Inductor

Abstract

The utility model relates to the technical field of inductors, in particular to an inductor. The inductor comprises a coil, a first insulator, a center pillar magnetic core, a yoke magnetic core and a second insulator. The first insulator wraps the inner circumferential face of the coil and part of the outer circumferential face and part of the end face of the coil. The middle column magnetic core is positioned on the inner side of the coil and is positioned and matched with the first insulator; the yoke magnetic core comprises a main body part and a convex part, the convex part is arranged on the side, close to the coil, of the main body part, located on the inner side of the coil and matched with the first insulator in a positioning mode, and the end face of the convex part is attached to the end face of the center pillar magnetic core; and the coil, the first insulator, the middle column magnetic core and the yoke magnetic core are wrapped and fixed by the second insulator. In the inductor, the coil is wrapped and fixed by the first insulator, and the first insulator can be positioned and matched with the middle column magnetic core and the yoke magnetic core, so that the relative position precision of the coil and the magnetic core is improved, an enough safe insulation distance is reserved between the coil and the magnetic core, and electrical faults are not easy to occur.

Description

Technical Field

[0001] The utility model relates to the technical field of inductors, in particular to an inductor. Background Art

[0002] Inductors are electronic components that can store magnetic field energy and perform functions such as filtering, energy storage, signal processing, and electromagnetic interference suppression in various electronic devices. Inductors typically consist of a coil, a magnetic core, and an insulator, which secures the coil and core. During the molding process, some inductors lack precise assembly precision between the core and coil, resulting in a failure to maintain a safe insulation distance between the two, making the inductor susceptible to electrical failure. Utility Model Content

[0003] The utility model mainly solves the problem that the assembly precision of the magnetic core and the coil of the inductor is low and electrical faults are likely to occur.

[0004] According to the first aspect, an embodiment provides an inductor, comprising a coil, a first insulator, a center column magnetic core, a yoke magnetic core, and a second insulator, wherein the first insulator covers the inner circumference of the coil and part of the outer circumference and part of the end face of the coil; the center column magnetic core is located on the inner side of the coil, and the center column magnetic core is positioned and matched with the first insulator covering the inner circumference of the coil; the yoke magnetic core comprises a main body and a convex portion, wherein the convex portion is arranged on a side of the main body close to the coil, the convex portion is located on the inner side of the coil and is positioned and matched with the first insulator, and the end face of the convex portion is in contact with the end face of the center column magnetic core; the second insulator covers and fixes the coil, the first insulator, the center column magnetic core, and the yoke magnetic core.

[0005] In some embodiments, the cross-sectional area of ​​the protrusion gradually decreases in a direction away from the main body.

[0006] In some embodiments, a first groove is provided on the outer periphery of the middle column magnetic core, and the first groove connects the two ends of the coil. A second groove is provided on the outer periphery of the yoke magnetic core, and the second groove is connected to the first groove. The first groove and the second groove are filled with the second insulator.

[0007] In some embodiments, the first groove extends along the axial direction of the coil.

[0008] In some embodiments, at least two first grooves are provided on the middle column magnetic core, and the first grooves are arranged at intervals on the outer circumference of the middle column magnetic core.

[0009] In some embodiments, the main body of the yoke magnetic core is positioned and matched with the first insulator covered on the end surface of the coil, and a gap is provided between the main body and the end surface of the coil. The gap is connected to the first groove and the second groove, and the gap is filled with the second insulator.

[0010] In some embodiments, the inductor includes an insert fixed in the second insulator.

[0011] In some embodiments, at least two coils are provided, and each coil has lead-out ends exposed to the first insulator and the second insulator, and the coils are connected in series via the lead-out ends.

[0012] In some embodiments, the coil has a heat dissipation surface exposed to the first insulator and the second insulator.

[0013] According to the inductor of the above embodiment, the first insulator covers and fixes the coil, and the first insulator covering the inner circumference of the coil can be positioned and matched with the center column magnetic core. The yoke magnetic core is provided with a boss, and the boss can be positioned and matched with the first insulator. The above arrangement improves the assembly accuracy of the coil and the center column magnetic core and the yoke magnetic core, so that a sufficient safe insulation distance is left between the coil and the center column magnetic core and the yoke magnetic core, and the inductor is not prone to electrical failure. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 This is a schematic structural diagram of the coil of the inductor of the present invention;

[0015] Figure 2 This is a schematic structural diagram of the first insulator of the inductor of the present invention;

[0016] Figure 3 This is a schematic diagram of the assembly of the coil and the first insulator of the inductor of the present invention;

[0017] Figure 4 It is a schematic structural diagram of the center column magnetic core and the yoke magnetic core of the inductor of the present invention;

[0018] Figure 5 This is a schematic structural diagram of the center column magnetic core of the inductor of the present invention;

[0019] Figure 6 This is a schematic structural diagram of the yoke core of the inductor of the present invention;

[0020] Figure 7 Schematic diagram of the assembly relationship between the magnetic core, coil, and first insulator of the inductor of the utility model Figure 1 ;

[0021] Figure 8Schematic diagram of the assembly relationship between the magnetic core, coil, and first insulator of the inductor of the utility model Figure 2 ;

[0022] Figure 9 This is a schematic structural diagram of the inductor of the utility model.

[0023] Reference numerals:

[0024] 1. Coil; 11. Inner circumference; 12. Outer circumference; 13. End surface; 14. Lead end; 15. Heat dissipation surface; 2. First insulator; 3. Center column core; 31. First groove; 4. Yoke core; 41. Main body; 42. Protrusion; 43. Second groove; 5. Second insulator; 6. Gap; 7. Insert. DETAILED DESCRIPTION

[0025] The present invention is further described in detail below by means of specific embodiments in conjunction with the accompanying drawings. Similar elements in different embodiments are numbered with associated similar elements. In the following embodiments, many detailed descriptions are provided to enable the present application to be better understood. However, those skilled in the art will readily appreciate that some of the features may be omitted under different circumstances, or may be replaced by other elements, materials, or methods. In some cases, some operations related to the present application are not shown or described in the specification. This is to avoid the core portion of the present application being overwhelmed by excessive descriptions. For those skilled in the art, it is not necessary to describe these related operations in detail. They can fully understand the related operations based on the description in the specification and the general technical knowledge in the art.

[0026] In addition, the features, operations, or characteristics described in the specification may be combined in any appropriate manner to form various embodiments. Furthermore, the steps or actions in the method description may be reordered or adjusted in a manner readily apparent to those skilled in the art. Therefore, the various sequences in the specification and drawings are provided solely for the purpose of clearly describing a particular embodiment and are not intended to be mandatory, unless otherwise specified.

[0027] The serial numbers assigned to components herein, such as "first," "second," etc., are used solely to distinguish the objects being described and do not convey any sequential or technical meaning. References to "connection" and "coupling" herein, unless otherwise specified, include both direct and indirect connections (couplings).

[0028] Inductors are generally formed by injection molding. Specifically, the magnetic core and coil are assembled and placed in a mold. During the assembly process, a certain gap needs to be left between the coil and the magnetic core. Then, plastic fluid is injected into the mold. The plastic fluid can flow into the gap between the coil and the magnetic core. After the plastic solidifies, it covers and fixes the coil and the magnetic core.

[0029] However, the magnetic core and coil cannot directly contact each other during assembly, resulting in low assembly precision. This can lead to areas in the final inductor that do not meet the safe insulation distance between the core and coil, making electrical failures more likely. To address this, the coil can be injection-molded to form a first insulator. This injection-molded first insulator is highly precise, allowing the magnetic core to be directly positioned and assembled with the first insulator, improving the relative positioning accuracy between the coil and core. Furthermore, the thickness of the first insulator can be controlled to the minimum safe insulation distance, which helps reduce the size of the inductor.

[0030] According to the first aspect, please refer to Figure 7-Figure 9 In one embodiment, an inductor is provided, including a coil 1, a first insulator 2, a center column magnetic core 3, a yoke magnetic core 4 and a second insulator 5.

[0031] Please refer to Figure 1-Figure 3 The first insulator 2 covers the inner circumference 11 of the coil 1, as well as part of the outer circumference 12 and part of the end face 13 of the coil 1. In this embodiment, two coils 1 are provided, and the two coils 1 are arranged side by side. Accordingly, two first insulators 2 are also provided, and each first insulator 2 corresponds to one coil 1. The material of the first insulator 2 can be plastic, and the molding method of the first insulator 2 is injection molding. After the first insulator 2 is molded, it covers the inner circumference 11, part of the outer circumference 12, and part of the end face 13 of the coil 1.

[0032] Please refer to Figure 4-Figure 8 The center column core 3 is located inside the coil 1 and is positioned and matched with the first insulator 2 covering the inner circumference 11 of the coil 1. The yoke core 4 includes a main body 41 and a protrusion 42. The protrusion 42 is provided on the side of the main body 41 close to the coil 1. The protrusion 42 is located inside the coil 1 and is positioned and matched with the first insulator 2. The end face of the protrusion 42 is in contact with the end face of the center column core 3.

[0033] A central magnetic core 3 is located inside a coil 1, with a yoke core 4 positioned at each end. The protrusions 42 on the yoke core 4 cooperate with the first insulator 2 covering the coil 1 to position the yoke core 4. Simultaneously, the two protrusions 42 of the two yoke cores 4 mate with the two end faces of the central magnetic core 3, respectively, to help position the central magnetic core 3.

[0034] In the above arrangement, the first insulator 2 wrapped around the coil 1 can be positioned and matched with the center column core 3 and the yoke core 4, thereby improving the assembly accuracy of the coil 1 and the center column core 3 and the yoke core 4. A sufficient safety insulation distance is left between the coil 1 and the center column core 3 and the yoke core 4, and the inductor is not prone to electrical failure.

[0035] Please refer to Figure 9 The second insulator 5 covers and secures the coil 1, the first insulator 2, the center-column core 3, and the yoke core 4. The first insulator 2 is secured to the coil 1 via a single injection molding process. After the center-column core 3, the yoke core 4, and the first insulator 2 are positioned and assembled, a secondary injection molding process can be performed to form the second insulator 5, which covers and secures the coil 1, the first insulator 2, the center-column core 3, and the yoke core 4.

[0036] In some embodiments, please refer to Figure 6 The cross-sectional area of ​​the protrusion 42 gradually decreases in the direction away from the main body 41. Specifically, the protrusion 42 can be a boss-like structure. The above-mentioned configuration of gradually decreasing cross-sectional area forms a chamfer-like structure on the boss, facilitating the assembly of the yoke core 4 and the first insulator 2. In addition, in the above-mentioned configuration, both the yoke core 4 and the center column core 3 can be formed by die pressing, facilitating mass production.

[0037] In some embodiments, please refer to Figure 4-Figure 6 The outer circumference of the center-column magnetic core 3 is provided with a first groove 31, which connects the two ends of the coil 1. The outer circumference of the yoke magnetic core 4 is provided with a second groove 43, which connects to the first groove 31. The first groove 31 and the second groove 43 are filled with the second insulator 5. Specifically, the first groove 31 is provided on the side of the center-column magnetic core 3, and the second groove 43 is provided on the side of the yoke magnetic core 4. After the yoke magnetic core 4 is aligned with the center-column magnetic core 3, the first groove 31 and the second groove 43 are connected. When the center-column magnetic core 3 and the yoke magnetic core 4 are assembled on the first insulator 2, the first groove 31 and the second groove 43 connect the two ends of the coil 1.

[0038] After the center-leg core 3, yoke core 4, and first insulator 2 are assembled, a secondary injection molding process can be performed to form the second insulator 5. During the secondary injection molding process, the plastic fluid can flow into the second groove 43 and the first groove 31, thereby securing the coil 1, first insulator 2, center-leg core 3, and yoke core 4 after solidification. The provision of the first groove 31 and the second groove 43 facilitates the flow of the plastic fluid, ultimately forming the second insulator 5 within the first groove 31 and the second groove 43, thereby improving the structural strength of the inductor.

[0039] In some embodiments, please refer to Figure 5 The first groove 31 extends along the axial direction of the coil 1. It is relatively simple to provide the first groove 31 extending axially on the center column magnetic core 3. The center column magnetic core 3 can be pressed and formed by a mold, which is convenient for mass production.

[0040] In some embodiments, please refer to Figure 4-6The center magnetic core 3 is provided with at least two first grooves 31, which are spaced apart around the outer periphery of the center magnetic core 3. Specifically, the center magnetic core 3 may be provided with two first grooves 31, one located on two opposing sides of the center magnetic core 3. Providing two or more first grooves 31 facilitates the flow of the plastic fluid during the secondary injection molding process, allowing the final second insulator 5 to fully penetrate and cover all parts of the inductor, thereby improving the structural strength of the inductor.

[0041] In some embodiments, please refer to Figure 7 、 Figure 8 The main body 41 of the yoke core 4 is positioned and matched with the first insulator 2 wrapped on the end face 13 of the coil 1. A gap 6 is provided between the main body 41 and the end face 13 of the coil 1. The gap 6 is connected to the first groove 31 and the second groove 43. The gap 6 is filled with the second insulator 5.

[0042] Because the first insulator 2 only partially covers the end face 13 of the coil 1, a gap 6 remains between the main body 41 of the magnetic core and the end face 13 of the coil 1 when the main body 41 contacts the first insulator 2. During the secondary injection molding process, the plastic fluid can flow into the second groove 43, the gap 6, and the first groove 31, and after solidification, form the second insulator 5. The second insulator 5 in the gap 6 provides insulation between the yoke core 4 and the coil 1. At the same time, the second insulator 5 fills the second groove 43, the gap 6, and the first groove 31, thereby improving the structural strength of the inductor.

[0043] In some embodiments, please refer to Figure 9 The inductor includes an insert 7, which is fixed in the second insulator 5. Specifically, the insert 7 includes a nut, a cylinder, etc. The insert 7 is provided to facilitate fixing the inductor in subsequent use.

[0044] In some embodiments, please refer to Figure 1 、 Figure 9 At least two coils 1 are provided, and each coil 1 has a lead-out terminal 14 exposed to the first insulator 2 and the second insulator 5, and the coils 1 are connected in series via the lead-out terminals 14. In this embodiment, two coils 1 are provided, and the lead-out terminals 14 of the two coils 1 are connected via a copper busbar.

[0045] In some embodiments, please refer to Figure 1 、 Figure 2 and Figure 9, the coil 1 has a heat dissipation surface 15 exposed to the first insulator 2 and the second insulator 5. Among the outer peripheral surface 12 of the coil 1, the surface at the bottom is not wrapped by the first insulator 2 and the second insulator 5, forming the heat dissipation surface 15. When the inductor is used, it can be used in conjunction with a heat dissipation pad and a radiator to release the generated heat in time. Specifically, the heat dissipation pad is attached to the heat dissipation surface 15, and the radiator is arranged on one side of the heat dissipation surface 15 of the heat dissipation pad. The heat dissipation pad is used to conduct the heat of the inductor to the radiator, and the radiator is used to release the heat to the external environment.

[0046] The following describes the method for forming the inductor in the above embodiment, which includes the following steps.

[0047] The coil 1 is subjected to a one-time injection molding to form a first insulator 2 . The first insulator 2 covers the inner circumference 11 of the coil 1 and a portion of the outer circumference 12 and a portion of the end surface 13 of the coil 1 .

[0048] When a single coil 1 is relatively large in width, two or more coils 1 can be placed side by side along the length and then connected in series. For inductors with two or more coils 1, each coil 1 can be injection molded separately. After the injection molding process, the two coils 1 can be positioned in the desired relationship.

[0049] Position and assemble the center core 3, yoke core 4, and first insulator 2. Specifically, first install the center core 3 inside the coil 1, then install the yoke cores 4 at either end of the center core 3. The center core 3 and yoke core 4 are positioned and aligned with the first insulator 2 covering the coil 1, ensuring the relative positional accuracy of the coil 1 and the core, and preventing the coil 1 from having insufficient insulation distance from the core.

[0050] The assembled coil 1, center core 3, and yoke core 4 are then subjected to secondary injection molding to form a second insulator 5, which secures the coil 1, center core 3, and yoke core 4. During this secondary injection molding process, inserts 7, such as nuts and cylinders, can be added. The center core 3 and yoke core 4 can be provided with grooves, etc. During secondary injection molding, the plastic fluid can fill the grooves. The resulting second insulator 5, formed after curing, effectively penetrates and encapsulates all parts of the inductor, thereby enhancing the structural strength of the inductor.

[0051] The above examples are used to illustrate the present invention, which are only used to help understand the present invention and are not intended to limit the present invention. Those skilled in the art of the present invention can make some simple deductions, modifications or substitutions based on the concept of the present invention.

Claims

1. An inductor, characterized in that: include: A coil and a first insulator, wherein the first insulator covers the inner circumference of the coil and part of the outer circumference and part of the end surface of the coil; a center column magnetic core, the center column magnetic core being located inside the coil and being positioned and matched with the first insulator covering the inner circumference of the coil; a yoke magnetic core, the yoke magnetic core comprising a main body and a convex portion, the convex portion being disposed on a side of the main body close to the coil, the convex portion being located inside the coil and positioned in cooperation with the first insulator, the end face of the convex portion being in contact with the end face of the center column magnetic core; A second insulator is provided, wherein the second insulator covers and fixes the coil, the first insulator, the center column magnetic core, and the yoke magnetic core.

2. The inductor according to claim 1, wherein The cross-sectional area of ​​the convex portion gradually decreases in a direction away from the main body portion.

3. The inductor according to claim 1, wherein A first groove is provided on the outer periphery of the middle column magnetic core, and the first groove connects the two ends of the coil. A second groove is provided on the outer periphery of the yoke magnetic core, and the second groove is connected to the first groove. The first groove and the second groove are filled with the second insulator.

4. The inductor according to claim 3, wherein: The first groove extends along the axial direction of the coil.

5. The inductor according to claim 3, wherein: At least two first grooves are provided on the middle column magnetic core, and the first grooves are arranged at intervals on the outer circumference of the middle column magnetic core.

6. The inductor according to claim 3, wherein: The main body of the yoke core is positioned and matched with the first insulator covered on the end surface of the coil. A gap is provided between the main body and the end surface of the coil. The gap is connected to the first groove and the second groove, and the gap is filled with the second insulator.

7. The inductor according to any one of claims 1 to 6, characterized in that: An insert is included, and the insert is fixed in the second insulator.

8. The inductor according to any one of claims 1 to 6, wherein: At least two coils are provided, and each coil has lead-out ends exposed to the first insulator and the second insulator, and the coils are connected in series via the lead-out ends.

9. The inductor according to any one of claims 1 to 6, wherein: The coil has a heat dissipation surface exposed to the first insulator and the second insulator.

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