Inductor module and inductor

Abstract

The utility model discloses an inductor module and an inductor, and the inductor module comprises at least one coil which is provided with two wire outlet ends; the lead frame is provided with a frame main body, at least one electrode structure and a plurality of wrapping structures which are oppositely arranged in pairs; at least one magnetic core; the wrapping structure wraps the wire outlet end in the circumferential direction of the wire outlet end, and the wire outlet end and the wrapping structure are welded to form a welding structure; one part of the wire outlet end extends out of the wrapping structure to form a remelting section used for remelting during welding, the welding structure comprises a welding wrapping part, the remelting section forms the welding wrapping part through welding, and at least one part of the wrapping structure is wrapped by the welding wrapping part. According to the utility model, the wrapping force of the wrapping structure is utilized to improve the connection stability between the wrapping structure and the leading-out terminal, and the welding area between the wrapping structure and the leading-out terminal is also increased, so that the improvement of the welding quality is facilitated, and the problem of easy interruption / open circuit caused by weak connection between the leading-out terminal of the coil and the lead frame is avoided.

Description

TECHNICAL FIELD

[0001] The utility model relates to inductance production technical field, especially, relate to a kind of inductance module, inductance and its manufacturing method. BACKGROUND

[0002] In industry, the inductance is formed by welding the lead frame and the coil, then the magnetic core is formed by pressure casting magnetic powder, and finally the lead-out end of the lead frame is bent to form the inductance pin. The connection quality between the coil and the lead frame is the key to the quality of the inductance.

[0003] In the prior art, it is often found that the connection between the coil and the lead frame is weak, which causes the interruption / open circuit defect. However, since the connection between the coil and the lead frame after the inductance is formed is buried in the interior of the magnetic core, the welding point connection strength cannot be directly detected. When the inductance is welded to the PCB, due to the thermal expansion and contraction of the material, the weak connection point between the coil and the lead frame will separate, resulting in an interruption defect. However, any test on the connection strength before forming is destructive, so currently only the appearance of the connection can be checked manually to determine whether the connection is reliable, but there is a risk of missing. SUMMARY

[0004] The utility model aims to provide an inductance module, inductance and its manufacturing method to solve the technical problem of weak connection between the coil and the lead frame in the current inductance.

[0005] The above-mentioned purpose of the utility model can be achieved by using the following technical solutions:

[0006] The utility model provides an inductance module, comprising: at least one coil, the coil has two wire ends; a lead frame having a frame body, at least one electrode structure, and a plurality of wrapping structures arranged opposite to each other, the electrode structure comprises two electrode parts arranged opposite to each other, one end of the electrode part is connected to the frame body, and the other end of the electrode part is connected to the wrapping structure; at least one magnetic core, the magnetic core is formed by powder pressure casting, and the coil and the wrapping structure are buried in the magnetic core; wherein the wrapping structure is wrapped outside the wire end in the circumferential direction of the wire end, and the wire end and the wrapping structure are welded to form a welding structure; a part of the wire end extends out of the wrapping structure to form a back-melting section for back-melting during welding, the welding structure comprises a welded wrapping part, the back-melting section forms the welded wrapping part by welding, and at least a part of the wrapping structure is wrapped by the welded wrapping part.

[0007] The utility model discloses an implementation manner of the utility model discloses a kind of wrapping structure, it includes wrapping arm, and the wrapping arm has horizontal state and wrapping state;In the horizontal state, the wrapping arm is horizontally arranged, and the outgoing terminal is placed on the wrapping arm;In the wrapping state, the wrapping arm is formed by bending and forms wrapping frame, and the wrapping frame is wrapped outside the outgoing terminal in the circumference of the outgoing terminal, and part of the outgoing terminal is stretched from the wrapping frame and forms the reflow section.

[0008] The utility model discloses an implementation manner of the utility model discloses a kind of welding structure, it includes reinforcing welding portion;Wherein, in the wrapping state, the outgoing terminal and the inner wall surface between the wrapping frame are formed by welding and form the reinforcing welding portion.

[0009] The utility model discloses an implementation manner of the utility model discloses a kind of reinforcing welding portion, it includes axial welding portion and circumferential welding portion;Wherein, the axial welding portion is formed between the two ends of the wrapping arm and is connected with the outgoing terminal by welding along the axial direction of the outgoing terminal, and the circumferential welding portion is formed between the wrapping arm and the outgoing terminal by welding along the circumference of the outgoing terminal.

[0010] The utility model discloses an implementation manner of the utility model discloses a kind of wrapping arm, it also has clamping state, in the clamping state, the two ends of the wrapping arm are formed by bending and form two clamping portions, and the outgoing terminal is clamped between two clamping portions, and part of the outgoing terminal is stretched between two clamping portions.

[0011] The utility model discloses an implementation manner of the utility model discloses a kind of welding structure, it includes initial welding portion;Wherein, in the clamping state, the outgoing terminal and the inner wall surface between two clamping portions are formed by welding and form the initial welding portion.

[0012] The utility model discloses an implementation manner of the utility model discloses a kind of wrapping arm, it includes support portion, first side portion and second side portion, the first side portion and the second side portion are connected with the two ends of the support portion, and the first side portion and the second side portion are bent and can cooperate with the support portion to wrap the outgoing terminal.

[0013] The utility model discloses an implementation manner of the utility model discloses a kind of first side portion, it is formed by bending and forms one clamping portion, and the second side portion is formed by bending and forms another clamping portion and compression portion, and the compression portion is fixed on the support portion and is pressed tightly to the outgoing terminal.

[0014] The utility model discloses an implementation manner of the utility model discloses a kind of welding structure, it is formed by resistance welding and laser welding mode welding.

[0015] The utility model discloses still provide a kind of inductance, at least one described inductance is processed using above-mentioned inductance module, the inductance includes coil, magnetic core and two electrode pieces, the two electrode parts of the electrode structure are separated from the frame main body cutting and form two electrode pieces, and two electrode pieces are adhered with the magnetic core by bending.

[0016] The utility model has the characteristics and advantages that:

[0017] The inductance module, the inductance and the manufacturing method of the utility model, the wrapping structure is wrapped outside the outgoing terminal and is welded with the outgoing terminal in the circumferential direction of the outgoing terminal, so that the wrapping force of the wrapping structure can be used to improve the connection stability between the wrapping structure and the outgoing terminal, and the welding area between the wrapping structure and the outgoing terminal is also improved, thereby facilitating the improvement of the welding quality. In addition, by extending a part of the outgoing terminal from the wrapping structure to form a reflow section, a welding wrapping part is formed by welding, and at least a part of the wrapping structure is wrapped by the welding wrapping part, thereby further improving the welding area and the welding quality between the wrapping structure and the outgoing terminal. Therefore, the utility model can effectively avoid the problem of weak connection between the outgoing terminal of the coil and the lead frame, which is prone to interruption / open circuit. BRIEF DESCRIPTION OF DRAWINGS

[0018] In order to more clearly illustrate the technical solutions in the embodiments of the utility model, the following will briefly introduce the drawings needed to be used in the embodiment description. Obviously, the drawings in the following description are only some embodiments of the utility model, and other drawings can be obtained by those skilled in the art without creative labor.

[0019] Figure 1 It is a structure diagram of the lead frame in the utility model when the wrapping arm is in a wrapped state.

[0020] Figure 2 It is a structure diagram of the wrapping structure wrapping the outgoing terminal of the coil in the utility model.

[0021] Figure 3 It is a structure diagram of the wrapping structure and the outgoing terminal after welding in the utility model.

[0022] Figure 4 It is a structure diagram of the inductance module in the utility model.

[0023] Figure 5 It is a structure diagram of the lead frame in the utility model when the wrapping arm is in a horizontal state.

[0024] Figure 6 It is a structure diagram of the wrapping arm in the horizontal state in the utility model.

[0025] Figure 7 Fig. 6 is a structural schematic view of the lead frame in the clamping state of the wrapping arm according to the present application.

[0026] Figure 8 Fig. 6 is a structural schematic view of the lead frame in the clamping state of the wrapping arm according to the present application.

[0027] Figure 9 Fig. 6 is a structural schematic view of the lead frame in the clamping state of the wrapping arm according to the present application.

[0028] Figure 10 Fig. 6 is a structural schematic view of the lead frame in the clamping state of the wrapping arm according to the present application.

[0029] Figure 11 Fig. 6 is a structural schematic view of the lead frame in the clamping state of the wrapping arm according to the present application.

[0030] In the drawings:

[0031] 1, lead frame; 11, frame body; 12, electrode structure; 121, electrode part; 13, wrapping structure; 131, wrapping arm; 1311, wrapping frame; 1312, clamping part; 1313, supporting part; 1314, first side part; 1315, second side part; 1316, pressing part; 132, connecting arm;

[0032] 2, coil; 21, wire outlet end; 211, re-melting section;

[0033] 3, magnetic core;

[0034] 4, electrode sheet;

[0035] 5, welding structure; 51, welding wrapping part. DETAILED DESCRIPTION

[0036] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments of the present application, all the other embodiments obtained by those skilled in the art without creative labor fall within the scope of the present application.

[0037] Embodiment one

[0038] As Figure 1 , Figure 2 and Figure 3As shown in the utility model provides a kind of inductance module, comprising: at least one coil 2, coil 2 has two outlet ends 21;Lead frame 1, with frame main body 11, at least one electrode structure 12 and the multiple wrapping structures 13 of two two opposite settings, electrode structure 12 includes two electrode parts 121 of opposite settings, one end of electrode part 121 is connected with frame main body 11, the other end of electrode part 121 is connected with wrapping structure 13;At least one magnetic core 3( Figure 7 As shown in the utility model provides a kind of inductance module, comprising: at least one coil 2, coil 2 has two outlet ends 21;Lead frame 1, with frame main body 11, at least one electrode structure 12 and the multiple wrapping structures 13 of two two opposite settings, electrode structure 12 includes two electrode parts 121 of opposite settings, one end of electrode part 121 is connected with frame main body 11, the other end of electrode part 121 is connected with wrapping structure 13;At least one magnetic core 3(

[0039] Wherein, the two outlet ends 21 of one coil 2 correspond to the two electrode parts 121 of one electrode structure 12 and the two wrapping structures 13 of opposite settings, i.e. the number of coil 2 can be set to one, two, three or more, accordingly, the number of electrode structure 12 is set to one, two, three or more, and the number of wrapping structure 13 is set to two, four, six or more even numbers.

[0040] The inductance module of the utility model, by wrapping structure 13 in the circumferential direction of outlet end 21 is wrapped outside outlet end 21 and is welded with outlet end 21, so that the wrapping force of wrapping structure 13 can be used to improve the connection stability between wrapping structure 13 and outlet end 21, and the welding area between wrapping structure 13 and outlet end 21 is also improved, thereby facilitating the improvement of welding quality, in addition, by forming a reflow section 211 by extending a part of outlet end 21 from wrapping structure 13, and then forming a welding wrapping part 51 by welding, at least a part of wrapping structure 13 is wrapped by welding wrapping part 51, so as to further improve the welding area and welding quality between wrapping structure 13 and outlet end 21;Therefore, the utility model can effectively avoid the problem of weak connection between the outlet end 21 of coil 2 and lead frame 1, which is easy to cause interruption / open circuit.

[0041] Specifically, in combination with Figure 2 And Figure 3 As shown in the utility model provides a kind of inductance module, comprising: at least one coil 2, coil 2 has two outlet ends 21;Lead frame 1, with frame main body 11, at least one electrode structure 12 and the multiple wrapping structures 13 of two two opposite settings, electrode structure 12 includes two electrode parts 121 of opposite settings, one end of electrode part 121 is connected with frame main body 11, the other end of electrode part 121 is connected with wrapping structure 13;At least one magnetic core 3( Figure 4As shown, the two wire ends 21 of the coil 2 are connected with the wrapping structure 13, and then are placed in a forming mold of the magnetic core 3, so that the powder is placed in the forming mold for die casting, and the magnetic core 3 is formed. A part of the two electrode parts 121 of the electrode structure 12 is embedded in the magnetic core 3, and another part is located outside the magnetic core 3. In combination with Figure 4 and Figures 9 to 11 As shown, the inductance module can be further processed to obtain at least one inductor. That is, the two electrode parts 121 of the electrode structure 12 are separated from the frame body 11 by cutting, and then the two electrode parts 121 form two electrode sheets 4 of the inductor. The part of the two electrode sheets 4 located outside the magnetic core 3 is bent to be attached to the magnetic core 3, so that the inductor is processed. The two electrode sheets 4 can be welded and fixed on the circuit board, so that the inductor is electrically connected with the circuit board.

[0042] As shown, Figure 3 In the embodiment of the utility model, the welding structure 5 is welded by resistance welding and laser welding. The welding structure 5 is welded by double welding, so that false welding can be effectively avoided. The wire end 21 and the wrapping structure 13 can be welded along a welding path by resistance welding first, and then the wire end 21 and the wrapping structure 13 are welded along the same welding path by laser welding, so that the welding structure 5 is formed. Alternatively, the wire end 21 and the wrapping structure 13 can be welded along a welding path by laser welding first, and then the wire end 21 and the wrapping structure 13 are welded along the same welding path by resistance welding, so that the welding structure 5 is formed.

[0043] As shown, Figure 1 and Figure 2 The wrapping structure 13 includes a wrapping arm 131. The wire end 21 is wrapped by the wrapping arm 131, that is, the wrapping arm 131 is generally a frame-shaped wrapping frame 1311. Preferably, the two ends of the wrapping arm 131 are butt-jointed or overlapped, and the wrapping arm 131 is wrapped around the wire end 21 at an angle of 360 degrees in the circumferential direction B. Alternatively, the wrapping arm 131 is wrapped around the wire end 21 at an angle less than 360 degrees in the circumferential direction B, and the two ends of the wrapping arm 131 have a gap therebetween, and the width of the gap is less than the diameter of the wire end 21, so that the wire end 21 is prevented from being pulled out of the gap. In addition, the wrapping structure 13 further includes a connecting arm 132. One end of the connecting arm 132 is connected with the wrapping arm 131, and the other end of the connecting arm 132 is connected with the electrode part 121.

[0044] In some embodiments of the utility model, the wrapping arm 131 has a horizontal state and a wrapping state. As shown, Figure 5 and Figure 6 In the horizontal state, the wrapping arm 131 is horizontally arranged, and the wire end 21 is placed on the wrapping arm 131. As shown, Figure 1 and Figure 2As shown, in the wrapped state, the wrapping arm 131 is bent to form a wrapping frame 1311, the wrapping frame 1311 wraps the outlet end 21 outside in the circumferential direction B of the outlet end 21, and a part of the outlet end 21 extends from the wrapping frame 1311 to form a melting section 211. By arranging the wrapping arm 131 horizontally first and then bending and wrapping, the assembly is more convenient, and the wrapping arm 131 can be adaptively wrapped according to the cross-sectional shape of the outlet end 21, so that the outlet end 21 is wrapped more tightly.

[0045] As shown in Figure 1 and Figure 2 In other embodiments of the utility model, the wrapping arm 131 can be directly bent to form a wrapping frame 1311, and then the outlet end 21 of the coil 2 is arranged in the wrapping frame 1311, so that the assembly of the outlet end 21 and the wrapping arm 131 is realized.

[0046] As shown in Figure 2 In order to further improve the welding area and welding quality between the wrapping structure 13 and the outlet end 21, in the embodiments of the utility model, the welding structure 5 further includes a reinforcing welding part; wherein, in the wrapped state, the reinforcing welding part is formed by welding between the outlet end 21 and the inner wall surface of the wrapping frame 1311, that is, after the outlet end 21 is assembled with the wrapping arm 131, that is, after the outlet end 21 is wrapped by the wrapping arm 131, the reinforcing welding part can be formed by welding to connect the outlet end 21 and the inner wall surface of the wrapping frame 1311.

[0047] Specifically, as shown in Figure 2 The reinforcing welding part includes an axial welding part and a circumferential welding part; wherein, the axial welding part is formed between the two ends of the wrapping arm 131 and is attached to the outlet end 21 by welding along the axial direction A of the outlet end 21, and the circumferential welding part is formed between the wrapping arm 131 and the outlet end 21 by welding along the circumferential direction B of the outlet end 21. By welding the wrapping arm 131 and the outlet end 21 along the axial direction A of the outlet end 21 and along the circumferential direction B of the outlet end 21, the reliability of welding is improved.

[0048] As shown in Figure 7 and Figure 8As shown, in the embodiment of the utility model, the wrapping arm 131 also has a clamping state, in the clamping state, the two ends of the wrapping arm 131 are bent to form two clamping portions 1312, the outgoing terminal 21 is clamped between the two clamping portions 1312, and a part of the outgoing terminal 21 extends from between the two clamping portions 1312. Before the wrapping arm 131 forms the wrapping state, the outgoing terminal 21 is clamped by first bending the two ends of the wrapping arm 131 to form two clamping portions 1312, on the one hand, it is convenient for the subsequent wrapping arm 131 to continue to bend to wrap the outgoing terminal 21, on the other hand, it can also further improve the wrapping force between the wrapping arm 131 and the outgoing terminal 21, thereby improving the connection quality of the wrapping arm 131 and the outgoing terminal 21. In addition, the welding structure 5 includes an initial welding portion, wherein in the clamping state, the initial welding portion is formed by welding between the outgoing terminal 21 and the inner wall surface of the two clamping portions 1312. By first welding the initial welding portion in the clamping state to weld and connect the wrapping arm 131 and the outgoing terminal 21, and then welding the reinforcing welding portion in the wrapping state to weld and connect the wrapping arm 131 and the outgoing terminal 21, the connection quality of the wrapping arm 131 and the outgoing terminal 21 is further improved, and finally the reflow section 211 of the outgoing terminal 21 is welded to form the welding wrapping portion 51 and is welded and wrapped on the wrapping frame 1311, ensuring reliable welding quality.

[0049] Specifically, as shown in Figure 2 、 Figure 6 and Figure 8 , the wrapping arm 131 includes a supporting portion 1313, a first side portion 1314 and a second side portion 1315, the first side portion 1314 and the second side portion 1315 are connected to the two ends of the supporting portion 1313, and the first side portion 1314 and the second side portion 1315 can wrap the outgoing terminal 21 by bending to cooperate with the supporting portion 1313. The first side portion 1314 is bent to form a clamping portion 1312, the second side portion 1315 is bent to form another clamping portion 1312 and a pressing portion 1316, and the pressing portion 1316 tightly fixes the outgoing terminal 21 on the supporting portion 1313. Wherein, the length of the second side portion 1315 is greater than the length of the first side portion 1314, the first side portion 1314 only needs to form a clamping portion 1312 by one-time bending, and the second side portion 1315 needs to form another clamping portion 1312 by one-time bending and then form a pressing portion 1316 by one-time bending.

[0050] Embodiment two

[0051] As Figure 7As shown, the utility model also provides a kind of inductance, at least one inductance is processed using inductance module, and inductance includes coil 2, magnetic core 3 and two electrode pieces 4, the two electrode parts 121 of electrode structure 12 are cut and separated from frame main body 11 to form two electrode pieces 4, and two electrode pieces 4 are adhered to magnetic core 3 by bending.Inductance module in the embodiment and the specific structure, working principle and beneficial effect of inductance module in embodiment one are same, and here will not be repeated.

[0052] Combination Figure 1 、 Figure 2 And Figure 7 As shown, the manufacture of inductance includes the following steps:

[0053] The two outgoing line ends 21 of at least one coil 2 are placed on the two wrapping structures 13 of the lead frame 1 arranged oppositely, and the two wrapping structures 13 wrap the two outgoing line ends 21 in the circumferential direction B of the outgoing line ends 21, and a part of the outgoing line ends 21 extends out of the wrapping structures 13 to form a reflow section 211;

[0054] The two wrapping structures 13 and the two outgoing line ends 21 wrapped thereby are welded and connected; wherein the reflow section 211 forms a welded wrapping part 51 by welding to wrap at least a part of the wrapping structure 13;

[0055] At least one magnetic core 3 is formed by powder die casting, and the coil 2 and the corresponding two wrapping structures 13 are embedded in the magnetic core 3, so as to obtain an inductance module; wherein the specific structure, working principle and beneficial effect of the inductance module and the inductance module in embodiment one are same, and here will not be repeated;

[0056] The two electrode parts 121 connected by the two wrapping structures 13 are cut and separated from the frame main body 11 of the lead frame 1, so as to form two electrode pieces 4;

[0057] The two electrode pieces 4 are bent and adhered to the magnetic core 3, so as to obtain at least one inductance.

[0058] The above only describes several embodiments of the utility model, and those skilled in the art can make various changes or modifications to the embodiments of the utility model according to the content disclosed in the application file without departing from the spirit and scope of the utility model.

Claims

1. An inductive module, characterized by The inductor module comprises: at least one coil having two wire ends; a lead frame having a frame body, at least one electrode structure and a plurality of wrapping structures arranged opposite to each other, the electrode structure comprising two electrode parts arranged opposite to each other, one end of the electrode part being connected to the frame body, the other end of the electrode part being connected to the wrapping structure; at least one magnetic core formed by powder compression molding, and the coil and the wrapping structure being embedded in the magnetic core; wherein the wrapping structure wraps the wire end outside in the circumferential direction of the wire end, and the wire end and the wrapping structure are welded to form a welding structure; a part of the wire end extends out of the wrapping structure to form a reflow section for reflowing during welding, the welding structure comprises a welding wrapping part, the reflow section forms the welding wrapping part by welding, and at least a part of the wrapping structure is wrapped by the welding wrapping part.

2. The inductor module of claim 1, wherein: the wrapping structure comprises a wrapping arm, the wrapping arm having a horizontal state and a wrapping state; in the horizontal state, the wrapping arm is arranged horizontally, and the wire end is placed on the wrapping arm; in the wrapping state, the wrapping arm is bent to form a wrapping frame, the wrapping frame wraps the wire end outside in the circumferential direction of the wire end, and a part of the wire end extends out of the wrapping frame to form the reflow section.

3. The inductor module of claim 2, wherein: the welding structure further comprises a reinforcing welding part; in the wrapping state, the reinforcing welding part is formed by welding between the wire end and the inner wall surface of the wrapping frame.

4. The inductor module of claim 3, wherein: the reinforcing welding part comprises an axial welding part and a circumferential welding part; the axial welding part is formed by welding along the axial direction of the wire end between the two ends of the wrapping arm and connected to the wire end, and the circumferential welding part is formed by welding along the circumferential direction of the wire end between the wrapping arm and the wire end.

5. The inductive module of claim 2, wherein the first and second inductive elements are formed by a single inductive element. the wrapping arm further has a clamping state, in which the two ends of the wrapping arm are bent to form two clamping parts, the wire end is clamped between the two clamping parts, and a part of the wire end extends out of the two clamping parts.

6. The inductor module of claim 5, wherein: the welding structure comprises an initial welding part; in the clamping state, the initial welding part is formed by welding between the wire end and the inner wall surface of the two clamping parts.

7. The inductor module of claim 5, wherein: the wrapping arm comprises a supporting part, a first side part and a second side part, the first side part and the second side part being connected to the two ends of the supporting part, and the first side part and the second side part are bent to cooperate with the supporting part to wrap the wire end.

8. The inductor module of claim 7, wherein: The first side part is bent to form the clamping part, and the second side part is bent to form the other clamping part and the pressing part, which presses and fixes the wire end on the support part.

9. The inductor module of any one of claims 1-8, wherein, The welding structure is welded by resistance welding and laser welding.

10. An inductor, characterized by The inductor module of any one of claims 1-9 is used to process at least one inductor, which includes a coil, a magnetic core, and two electrode sheets, the two electrode parts of the electrode structure are cut and separated from the frame body to form the two electrode sheets, and the two electrode sheets are bent to be attached to the magnetic core.

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