greater than or equal to two.
[0048] Although ordinal numbers such as "first", "second", etc. will be used to describe various components, those components are not limited herein. The term is only used to distinguish one component from another. For example, the first component can be referred to as the second component, and similarly, the second component can also be referred to as the first component, without departing from the teachings of the concept of the present application. The term "and / or" used herein includes any and all combinations of one or more of the associated listed items.
[0049] The terms used herein are for the purpose of describing various embodiments only and are not intended to be limiting. As used herein, the singular form also includes the plural form unless the context clearly indicates otherwise. Additionally, it will be understood that the terms "comprising" and / or "having" when used in this specification specify the presence of the stated features, numbers, operations, components, elements, or combinations thereof, without excluding the presence or addition of one or more other features, numbers, operations, components, elements, or combinations thereof.
[0050] Application Overview: As described above, as Figures 1 to 6 shown, the inductive element mainly consists of a magnetic core P0 and a wire winding P1 wound around the magnetic core P0. However, some current inductive elements have some problems. For example, they are relatively large in size and the wires have poor anti-vibration performance, etc.
[0051] The inventors of the present application have found that some current problems of inductance components, such as large size and poor anti-vibration performance, are mainly related to the mobility of the wire winding P1 and the gap between the wire winding P1 and the magnetic core P0.
[0052] Specifically, for some current inductance components, the shape of the cross-section of the magnetic core P0 parallel to its axis is rectangular, and the shape of the cross-section of the wire winding P1 is circular. When the wire winding P1 is wound around the magnetic core P0, the inner diameter D of the wire winding P1 needs to be greater than the size of the diagonal E of the rectangle of the cross-section of the magnetic core P0, as Figure 6 shown; and the gaps between different parts of the wire winding P1 and the magnetic core P0 are different, that is, the gaps between the wire winding P1 and the magnetic core P0 are uneven. The gap between the wire winding P1 and the magnetic core P0 is an ineffective space. The gaps between some positions of the wire winding P1 and the magnetic core P0 are large, which makes the overall size of the wire winding P1 large and also makes the movement range of the wire winding P1 large. Especially when the inductance component vibrates, the wires of the wire winding P1 are likely to become loose, and the anti-vibration performance is poor.
[0053] As Figure 4 shown, some inductance components insert the wire winding P1 into the bottom plate P2 and fix the wire winding P1 by gluing. However, in the fixing method of inserting the wire winding P1 into the bottom plate, only the position near the end of the wire winding P1 is point-fixed, and the fixing property of the gluing type is poor. Whether it is the fixing position (i.e., the position near the end), or the fixing area (i.e., point-fixing), or the fixing process (i.e., gluing fixation), the fixing effect is poor.
[0054] In addition, the wire winding P1 of some inductance components is of an integral structure, or the shape configuration is not conducive to assembly or not conducive to reducing the overall volume of the inductance component.
[0055] Correspondingly, the present application proposes to limit the movement range of the wires, that is, the turn conductors, by designing a limiting structure to improve the structural stability of the inductance component, and thus enhance the anti-vibration performance of the inductance component to a certain extent; in addition, reducing the gap between the turn conductor and the magnetic core, on the one hand, reduces the ineffective space and thus reduces the overall size of the inductance component, and on the other hand, further enhances the anti-vibration performance of the inductance component.
[0056] The present application also proposes to design the turn conductor as a split structure, formed by combining at least two turn sub-components, so that the shape of each turn sub-component and the combination form between each turn sub-component are relatively flexible. Further, the present application also proposes to make the inductance component easy to assemble through specific shape configuration and position configuration of the turn sub-components.
[0057] Schematic inductance component: As Figures 7 to 14As shown, the inductive element 100 according to an embodiment of the present application is illustrated. As Figures 7 to 10 shown, the inductive element 100 includes a limiting magnetic core 10 and at least one winding conductor 20. The limiting magnetic core 10 includes an annular magnetic core 11 and a limiting structure 12. The inductive element 100 restricts the movement range of the winding conductor 20 through the limiting structure 12, so that the structure of the inductive element 100 is relatively stable and the vibration resistance performance is enhanced.
[0058] Specifically, as Figure 11 and Figure 12 shown, the annular magnetic core 11 has a first magnetic core end 101, a second magnetic core end 102, a magnetic core peripheral wall 103, and a central through hole 104. The first magnetic core end 101 and the second magnetic core end 102 of the annular magnetic core 11 are opposite to each other in the axial direction defined by the annular magnetic core 11. The magnetic core peripheral wall 103 extends between the first magnetic core end 101 and the second magnetic core end 102. The magnetic core peripheral wall 103 is annular and encloses to form the central through hole 104. The limiting structure 12 forms at least one limiting space 1201. At least one of the winding conductors 20 passes through the central through hole 104 of the annular magnetic core 11 and surrounds the annular magnetic core 11. And at least a part of at least one of the winding conductors 20 located on the peripheral side of the annular magnetic core 11 passes through the limiting space 1201, so that at least one of the winding conductors 20 is limited by at least one of the limiting spaces 1201.
[0059] In the present application, the extending direction of the longitudinal central axis L of the annular core 11 is defined as the axial direction of the annular core 11; the direction perpendicular to the set axial direction of the annular core 11 is defined as the radial direction of the annular core 11. The set axial direction of the annular core 11 is consistent with the set axial direction of the inductance element 100; the set radial direction of the annular core 11 is consistent with the set radial direction of the inductance element 100. In the present application, the two outer sides of the annular core 11 that are opposite to each other in the set axial direction are respectively defined as the first core side 105 (i.e., the first side of the annular core 11) and the second core side 106 (i.e., the second side of the annular core 11), where the first core side 105 is the side close to the first core end 101, that is, the axial outer side of the first core end 101, and the second core side 106 is the side close to the second core end 102, that is, the axial outer side of the second core end 102; the side of the annular core 11 in the set radial direction is defined as the circumferential core side 107 (i.e., the circumferential side of the annular core 11), where the inner side of the core circumferential wall 103 of the annular core 11 is set as the inner circumferential core side (i.e., the inner circumferential side of the annular core 11), and the outer side of the core circumferential wall 103 of the annular core 11 is set as the outer circumferential core side (i.e., the outer circumferential side of the annular core 11); the surface of the core circumferential wall 103 facing the central through hole 104 is defined as the inner circumferential core surface 108 (i.e., the inner circumferential surface of the annular core 11); the surface of the core circumferential wall 103 facing away from the central through hole 104 is defined as the outer circumferential core surface 109 (i.e., the outer circumferential surface of the annular core 11); where the outer circumferential core surface 109 and the inner circumferential core surface 108 are opposite to each other in the set radial direction of the annular core 11.
[0060] In the present application, as Figure 11 and Figure 13 shown, the winding conductor 20 portion can be divided into a first conductor end 210, a middle conductor section 230, and a second conductor end 220. The middle conductor section 230 is located between the first conductor end 210 and the second conductor end 220. In the present application, the middle conductor section 230 specifically refers to the portion of the winding conductor 20 that overlaps with the annular core 11 in the set radial direction of the annular core 11 when installed on the limiting core 10. Structurally, the middle conductor section 230 is located on the circumferential side of the annular core 11, where a part of the middle conductor section 230 passes through the central through hole 104 of the annular core 11 and is located on the inner circumferential side of the annular core 11, and another part of the middle conductor section 230 is located on the outer circumferential side of the annular core 11. The first conductor end 210 is located on the first side of the annular core 11; the second conductor end 220 is located on the second side of the annular core 11.
[0061] Accordingly, in the present application, for the middle section 230 of the conductor of the winding conductor 20, that is, the portion of the winding conductor 20 located on the circumferential side of the annular magnetic core 11, the movement range is restricted by the limiting structure 12. It should be understood that restricting the movement range of the middle section 230 of the winding conductor 20 can, to a certain extent, enhance the limiting effect compared to restricting the movement range of the end of the winding conductor 20, making the entire winding conductor 20 not easily loosen, thereby improving the structural stability of the inductor element 100.
[0062] Specifically, the limiting space 1201 can be formed on the inner circumferential side of the annular magnetic core 11 to restrict the movement range of the middle section 230 of the winding conductor 20, or the limiting space 1201 can be formed on the outer circumferential side of the annular magnetic core 11 to restrict the movement range of the middle section 230 of the winding conductor 20. The limiting structure 12 can form the limiting space 1201 through its own structure, or can cooperate with the annular magnetic core 11 to form the limiting space 1201.
[0063] Accordingly, in an embodiment of the present application, at least one of the limiting spaces 1201 is formed on the inner circumferential side of the annular magnetic core 11, and at least a portion of at least one of the winding conductors 20 located on the circumferential side of the annular magnetic core 11 passes through at least one of the limiting spaces 1201 formed on the inner circumferential side of the annular magnetic core 11. The specific implementation manner of forming at least one of the limiting spaces 1201 on the inner circumferential side of the annular magnetic core 11 is not limited by the present application.
[0064] In an example of the present application, as Figure 7 and Figure 11 shown, the limiting structure 12 includes at least one inner limiting wall 121. Among them, at least a portion of at least one of the inner limiting walls 121 is located in the central through hole 104 of the annular magnetic core 11, and the inner limiting wall 121 divides the space in the central through hole 104 into at least two inner limiting spaces 1202; at least one of the winding conductors 20 passes through the inner limiting space 1202, so that at least one of the winding conductors 20 is limited by the inner limiting space 1202.
[0065] In this example, the inductive element 100 includes a cover 13, wherein a partial structure of the cover 13 forms at least part of the limiting structure 12. Specifically, the cover 13 includes an inner sleeve 131, an outer sleeve 132, and an end wall 133. The inner sleeve 131 is sleeved in the central through hole 104 of the annular magnetic core 11 and is formed by at least one inner limiting wall 121. The outer sleeve 132 is spaced from the inner sleeve 131 and is sleeved outside the annular magnetic core 11. The end wall 133 extends between the inner sleeve 131 and the outer sleeve 132 and is located outside the annular magnetic core 11. Specifically, the end wall 133 is located on a first side of the annular magnetic core 11.
[0066] In this example, a plurality of the inner limiting walls 121 enclose to form at least one inner limiting hole, forming a space with a limiting function. When the inner limiting wall 121 is installed in the central through hole 104 of the annular magnetic core 11, the inner limiting hole divides the central through hole 104 into at least two inner limiting spaces 1202.
[0067] In other examples, the inner limiting wall 121 itself may not form the inner limiting hole. When the inner limiting wall 121 is installed in the central through hole 104 of the annular magnetic core 11, the inner limiting wall 121 divides the central through hole 104 into at least two inner limiting spaces 1202.
[0068] In this example, the length dimension of the inner limiting wall 121 in the set axial direction of the annular magnetic core 11 is greater than or equal to the length dimension of the annular magnetic core 11 in its set axial direction, so that the entire conductor middle section 230 of the winding conductor 20, that is, the entire part of the winding conductor 20 extending into the annular magnetic core 11, has its movable range restricted by the inner limiting space 1202. Furthermore, the overall movability of the winding conductor 20 is relatively small, and the structure of the inductive element 100 is relatively stable.
[0069] It should be understood that in other examples, the length dimension of the inner limiting wall 121 in the set axial direction of the annular magnetic core 11 may also be smaller than the length dimension of the annular magnetic core 11 in its set axial direction, so that a partial conductor middle section 230 of the winding conductor 20 has its movable range restricted by the inner limiting space 1202.
[0070] In another embodiment of the present application (this embodiment is not shown in the figure), at least one of the limiting spaces 1201 is formed on the outer peripheral side of the annular magnetic core 11. Among them, at least a part of at least one of the winding conductors 20 located on the circumferential side of the annular magnetic core 11 passes through at least one of the limiting spaces 1201 formed on the outer peripheral side of the annular magnetic core 11. The length dimension of at least one of the limiting spaces 1201 formed on the outer peripheral side of the annular magnetic core 11 in the set axial direction of the annular magnetic core 11 can be designed to be greater than or equal to the length dimension of the annular magnetic core 11 in its set axial direction, so that the entire conductor middle section 230 of the winding conductor 20 is restricted in its movement range. The length dimension of at least one of the limiting spaces 1201 formed on the outer peripheral side of the annular magnetic core 11 in the set axial direction of the annular magnetic core 11 can also be designed to be less than the length dimension of the annular magnetic core 11 in its set axial direction, so that a part of the conductor middle section 230 of the winding conductor 20 is restricted in its movement range.
[0071] In yet another embodiment of the present application (this embodiment is not shown in the figure), at least one of the limiting spaces 1201 is formed on the outer peripheral side of the annular magnetic core 11, and at least one of the limiting spaces 1201 is formed on the inner peripheral side of the annular magnetic core 11. At least a part of at least one of the winding conductors 20 located on the circumferential side of the annular magnetic core 11 passes through at least one of the limiting spaces 1201 formed on the outer peripheral side of the annular magnetic core 11, and at least a part of at least one of the winding conductors 20 located on the circumferential side of the annular magnetic core 11 passes through at least one of the limiting spaces 1201 formed on the inner peripheral side of the annular magnetic core 11.
[0072] In one embodiment of the present application, as Figures 7 to 11 shown, the limiting structure 12 further includes at least one outer limiting element 14. The outer limiting element 14 is located outside the annular magnetic core 11 and has at least one outer limiting hole 1401. The outer limiting hole 1401 forms an outer limiting space 1203 located outside the annular magnetic core 11. At least a part of at least one of the winding conductors 20 is located in the outer limiting hole 1401, so that at least one of the winding conductors 20 is limited by the outer limiting space 1203.
[0073] In an example of the present application, the outer limiting element 14 is opposite to the cover body 13 and is located on the second side of the annular magnetic core 11; the annular magnetic core 11 is arranged between the outer limiting element 14 and the cover body 13; at least one of the winding conductors 20 passes through the inner limiting space 1202 and the outer limiting hole 1401 of the outer limiting element 14.
[0074] In this example, as Figure 11As shown, the outer limiting element 14 includes an inner region 141 and an outer region 142. The outer region 142 is defined as the region of the outer limiting element 14 that radially exceeds the annular magnetic core 11 and the cover 13 as set by the inductive element 100. The inner region 141 is defined as the region of the outer limiting element 14 that is within the outer region 142. The inner region 141 has at least one of the outer limiting holes 1401. The outer region 142 has at least one of the outer limiting holes 1401. At least one of the winding conductors 20 passes through the inner limiting space 1202, the outer limiting hole 1401 of the inner region 141, and the outer limiting hole 1401 of the outer region 142.
[0075] The outer limiting element 14 and the cover 13 form the outer housing of the inductive element 100, which can not only limit the winding conductor 20, but also act as an outer cover for the winding conductor 20, playing a role in preventing pollution and protecting to a certain extent.
[0076] In other examples of the present application, the outer limiting element 14 can also be arranged at other positions, for example, on the circumferential side of the annular magnetic core 11.
[0077] In the present application, not only the movement range of the winding conductor 20 is restricted by the limiting structure; but also the stability of the inductive element 100 is further improved by reducing the gap between the winding conductor 20 and the annular magnetic core 11.
[0078] In the present application, the winding conductor 20 has an inner conductor surface 201 and an outer conductor surface 202. The inner conductor surface 201 faces the outer magnetic core surface 109. The outer conductor surface 202 faces away from the outer magnetic core surface 109. The inner conductor surface 201 and the outer conductor surface 202 are opposite to each other in the radial direction set by the inductive element 100. The shapes of the inner conductor surface 201 and the outer magnetic core surface 109 are the same, so that the gaps between the winding conductor 20 and the annular magnetic core 11 at various places can be basically the same, which can avoid the gaps between some parts of the winding conductor 20 and the annular magnetic core 11 being too large to a certain extent, minimize the ineffective space as much as possible, thereby reducing the overall size of the inductive element 100, reducing the space occupied by the inductive element 100, and further enhancing the anti-vibration performance of the inductive element 100.
[0079] It is worth mentioning that in the present application, the size of the winding conductor 20 and its gap with the annular magnetic core 11 are reduced by adjusting the shape of the winding conductor 20, and the adjustment cost is relatively low.
[0080] Specifically, in an example of the present application, the cross-sectional shape of the inner circumferential surface 201 of the winding conductor 20 and the cross-sectional shape of the outer circumferential surface 109 of the annular magnetic core 11 are both rectangular, wherein the cross-section of the inner circumferential surface 201 of the winding conductor 20 and the cross-section of the outer circumferential surface 109 of the annular magnetic core 11 are respectively parallel to the set axial direction of the inductor element 100.
[0081] In the present application, the winding conductor 20 is designed as a split structure, which is formed by combining at least two winding segments, so that the shapes of the respective winding segments and the combination form between the respective winding segments are relatively flexible. Correspondingly, in the present application, the winding conductor 20 includes at least two winding segments. At least two of the winding segments are connected in a split manner and combined to form the winding conductor 20. In the present application, being connected in a split manner means being connected in a non-integrally formed manner, that is, connecting two already formed parts. Ways such as welding, fusion welding, adhesive bonding, and fitting belong to split connection.
[0082] In an example of the present application, as Figure 11 shown, the winding conductor 20 includes a first winding segment 21 and a second winding segment 22. The first winding segment 21 and the second winding segment 22 are connected in a split manner and combined to form the winding conductor 20. Specifically, the first winding segment 21 and the second winding segment 22 are connected to each other by welding.
[0083] Furthermore, in the present application, through specific shape configuration and position configuration of the winding segments, the inductor element 100 is made convenient for assembly.
[0084] Specifically, the first winding segment 21 has a U-shaped structure, and the second winding segment 22 has an I-shaped structure. The U-shaped structure of the first winding segment 21 has two longitudinal arms spaced from each other. The U-shaped structure of the first winding segment 21 passes through the limiting space 1201 and the central through hole 104 of the annular magnetic core 11 from the first side of the annular magnetic core 11 and extends to the second side of the annular magnetic core 11. Specifically, one of the two longitudinal arms of the U-shaped structure passes through the central through hole 104 of the annular magnetic core 11 from the first side of the annular magnetic core 11 and passes through the inner limiting space 1202 in the central through hole 104.
[0085] The second winding segment 22 is connected between the two longitudinal arms of the U-shaped structure of the first winding segment 21 on the second side of the annular magnetic core 11.
[0086] The two mutually spaced longitudinal arms of the first winding segment 21 are respectively a first longitudinal arm 211 and a second longitudinal arm 212. Correspondingly, the first winding segment 21 includes a first longitudinal arm 211, a second longitudinal arm 212, and a first transverse arm 213, wherein the first longitudinal arm 211 and the second longitudinal arm 212 are mutually spaced, and the first transverse arm 213 extends between a first end of the first longitudinal arm 211 and a first end of the second longitudinal arm 212. The first longitudinal arm 211, the second longitudinal arm 212, and the first transverse arm 213 form a U-shaped structure.
[0087] The first longitudinal arm 211 passes through the inner limiting space 1202 from a first side of the annular magnetic core 11, extends to a second side of the annular magnetic core 11, and passes through the outer limiting hole 1401 of the inner region 141 of the outer limiting element 14. The first side and the second side of the annular magnetic core 11 are opposite in the axial direction set by the inductor element 100. The second longitudinal arm 212 is located on the outer peripheral side of the annular magnetic core 11 and is opposite to the first longitudinal arm 211 in the radial direction set by the inductor element 100. The second longitudinal arm 212 extends from the first side of the annular magnetic core 11 to the outer limiting element 14, and then passes through the outer limiting hole 1401 of the outer region 142 of the outer limiting element 14. The first transverse arm 213 is located on the first side of the annular magnetic core 11 and is outside the end wall 133 of the cover body 13, that is, on a side of the end wall 133 facing away from the annular magnetic core 11.
[0088] The second winding segment 22 is connected between a second end of the first longitudinal arm 211 and a second end of the second longitudinal arm 212, is located on the second side of the annular magnetic core 11, and is outside the outer limiting element 14, that is, on a side of the outer limiting element 14 facing away from the annular magnetic core 11.
[0089] The first end and the second end of the first longitudinal arm 211 are opposite in the axial direction set by the inductor element 100; the first end and the second end of the second longitudinal arm 212 are opposite in the axial direction set by the inductor element 100. The first end of the first longitudinal arm 211 and the first end of the second longitudinal arm 212 are located on the first side of the annular magnetic core 11. The second end of the first longitudinal arm 211 and the second end of the second longitudinal arm 212 are located on the second side of the annular magnetic core 11.
[0090] It is worth mentioning that in the present application, the winding conductor 20 is formed by combining at least two winding segments, so that the shapes of the respective winding segments and the combination forms between the respective winding segments are relatively flexible. It should be understood that the shapes and combination methods of the respective winding segments are implemented as other types.
[0091] Manufacturing method of a schematic inductor element: A manufacturing method of an inductor element according to an embodiment of the present application is illustrated. The manufacturing method of the inductor element includes steps: S110, mounting at least one turn conductor 20 on an annular magnetic core 11, wherein the annular magnetic core 11 has a central through hole 104, the turn conductor 20 includes a first turn segment 21 and a second turn segment 22, the first turn segment 21 has a U-shaped structure, and the second turn segment 22 has an I-shaped structure; the U-shaped structure of the first turn segment 21 has two longitudinal arms spaced from each other; wherein, in the process of mounting at least one turn conductor 20 on the annular magnetic core 11, first, one of the two longitudinal arms of the U-shaped structure is passed through the central through hole 104 of the annular magnetic core 11 from a first side of the annular magnetic core 11 and extends along the set axial direction of the annular magnetic core 11 to a second side of the annular magnetic core 11; then the second turn segment 22 is connected between the two longitudinal arms along the set radial direction of the annular magnetic core 11 on the second side of the annular magnetic core 11; the first side and the second side of the annular magnetic core 11 are opposite to each other in the set axial direction of the annular magnetic core 11.
[0092] Specifically, in the process of mounting at least one turn conductor 20 on the annular magnetic core 11, before one of the two longitudinal arms of the U-shaped structure is passed through the central through hole 104 of the annular magnetic core 11 from a first side of the annular magnetic core 11 and extends along the set axial direction of the annular magnetic core 11 to a second side of the annular magnetic core 11, a limiting structure 12 is provided on the annular magnetic core 11, wherein the limiting structure 12 forms at least one limiting space 1201.
[0093] In the process of mounting at least one turn conductor 20 on the annular magnetic core 11, at least a part of at least one turn conductor 20 located on the circumferential side of the annular magnetic core 11 is passed through the limiting space 1201, so that at least one turn conductor 20 is limited by at least one limiting space 1201.
[0094] Specifically, the limiting space 1201 includes an inner limiting space 1202 located in the central through hole 104 and an outer limiting space 1203 located outside the annular magnetic core 11.
[0095] One of the two longitudinal arms of the U-shaped structure passes through the central through-hole 104 of the annular magnetic core 11 from the first side of the annular magnetic core 11 and at the same time passes through the part of the limiting space 1201 located within the central through-hole 104, that is, the inner limiting space 1202, and the other longitudinal arm passes through the part of the limiting space 1201 located outside the annular magnetic core 11, that is, the outer limiting space 1203, so that at least one of the winding conductors 20 is limited by at least one of the limiting spaces 1201.
[0096] For the formation methods of the inner limiting space 1202 and the outer limiting space 1203, refer to the descriptions of the inner limiting space 1202 and the outer limiting space 1203 in the process of obtaining the limiting magnetic core 10 in step S110A below.
[0097] The present application also proposes another manufacturing method of an inductive element. The manufacturing method of the inductive element includes steps: S110A, obtaining a limiting magnetic core 10, where the limiting magnetic core 10 includes an annular magnetic core 11 and a limiting structure 12, the annular magnetic core 11 has a central through-hole 104, and the limiting structure 12 forms at least one limiting space 1201; and S120A, installing at least one winding conductor 20 on the limiting magnetic core 10, where at least a part of at least one winding conductor 20 located on the circumferential side of the annular magnetic core 11 passes through the limiting space 1201, so that at least one winding conductor 20 is limited by at least one limiting space 1201.
[0098] As Figure 12 shown, in step S110A, a limiting magnetic core 10 is obtained. Specifically, the annular magnetic core 11 is installed between a cover body 13 and an outer limiting element 14. A part of the structure of the cover body 13 forms at least a part of the limiting structure 12. Specifically, the cover body 13 includes an inner sleeve body 131, an outer sleeve body 132, and an end wall 133. Among them, the inner sleeve body 131 is formed by at least one inner limiting wall 121. The inner sleeve body 131 and the outer sleeve body 132 are spaced from each other, and the end wall 133 extends between the inner sleeve body 131 and the outer sleeve body 132. In the process of installing the annular magnetic core 11 between the cover body 13 and the outer limiting element 14, the positional relationship between the annular magnetic core 11 and the outer limiting element 14 is as follows: the inner sleeve body 131 is sleeved in the central through-hole 104 of the annular magnetic core 11, the outer sleeve body 132 is sleeved outside the annular magnetic core 11, and the end wall 133 is located outside the annular magnetic core 11.
[0099] In an example of the present application, a plurality of the inner limiting walls 121 enclose to form at least one inner limiting hole, forming a space with a limiting function. When the inner limiting wall 121 is installed in the central through hole 104 of the annular magnetic core 11, the inner limiting hole divides the central through hole 104 into at least two inner limiting spaces 1202.
[0100] In other examples, the inner limiting wall 121 itself may not form the inner limiting hole. When the inner limiting wall 121 is installed in the central through hole 104 of the annular magnetic core 11, the inner limiting wall 121 divides the central through hole 104 into at least two inner limiting spaces 1202.
[0101] In this example, the length dimension of the inner limiting wall 121 in the axial direction set by the annular magnetic core 11 is greater than or equal to the length dimension of the annular magnetic core 11 in its set axial direction, so that the entire conductor middle section 230 of the winding conductor 20, that is, the entire part of the winding conductor 20 extending into the annular magnetic core 11, has its movable range restricted by the inner limiting space 1202. Furthermore, the overall movability of the winding conductor 20 is relatively small, and the structure of the inductance element 100 is relatively stable.
[0102] It should be understood that in other examples, the length dimension of the inner limiting wall 121 in the axial direction set by the annular magnetic core 11 may also be the length dimension of the annular magnetic core 11 in its set axial direction, so that a part of the conductor middle section 230 of the winding conductor 20 has its movable range restricted by the inner limiting space 1202.
[0103] In another embodiment of the present application (this embodiment is not shown in the figure), at least one limiting space 1201 is formed on the outer peripheral side of the annular magnetic core 11. Among them, at least a part of at least one winding conductor 20 located on the circumferential side of the annular magnetic core 11 passes through at least one limiting space 1201 formed on the outer peripheral side of the annular magnetic core 11. The length dimension of at least one limiting space 1201 formed on the outer peripheral side of the annular magnetic core 11 in the axial direction set by the annular magnetic core 11 can be designed to be greater than or equal to the length dimension of the annular magnetic core 11 in its set axial direction, so that the entire conductor middle section 230 of the winding conductor 20 has its movable range restricted. The length dimension of at least one limiting space 1201 formed on the outer peripheral side of the annular magnetic core 11 in the axial direction set by the annular magnetic core 11 can also be designed to be less than the length dimension of the annular magnetic core 11 in its set axial direction, so that a part of the conductor middle section 230 of the winding conductor 20 has its movable range restricted.
[0104] In yet another embodiment of the present application (this embodiment is not illustrated in the figures), at least one of the limiting spaces 1201 is formed on the outer peripheral side of the annular magnetic core 11, and at least one of the limiting spaces 1201 is formed on the inner peripheral side of the annular magnetic core 11. At least a part of at least one of the winding conductors 20 located on the peripheral side of the annular magnetic core 11 passes through at least one of the limiting spaces 1201 formed on the outer peripheral side of the annular magnetic core 11, and at least a part of at least one of the winding conductors 20 located on the peripheral side of the annular magnetic core 11 passes through at least one of the limiting spaces 1201 formed on the inner peripheral side of the annular magnetic core 11.
[0105] In one embodiment of the present application, the limiting structure 12 further includes at least one outer limiting element 14. The outer limiting element 14 is located outside the annular magnetic core 11 and has at least one outer limiting hole 1401. The outer limiting hole 1401 forms an outer limiting space 1203 located outside the annular magnetic core 11. At least a part of at least one of the winding conductors 20 is located in the outer limiting hole 1401, so that at least one of the winding conductors 20 is limited by the outer limiting space 1203.
[0106] In an example of the present application, the outer limiting element 14 faces the cover body 13 and is located on the second side of the annular magnetic core 11; the annular magnetic core 11 is disposed between the outer limiting element 14 and the cover body 13. In this example, the outer limiting element 14 includes an inner region 141 and an outer region 142. The outer region 142 is defined as the region of the outer limiting element 14 that extends beyond the annular magnetic core 11 and the cover body 13 in the radial direction set by the inductive element 100. The inner region 141 is defined as the region of the outer limiting element 14 that is located within the outer region 142. The inner region 141 has at least one of the outer limiting holes 1401. The outer region 142 has at least one of the outer limiting holes 1401.
[0107] As Figure 13 and Figure 14As shown, in step S120A, at least one turn conductor 20 is mounted on the limiting magnetic core 10. Specifically, step S120A includes steps: S121A, mounting at least one first turn segment 21 on the limiting magnetic core 10, wherein the first turn segment 21 includes a first longitudinal arm 211, a second longitudinal arm 212, and a first transverse arm 213, the first longitudinal arm 211 and the second longitudinal arm 212 are spaced apart from each other, and the first transverse arm 213 extends between a first end of the first longitudinal arm 211 and a first end of the second longitudinal arm 212; the first longitudinal arm 211, the second longitudinal arm 212, and the first transverse arm 213 form a U-shaped structure; the first longitudinal arm 211 passes through the inner limiting space 1202 from a first side of the annular magnetic core 11, extends to a second side of the annular magnetic core 11 and passes through the outer limiting hole 1401 of the inner region 141 of the outer limiting element 14, wherein the first side and the second side of the annular magnetic core 11 are opposite to each other in the axial direction set by the inductance element 100; the second longitudinal arm 212 is located on the outer peripheral side of the annular magnetic core 11, extends from the first side of the annular magnetic core 11 to the outer limiting element 14, and then passes through the outer limiting hole 1401 of the outer region 142 of the outer limiting element 14; the second longitudinal arm 212 is opposite to the first longitudinal arm 211 in the radial direction set by the inductance element 100; the first transverse arm 213 is located on the first side of the annular magnetic core 11; and, S122A, connecting a second turn segment 22 between the first longitudinal arm 211 and the second longitudinal arm 212; the second turn segment 22 is located on the second side of the annular magnetic core 11.
[0108] In summary, the inductance element 100 and its manufacturing method according to the embodiments of the present application are elucidated. The structure of the inductance element 100 is relatively stable, and the anti-vibration performance can be enhanced to a certain extent. The volume of the inductance element 100 is relatively small, and the occupied space can be reduced to a certain extent.
[0109] The above description of the present application and its implementation manners is not restrictive. What is shown in the drawings is only one of the implementation manners of the present application, and the actual structure is not limited thereto. Generally speaking, if those of ordinary skill in the art are inspired by it and design similar structural manners and embodiments without creative efforts without departing from the creative purpose of the present application, they should all fall within the protection scope of the present application.
Claims
1. An inductive component, characterized in that, Comprising: A toroidal core having a central through-hole; and At least one turn conductor, at least one of the turn conductors passing through the central through-hole of the toroidal core and surrounding the toroidal core; Wherein the turn conductor includes a first turn segment and a second turn segment, the first turn segment and the second turn segment being detachably connected and combined to form the turn conductor; The first turn segment has a U-shaped structure, and the second turn segment has an I-shaped structure; the U-shaped structure of the first turn segment has two longitudinal arms spaced apart from each other; one of the two longitudinal arms of the U-shaped structure passes through the central through-hole of the toroidal core from a first side of the toroidal core and extends along an axial direction defined by the toroidal core to a second side of the toroidal core; the second turn segment is connected between the two longitudinal arms along a radial direction defined by the toroidal core on the second side of the toroidal core; the first side of the toroidal core and the second side of the toroidal core are opposite to each other in the axial direction defined by the toroidal core.
2. The inductive component according to claim 1, wherein The inductive element further includes a limiting structure, the limiting structure forming at least one limiting space; wherein at least a part of at least one of the turn conductors located on the circumferential side of the toroidal core passes through the limiting space, such that at least one of the turn conductors is limited by at least one of the limiting spaces.
3. The inductive component according to claim 2, wherein, The limiting structure includes at least one inner limiting wall; at least a part of at least one of the inner limiting walls is located in the central through-hole of the toroidal core, and the inner limiting wall divides the space in the central through-hole into at least two inner limiting spaces; wherein at least one of the turn conductors passes through the inner limiting space, such that at least one of the turn conductors is limited by the inner limiting space.
4. The inductive component according to claim 3, wherein, The inductive element includes a cover body, the cover body including an inner sleeve, an outer sleeve and an end wall, wherein the inner sleeve is sleeved in the central through-hole of the toroidal core and is formed by at least one of the inner limiting walls, the outer sleeve is sleeved outside the toroidal core, and the end wall extends between the inner sleeve and the outer sleeve and is located outside the toroidal core.
5. The inductive component according to claim 2, wherein, The limiting structure further includes at least one outer limiting element, the outer limiting element being located outside the toroidal core and having at least one outer limiting hole, the outer limiting hole forming an outer limiting space located outside the toroidal core; at least a part of at least one of the turn conductors is located in the outer limiting hole, such that at least one of the turn conductors is limited by the outer limiting space.
6. The inductive component according to claim 4, wherein, The limiting structure further includes at least one outer limiting element; the outer limiting element is located outside the toroidal core and has at least one outer limiting hole, the outer limiting hole forming an outer limiting space located outside the toroidal core; the outer limiting element is opposite to the cover body; the toroidal core is disposed between the outer limiting element and the cover body; at least one of the turn conductors passes through the inner limiting space and the outer limiting hole of the outer limiting element.
7. The inductive element according to claim 3, wherein, The two longitudinal arms are respectively a first longitudinal arm and a second longitudinal arm. The first winding split body further includes a first transverse arm. The first longitudinal arm and the second longitudinal arm are spaced apart from each other. The first transverse arm extends between a first end portion of the first longitudinal arm and a first end portion of the second longitudinal arm. The first longitudinal arm, the second longitudinal arm, and the first transverse arm form a U-shaped structure. The first longitudinal arm passes through the inner limiting space from a first side of the annular magnetic core and extends to a second side of the annular magnetic core. The second longitudinal arm is located on an outer peripheral side of the annular magnetic core and is opposite to the first longitudinal arm in a set radial direction of the annular magnetic core. The second winding split body is connected between a second end portion of the first longitudinal arm and a second end portion of the second longitudinal arm. The first end portion of the first longitudinal arm and the first end portion of the second longitudinal arm are located on the first side of the annular magnetic core. The second end portion of the first longitudinal arm and the second end portion of the second longitudinal arm are located on the second side of the annular magnetic core.
8. The inductive element according to claim 1, wherein, The first winding split body and the second winding split body are connected to each other by welding.