Integrally-formed inductance coil assembly and terminal strip

Abstract

The utility model provides an integrally-formed inductance coil assembly and a terminal strip. The integrally-formed inductance coil assembly comprises a terminal strip and a plurality of coils, the terminal strip comprises a plurality of pairs of terminals, each pair of terminals is welded to one coil, each coil extends outwards to form two lead heads, each terminal is provided with a main body part and a welding part, the welding part is arranged at the end of the main body part and is adjacent to the corresponding coil, the welding part is provided with two limiting pieces, and the limiting pieces are arranged on the main body part. Each limiting piece is formed by bending a convex angle arranged on the welding part, the two limiting pieces are oppositely arranged along the extension direction of the same lead head and respectively surround the same lead head, and at least one limiting piece is welded with the lead head. On the basis, the lead head can be limited so that the lead head and the terminal can be relatively fixed, and after the at least one limiting piece and the corresponding lead head are welded so that the terminal and the lead head can be welded, the welding effect can be improved, the welding point is not prone to being extruded open when being formed and after being formed, and the welding quality is improved. Therefore, the occurrence probability of poor open circuit is reduced and even eliminated.

Description

Technical Field

[0001] This application relates to the field of electromagnetic devices, specifically to an integrally molded inductor coil assembly and terminal block. Background Technology

[0002] With the rapid development of technology, especially the emergence of multifunctional devices, the demand for passive components is increasing. Magnetic components, such as inductors, are widely used, and the requirements for high current, high frequency, and high reliability in magnetic components are constantly being upgraded. Taking passive components used in automobiles as an example, with the continuous improvement of automotive electronics, the types and quantities of passive components are constantly increasing. These components have higher requirements than ordinary passive components, mainly due to their harsher operating environments, demanding longer design life, higher safety, and higher reliability. This has led to the wider application of molded inductors. In molded inductors, the coil leads are typically welded to the corresponding terminals in the terminal block using laser welding. Because there are often noticeable gaps between the leads and terminals, and the weld joints do not restrict the leads, cold solder joints are prone to occur, resulting in poor welding quality. More importantly, the solder joints are easily squeezed open during and after molding, leading to open circuit problems. Utility Model Content

[0003] In view of this, this application provides an integrally molded inductor coil assembly and terminal block, which can improve the problem of open circuit failure caused by poor soldering of leads and terminals.

[0004] This application provides an integrally molded inductor coil assembly, including a terminal block and several coils. The terminal block includes multiple pairs of terminals, each pair of terminals is soldered to a coil, and each coil has two lead ends extending outward. Each terminal is provided with a main body and a soldering part. The soldering part is provided at the end of the main body and adjacent to the corresponding coil. The soldering part is provided with two limiting members. Each limiting member is formed by bending a convex angle provided in the soldering part. The two limiting members are arranged opposite to each other along the extension direction of the same lead end and respectively surround the same lead end. At least one limiting member is soldered to the corresponding lead end.

[0005] Optionally, the two protruding corners of the two limiting members are bent in opposite directions, and their bending directions are also opposite.

[0006] Optionally, the main body is a sheet-like structural component, with two unbent convex corners parallel to the main body.

[0007] Optionally, one limiting member, located away from the coil, is welded to the corresponding lead end, while the other limiting member is not welded to the lead end.

[0008] Optionally, the width of the convex angle forming the limiting member away from the coil is greater than the width of the other convex angle.

[0009] Optionally, the welding point between the limiting member and the corresponding lead head is located at the center of the limiting member.

[0010] Optionally, the two leads of the same coil extend in the same direction, and the limiting members of the two terminals welded to the same coil are located on the same side of the coil.

[0011] Optionally, the welding part is provided with a branch, the two limiting members are connected to opposite sides of the branch, and the lead wire head is supported on the branch.

[0012] Optionally, the minimum width of the branch is equal to the diameter of the lead end.

[0013] This application provides a terminal block for welding to a plurality of coils, each coil having two leads extending outwards. The terminal block includes multiple pairs of terminals, each terminal having a main body and a welding part. The welding part is located at the end of the main body and adjacent to the corresponding coil. The welding part has two protruding corners, which are arranged opposite to each other along the extension direction of the same lead, for bending and wrapping around the same lead, and for welding at least one of the bent leads to the lead.

[0014] As described above, in the integrally molded inductor coil assembly and terminal block of this application, the welding portion of the terminal is provided with two limiting members. Each limiting member is formed by bending a convex angle provided in the welding portion. The two limiting members are arranged opposite to each other along the extension direction of the same lead head and surround the same lead head respectively. Therefore, the lead head can be limited so that the lead head and the terminal are relatively fixed. After welding at least one limiting member to the corresponding lead head to realize the welding of the terminal and the lead head, it is beneficial to improve the welding effect and also makes it less likely to be squeezed open by force during and after the welding point is formed, thereby reducing or even eliminating the probability of open circuit failure. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of an integrally molded inductor coil assembly according to an embodiment of this application;

[0016] Figure 2 yes Figure 1 Enlarged view of the structure of region A defined by the dashed line in the middle;

[0017] Figure 3 yes Figure 2 The rear view of the area A defined by the dashed line shown;

[0018] Figure 4 yes Figure 1 The diagram shows the structure of the terminal block.

[0019] Figure 5 yes Figure 4 A schematic diagram of the structure of one terminal of the terminal block shown;

[0020] Figure 6 yes Figure 4 The diagram shows the structure of the terminal block and each coil assembled but not soldered.

[0021] Figure 7 yes Figure 6 Enlarged view of the structure of region B defined by the dashed line;

[0022] Figure 8 yes Figure 7 The rear view of region B, defined by the dashed line shown.

[0023] First direction x, second direction y, third direction;

[0024] Terminal block 1, terminal strip 1a, connecting part 1b, terminal 10;

[0025] Main body 11, welding part 12, limiting part 120, protruding corner 121, branch 122;

[0026] First convex angle 121a, second convex angle 121b, first limiting member 120a, second limiting member 120b;

[0027] Coil 2, lead 20a, lead end 20. Detailed Implementation

[0028] To address the aforementioned technical problems in the prior art, the terminal block of this application includes a terminal with two limiting members on its welding portion. Each limiting member is formed by bending a convex angle provided on the welding portion. The two limiting members are arranged opposite each other along the extension direction of the same lead head and surround the same lead head, thereby limiting the lead head and fixing the lead head and the terminal relative to each other. After the terminal and the lead head are welded, the welding point is not easily squeezed open by force, thereby reducing or even eliminating the probability of open circuit failure.

[0029] The specific form of the shape, quantity, size, and other parameters of any of the terminals, limiting members, and protrusions can be determined according to the adaptability required by the actual scenario, and this application does not limit them.

[0030] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions of this application will be clearly described below in conjunction with specific embodiments and corresponding drawings. Obviously, the embodiments described below are only a part of the embodiments of this application, and not all of them. Unless otherwise specified, the following embodiments and their technical features can be combined with each other, and also belong to the technical solutions of this application.

[0031] In the description of the embodiments of this application, the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the technical solutions of the corresponding embodiments, and are not intended to indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation. They should not be construed as limitations on this application.

[0032] Please refer to the following: Figures 1 to 8 As shown, the integrally molded inductor coil assembly (which may be simply referred to as the "inductor coil assembly" or "coil assembly") of this example includes a terminal block 1 and a plurality of coils 2.

[0033] For ease of description and understanding, combined with Figures 1 to 8 In the arrangement shown, the length direction of terminal block 1 is referred to as the first direction x, the thickness direction as the second direction y, and the width direction as the third direction z. The first direction x, the second direction y, and the third direction z are all perpendicular to each other and can be regarded as the three coordinate axes of a three-dimensional rectangular coordinate system. It should be understood that the term "perpendicular" throughout this application does not require that the angle between the two directions must be 90°, but allows for deviations of, for example, ±10°. That is, "perpendicular" can be understood as the angle between any two directions being 80° to 100°. Similarly, the term "parallel" throughout this application does not require that the angle between the two directions be 0° or 180°, but allows for deviations of, for example, ±10°. That is, "parallel" can be understood as the angle between any two directions being 0° to 10° or 170° to 190°.

[0034] Each coil 2 can be formed into a cylindrical structure by winding lead wire 20a, such as enameled wire (enameled copper wire), turn by turn. A single coil 2 can be formed by winding one lead wire 20a, depending on the specific winding method. Each coil 2 has two lead wire ends 20 extending outwards. The lead wire ends 20 refer to the two end portions extending outwards after the lead wire 20a is wound. After subsequent soldering, the extended ends of the lead wire 20a are as follows: Figures 6 to 8 The two ends shown are burned off to form two lead ends 20.

[0035] Terminal block 1 includes multiple pairs of terminals 10, each pair of terminals 10 being soldered to a coil 2. Terminal block 1 is a thin sheet structure, comprising two terminal strips 1a arranged parallel to each other along a third direction z and laterally (parallel to the first direction x as shown in the figure). The two terminal strips 1a are fixedly connected by a connecting part 1b, which is formed as a narrow metal strip structure and is vertically fixed between the two terminal strips 1a. When there are multiple connecting parts 1b and multiple pairs of terminals 10, the connecting parts 1b and the multiple pairs of terminals 10 are alternately distributed along the first direction x.

[0036] At least one pair of terminals 10 are fixedly provided on the inner sides of the two terminal strips 1a respectively, and each terminal 10 can be regarded as a part led out from the terminal strip 1a. Figure 1 and Figure 6 The six pairs of terminals 10 and six coils 2 shown are merely illustrative and can be adapted to actual needs. This application does not limit the number of terminals 10 and coils 2. Each pair of terminals 10 can be symmetrically arranged, specifically symmetrically arranged along the central axis of the corresponding coil 2, which is parallel to the first direction y.

[0037] Terminal block 1 can be made from a thin sheet of conductive metal as the substrate and is produced by integral punching. The resulting terminal strip 1a, terminal 10 and connecting part 1b are integrally formed.

[0038] In one example, the terminal strip 1a is a straight metal strip with multiple through holes punched on it for bolts to pass through and secure the terminal block 1. During assembly, the terminal block 1 is placed on the corresponding insulating base (not shown in the figure) provided by the inductor. The through holes on the terminal block 1 are aligned with the threaded holes on the insulating base. Bolts are then passed through the through holes and tightened into the threaded holes of the insulating base, thus securing the terminal block 1 to the insulating base. This method is only one way to secure the terminal block 1; other methods such as snap-fit ​​fixing and embedded fixing can also be used as needed.

[0039] Each terminal 10 is provided with a main body 11 and a welding part 12. Each terminal 10 has an overall Y-shaped structure. The main body 11 includes a vertical rod and a transition part. One end of the vertical rod is fixedly connected to the terminal strip 1a, and the other end extends outward along its two apex corners to form a transition part. The end of the transition part can extend outward along the parallel direction of the terminal strip 1a to form a welding part 12, so that the vertical rod, transition part and welding part 12 are in an overall Y-shaped structure. The welding part 12 is the part that directly acts on the lead wire 20a of the coil 2 and is welded to it. The welding part 12 is provided at the end of the main body 11 and adjacent to the corresponding coil 2. The welding part 12 is provided with two limiting members 120. The two limiting members 120 are arranged opposite each other along the extension direction of the same lead wire head 20 (the first direction x in the figure) and surround the same lead wire head 20 respectively. At least one limiting member 120 is welded to the corresponding lead wire head 20.

[0040] Each limiting member 120 can be formed by bending the protruding corner provided in the welding part 12. (Combined) Figures 4 to 8 As shown, for any limiting member 120, the welding part 12 is provided with two protruding corners 121. These two protruding corners 121 are arranged opposite each other along the extension direction of the same lead head 20. In the placement position shown in the figure, these two protruding corners 121 can be arranged opposite each other along the first direction x. The so-called relative arrangement means that the distance between the two subjects is not equal to zero, that is, the two subjects do not contact each other. Before bending, the extension directions of these two protruding corners 121 are opposite. The extension direction of one protruding corner 121 is parallel to the third direction z, and the extension direction of the other protruding corner 121 is parallel to the opposite direction of the third direction z. For the main body 11 and terminal 10, which are integrally sheet-like structural parts, these two protruding corners 121 are parallel to the main body 11 when not bent, that is, they are located on the same plane, which is beneficial for forming by a single punching process.

[0041] Please continue reading. Figures 1 to 8 As shown, the welding part 12 is provided with a branch 122, that is Figure 5 In the area shown by the dashed line, the two limiting members 120 (and the two unbent protruding corners 121) are connected to the opposite sides of the branch 122, and the lead head 20 is carried on the branch 122.

[0042] Before welding, the coil 2 is placed on, for example, a coil support base (not shown in the figure). Two leads 20a extending on the same side and approximately parallel are drawn from the coil 2. The two leads 20a extend forward and are placed in the positioning groove of, for example, a lead positioning seat (not shown in the figure). The terminal block 1 is placed at the corresponding position of the coil 2, so that the coil 2 passes between a pair of terminals 10. The leads 20a are supported on the branch 122. Then, each convex corner 121 is bent so that it bends around the corresponding lead 20a. Then, welding is started, for example, with a laser to weld the lead 20a to the corresponding bent convex corner 121, and the excess wire end of the lead 20a is melted off so that the lead 20a extending out of the coil 2 becomes the lead end 20.

[0043] exist Figures 1 to 3 In the example shown, the convex corner 121, after being bent and welded to the lead wire 20a, can be melted by the high welding temperature and, after cooling, fuses with the lead wire head 20 to form a spherical or near-spherical structure. This arrangement makes the layout of the coil 2 and terminal 10 more reasonable, reduces the lead-out length of the lead wire 20a and additional wiring, and improves the overall product integrity.

[0044] For ease of distinction and description, this application refers to the convex angle 121 furthest from coil 2 as the first convex angle 121a, and the corresponding convex angle 121 as the second convex angle 121b. The second convex angle 121b is bent towards the main body 11, and the first convex angle 121a is bent towards coil 2; that is, the bending directions of these two convex angles 121 are opposite, thereby wrapping around the corresponding lead end 20 and fixing the lead end 20 relative to the terminal 10. During the bending process, the opposite bending directions of the two convex angles 121 can effectively limit the lateral displacement of the lead end 20, for example, controlling the displacement to 0.05mm to 0.3mm, preferably 0.2mm to 0.3mm, thus improving the welding stability of the product.

[0045] The first convex angle 121a is bent to become one of the limiting members 120, referred to as the first limiting member 120a. The second convex angle 121b is bent to become another limiting member 120, referred to as the second limiting member 120b. These two limiting members 120 respectively surround the same lead end 20. Then, by means of, laser welding, the limiting member 120 away from the coil 2 is welded to the corresponding lead end 20, while the other limiting member 120 is not welded to the lead end 20. That is, only the first limiting member 120a is welded to the lead end 20.

[0046] In this example, the two lead ends 20 of the same coil 2 extend in the same direction. Correspondingly, the limiting members 120 of the two terminals 10 welded to the coil 2 are located on the same side of the coil 2. Thus, the lead ends 20 of all coils 2 extend in the same direction, which facilitates the welding of the entire terminal block 1.

[0047] Optionally, the soldering point between the first limiting member 120a and the corresponding lead head 20 is located at the center of the first limiting member 120a, which can prevent the second limiting member 120b from being burned by the heat of the soldering high temperature.

[0048] Based on the above, the first limiting member 120a and the second limiting member 120b surround and bind the lead head 20, which can reduce or even eliminate the gap between the lead head 20 and the welding part 12, thus improving the welding effect. In addition, since there is a certain distance between the second limiting member 120b and the welding position, it can avoid being melted by the high temperature of welding, and always limit the lead head 20 and keep the lead head 20 and the terminal 10 relatively fixed. Even if the first limiting member 120a is melted by the high temperature of welding, it will not be squeezed open by force during or after the welding point is formed, thereby reducing or even eliminating the probability of open circuit defects.

[0049] In other examples, this application may only weld the second limiting member 120b to the lead head 20, while the first limiting member 120a is not welded to the lead head 20; or, both limiting members 120 may be welded to the same lead head 20, for example, the first limiting member 120a may be welded to the lead head 20 first, and after a period of time for the temperature of the welding point to cool down, the second limiting member 120b may be welded to the same lead head 20.

[0050] In the example where only the first limiting member 120a is welded to the lead head 20, the width of the first convex angle 121a can be greater than the width of the second convex angle 121b. In this way, the first limiting member 120a and the lead head 20 have a larger welding area and higher welding strength, which further reduces the probability of open circuit failure.

[0051] Optional, please continue reading Figure 5 As shown, the minimum width of the branch 122 (i.e., the length along the third direction z) is equal to the diameter of the lead 20 (or lead 20a). Therefore, the overlap area between the solder joint 12 and the lead 20 is relatively large, which increases the welding area between the solder joint 12 and the lead 20, thus improving the stability of the lead 20 after welding to the terminal 10.

[0052] This application embodiment also provides a terminal block for welding to a plurality of coils, each coil having two leads extending outwards. The terminal block includes multiple pairs of terminals, each terminal having a main body and a welding part. The welding part is located at the end of the main body and adjacent to the corresponding coil. The welding part has two protruding corners, which are arranged opposite to each other along the extension direction of the same lead, for bending and wrapping around the same lead, and for welding at least one of the bent leads to the lead.

[0053] The terminal block may have the structural design of the terminal block 3 in any of the aforementioned examples, and therefore the beneficial effects that the terminal block 3 in the corresponding examples can produce will not be described in detail here.

[0054] The above description is only a part of the embodiments of this application and does not limit the patent scope of this application. For those skilled in the art, any equivalent structural transformations made using the content of this specification and drawings are similarly included within the patent protection scope of this application.

[0055] Although this document uses terms such as "first," "second," etc., to describe various types of information, this information should not be limited to these terms. These terms are only used to distinguish information of the same type from one another. Furthermore, the singular forms "a," "an," and "the" are intended to also include the plural forms. The terms "or" and "and / or" are interpreted as inclusive, or meaning either one or any combination thereof. Exceptions to this definition only arise when combinations of elements, functions, steps, or operations are inherently mutually exclusive in some way.

Claims

1. A one-piece molded inductor coil assembly, comprising a terminal block and a plurality of coils, wherein the terminal block includes multiple pairs of terminals, each pair of terminals is soldered to a coil, and each coil has two leads extending outwards, characterized in that, Each terminal is provided with a main body and a welding part. The welding part is located at the end of the main body and adjacent to the corresponding coil. The welding part is provided with two limiting members. Each limiting member is formed by bending a convex angle provided in the welding part. The two limiting members are arranged opposite to each other along the extension direction of the same lead head and respectively surround the same lead head. At least one limiting member is welded to the corresponding lead head.

2. The integrally molded inductor coil assembly according to claim 1, characterized in that, The two protruding corners of the two limiting members are bent in opposite directions, and their bending directions are also opposite.

3. The integrally molded inductor coil assembly according to claim 2, characterized in that, The main body is a sheet-like structural component, with two unbent convex corners parallel to the main body.

4. The integrally molded inductor coil assembly according to claim 1, characterized in that, One limiting member, located away from the coil, is welded to the corresponding lead end, while the other limiting member is not welded to the lead end.

5. The integrally molded inductor coil assembly according to claim 4, characterized in that, The width of the convex angle of the limiting member formed by bending away from the coil is greater than the width of the other convex angle.

6. The integrally molded inductor coil assembly according to claim 4, characterized in that, The welding point between the limiting member and the corresponding lead head is located at the center of the limiting member.

7. The integrally molded inductor coil assembly according to any one of claims 1 to 6, characterized in that, The two leads of the same coil extend in the same direction, and the limiting members of the two terminals welded to the same coil are located on the same side of the coil.

8. The integrally molded inductor coil assembly according to any one of claims 1 to 6, characterized in that, The welding section is provided with branches, the two limiting members are connected to the opposite sides of the branches, and the lead wire head is supported on the branches.

9. The integrally molded inductor coil assembly according to claim 8, characterized in that, The minimum width of the branch is equal to the diameter of the lead end.

10. A terminal block for soldering to a plurality of coils, each coil having two leads extending outwards, characterized in that, The terminal block includes multiple pairs of terminals, each terminal having a main body and a welding part. The welding part is located at the end of the main body and adjacent to the corresponding coil. The welding part has two protruding corners, which are arranged opposite each other along the extension direction of the same lead head, for bending and wrapping around the same lead head, and for welding at least one of the bent leads head to the lead head.

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