Inductor with copper-aluminum composite terminal structure

Abstract

The utility model discloses an inductor with a copper-aluminum composite terminal structure, which comprises a shell, a copper-aluminum composite terminal structure and a copper-aluminum composite terminal structure, and is characterized in that the shell is internally provided with a mounting cavity with an open end; the magnetic core is arranged on the shell and is positioned in the mounting cavity; the coil sleeves the outer side of the magnetic core, and the coil is positioned in the mounting cavity; the aluminum bar is connected with the coil; the composite terminal is connected with the aluminum bar; and the solder layer is arranged between the composite terminal and the aluminum bar, and the composite terminal is connected with the aluminum bar through the solder layer. The composite terminal is welded to the aluminum bar through laser welding, welding wires are used for filling in the welding process to form a welding flux layer, and hard connection of the composite terminal and the aluminum bar is achieved through the welding flux layer. By arranging the welding flux layer, the welding penetration depth is high, the number of air holes of the welding flux layer is small, and the connection strength between the composite terminal and the aluminum bar is ensured. The visual degree of the welding penetration depth is high through the welding flux layer, the welding effect can be visually detected, defective products can be screened out conveniently and welded again, and the welding efficiency is high.

Description

TECHNICAL FIELD

[0001] The application relates to the technical field of inductors, in particular to an inductor with a copper-aluminum composite terminal structure. BACKGROUND

[0002] An inductor is an electronic component used to process current in a circuit. Inductors are widely used in industrial control, automotive electronics, new energy, high-current switching stabilizers and other electronic device fields. With the development of electronic devices towards high performance and high density, the installation requirements and performance requirements of inductors are continuously improved, and the industry competition is fierce, so there is an urgent need for an inductor with low cost, high stability and high performance in the industry.

[0003] In the related art, the aluminum bar and the composite terminal are directly connected by laser welding to form a hard connection, and the welding strength and toughness are low: since there is no additional filler material in direct laser welding, the strength and toughness of the weld joint mainly depend on the performance of the raw material in the welding area. If the raw material is not uniform or partially melted, it may result in weak welding strength. And the penetration depth of direct laser welding is limited, especially for the welding between aluminum bars and composite terminals with large thickness, insufficient penetration depth may affect the welding quality, and multiple welding or significantly increasing the welding power is required, but increasing the welding power will cause many pores and discoloration of the terminal contact surface. And for some difficult-to-weld materials, such as high-reflectivity materials (aluminum, copper, etc.) or dissimilar metals, direct laser welding is prone to welding defects or insufficient strength because the reflectivity or thermal conductivity of these materials affects the welding effect.

[0004] Therefore, it is necessary to provide an inductor with a copper-aluminum composite terminal structure to improve the connection strength between the aluminum bar and the composite terminal, which is an important technical problem to be solved. CONTENT OF THE INVENTION

[0005] The application provides an inductor with a copper-aluminum composite terminal structure, which aims to solve the problem of insufficient connection strength between the aluminum bar and the composite terminal in the prior art.

[0006] To achieve the above-mentioned purpose, the application provides an inductor with a copper-aluminum composite terminal structure, which comprises: an outer shell, an installation cavity with an open end is arranged in the outer shell; a magnetic core, the magnetic core is arranged in the outer shell and located in the installation cavity; a coil, the coil is sleeved on the outer side of the magnetic core, and the coil is located in the installation cavity; an aluminum bar, the aluminum bar is connected to the coil; a composite terminal, the composite terminal is connected to the aluminum bar; a solder layer, the solder layer is arranged between the composite terminal and the aluminum bar, and the composite terminal is connected to the aluminum bar through the solder layer.

[0007] In some embodiments, the composite terminal comprises: a first composite part connected to the aluminum bar, the first composite part being provided with a mounting surface; a second composite part integrally formed with the first composite part, the second composite part being provided with a mounting surface; and a copper layer covering the mounting surfaces.

[0008] In some embodiments, the composite terminal further comprises:

[0009] A cutting groove is arranged on an end surface of the first composite part opposite to the mounting surface.

[0010] In some embodiments, the composite terminal further comprises: a first side surface arranged on two sides of the first composite part; and a second side surface arranged on two sides of the second composite part, the first side surface and the second side surface on the same side being coplanar.

[0011] In some embodiments, the composite terminal further comprises:

[0012] A main mounting plate is arranged at one end of the coil;

[0013] A secondary mounting plate is arranged at the other end of the coil;

[0014] A main plate is arranged on the side of the main mounting plate and the secondary mounting plate away from the coil;

[0015] A connecting core is connected to one main plate at one end and connected to another main plate at the other end, and the coil is sleeved on the outside of the connecting core.

[0016] In some embodiments, the composite terminal further comprises:

[0017] A mounting member is arranged between the main mounting plate and the secondary mounting plate, and the mounting member is used for fixing the main plate.

[0018] In some embodiments, the composite terminal further comprises:

[0019] A connecting seat is arranged on the main mounting plate, and the connecting seat is provided with a positioning hole through which the aluminum bar and the composite terminal pass;

[0020] A first connecting hole is arranged on the connecting seat;

[0021] A second connecting hole is arranged on the composite terminal, and the second connecting hole is adapted to the first connecting hole.

[0022] In some embodiments, the composite terminal further comprises:

[0023] A potting glue body is arranged in the mounting cavity;

[0024] A heat-conducting member is arranged between the potting glue body and the coil.

[0025] In some embodiments, the composite terminal further comprises:

[0026] The third connecting hole is arranged on the shell;

[0027] The positioning pin is arranged on the shell.

[0028] In some embodiments, further comprising:

[0029] The heat dissipation member is arranged on the outer wall surface of the shell.

[0030] The technical scheme of the present application provides a copper-aluminum composite terminal structure inductor, comprising: a shell, a magnetic core, a coil, an aluminum bar, a composite terminal, and a solder layer; the shell is provided with an installation cavity with an open end; the magnetic core is arranged in the shell and located in the installation cavity; the coil is sleeved on the outer side of the magnetic core and located in the installation cavity; the aluminum bar is connected to the coil; the composite terminal is connected to the aluminum bar; the solder layer is arranged between the composite terminal and the aluminum bar, and the composite terminal is connected to the aluminum bar through the solder layer. In the installation process of the copper-aluminum composite terminal structure inductor, the composite terminal is welded to the aluminum bar by laser welding, and welding wire filler is used in the welding process to form a solder layer, thereby achieving hard connection of the composite terminal and the aluminum bar through the solder layer. By arranging the solder layer, the welding penetration is high, the solder layer has few pores, and the connection strength between the composite terminal and the aluminum bar is ensured. Moreover, the solder layer makes the welding penetration highly visible, the welding effect can be visually detected, and it is convenient to screen out defective products and re-weld, thereby improving the welding efficiency. BRIEF DESCRIPTION OF DRAWINGS

[0031] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiments or prior art description. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative effort, wherein:

[0032] Figure 1 It is a schematic diagram of the three-dimensional structure of the coil in an embodiment of the present application;

[0033] Figure 2 It is a schematic diagram of the three-dimensional structure of the composite terminal in an embodiment of the present application;

[0034] Figure 3 It is another schematic diagram of the three-dimensional structure of the composite terminal in an embodiment of the present application;

[0035] Figure 4 It is a schematic diagram of the three-dimensional structure of the copper-aluminum composite terminal structure inductor in an embodiment of the present application;

[0036] Figure 5 It is a schematic diagram of the three-dimensional structure of the copper-aluminum composite terminal structure inductor in an embodiment of the present application;

[0037] Figure 6 A schematic view of a three-dimensional structure of an inductance of a copper-aluminum composite terminal structure without a shell in an embodiment of the present application;

[0038] Figure 7 A schematic view of a three-dimensional structure of a main mounting plate, a secondary mounting plate and a magnetic core in an embodiment of the present application;

[0039] Figure 8 A schematic view of a three-dimensional structure of a shell in an embodiment of the present application. DETAILED DESCRIPTION

[0040] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by a person of ordinary skill in the art without creative effort fall within the scope of protection of the present application.

[0041] It should be noted that all directional indications, such as up, down, left, right, front, back, etc., in the embodiments of the present application are only used to explain the relative position relationship, movement condition, etc. between components in a certain posture (as shown in the drawings), and if the certain posture changes, the directional indications also change accordingly.

[0042] It should also be noted that when an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or can have a middle element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or can have a middle element.

[0043] In addition, the description of "first", "second", etc. in the present application is only for the purpose of description, and cannot be understood as indicating or implying the relative importance of the indicated technical features or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first", "second" can explicitly or implicitly include at least one of the features. In addition, the technical solutions of various embodiments can be combined with each other, but it must be based on the fact that a person of ordinary skill in the art can realize it, and when the combination of technical solutions contradicts each other or cannot be realized, it should be considered that the combination of technical solutions does not exist, and is not within the scope of protection claimed by the present application.

[0044] Reference is made to Figure 1 , Figure 4 , Figure 5 , Figure 6 and Figure 8As shown, the application proposes a copper-aluminum composite terminal structure inductor, comprising: a shell 4, the shell 4 is provided with an open mounting cavity; a magnetic core, the magnetic core is arranged in the shell 4 and located in the mounting cavity; a coil 1, the coil 1 is sleeved on the outside of the magnetic core, and the coil 1 is located in the mounting cavity; an aluminum bar 3, the aluminum bar 3 is connected with the coil 1; a composite terminal 2, the composite terminal 2 is connected with the aluminum bar 3; a solder layer, the solder layer is arranged between the composite terminal 2 and the aluminum bar 3, and the composite terminal 2 is connected with the aluminum bar 3 through the solder layer.

[0045] Among them, the shell 4 is the structural basis of the copper-aluminum composite terminal structure inductor, and the coil 1, the magnetic core, the aluminum bar 3, the composite terminal 2 and the solder layer are all arranged in the mounting cavity of the shell 4. The coil 1 and the magnetic core constitute an inductor structure, and the inductor structure is installed in the mounting cavity. The aluminum bar 3 and the composite terminal 2 form a wiring structure, the aluminum bar 3 is connected with the coil 1, the composite terminal 2 is electrically connected with external current, and the external current is introduced into the coil 1 through the two composite terminals 2. The solder layer is the core component of the copper-aluminum composite terminal structure inductor, and the connection strength between the aluminum bar 3 and the composite terminal 2 can be effectively enhanced through the solder layer.

[0046] Specifically, in the installation process of the copper-aluminum composite terminal structure inductor, the composite terminal 2 is welded to the aluminum bar 3 through laser welding, and welding wire filler is used in the welding process to form a solder layer, so as to realize the hard connection of the composite terminal 2 and the aluminum bar 3 through the solder layer. By setting the solder layer, the welding penetration is high, and the solder layer has few pores, so as to ensure the connection strength between the composite terminal 2 and the aluminum bar 3. Moreover, the solder layer makes the welding penetration highly visible, so that the welding effect can be detected by visual inspection, which is convenient for screening out defective products and re-welding, and the welding efficiency is high.

[0047] Among them, the shell 4 is made of ADC12 material. It has high fluidity and castability, and is suitable for the production of various aluminum alloy die castings. Moreover, it has excellent mechanical properties and corrosion resistance, which is conducive to the copper-aluminum composite terminal structure inductor, and adapts to various harsh environmental conditions.

[0048] Among them, the coil 1 adopts film-wrapped flat aluminum wire, and the two aluminum bars 3 are respectively the two ends of the film-wrapped flat aluminum wire. Compared with copper wire, the production cost of film-wrapped flat aluminum wire is significantly reduced, but the strength of aluminum is not high, so the composite terminal 2 is needed to connect to ensure the stability of the connection between the coil 1 and the external current.

[0049] Referring to Figure 1 and Figure 3As shown in the drawings, in some embodiments, the composite terminal 2 comprises: a first composite part 24, the first composite part 24 is connected with the aluminum bar 3, and the first composite part 24 is provided with a mounting surface 25; a second composite part 23, the second composite part 23 is integrally formed with the first composite part 24, the second composite part 23 is connected with the external current, and there is an included angle between the first composite part 24 and the second composite part 23, which is preferably 90°, of course, the included angle between the first composite part 24 and the second composite part 23 can also be changed according to the structural design, which is not specifically limited here, and the second composite part 23 is provided with a mounting surface 25; a copper layer, the copper layer is coated on the mounting surface 25. The copper layer is used to enhance the structural strength of the composite terminal 2, and the copper layer can improve the current carrying effect of the composite terminal 2.

[0050] In this embodiment, the copper layer is coated on the mounting surface 25 of the first composite part 24 and the second composite part 23 by oxygen-free semi-molten rolling composite technology, and the thickness of the copper layer is about 0.6 mm, and the first composite part 24 and the second composite part 23 are made of aluminum. By coating the copper layer, the structural strength and current carrying effect of the composite terminal 2 are enhanced. And compared with the terminal made of copper, the manufacturing cost of the composite terminal 2 with the copper layer is low.

[0051] Referring to Figure 1 , Figure 2 As shown in the drawings, in some embodiments, the composite terminal 2 further comprises: a cutout 22, the cutout 22 is arranged on the end surface opposite to the mounting surface 25 of the first composite part 24. The cutout 22 is used to increase the contact area between the composite terminal 2 and the solder layer, and further improve the soldering strength, and the cutout 22 can be any one or a combination of more than one of a rectangle, a triangle, an arc or a trapezoid.

[0052] In this embodiment, the cutout 22 is provided with two, the interface shape of the cutout 22 is a triangle and is distributed on both sides of the first composite part 24, so as to form an inclined groove on both sides of the end surface opposite to the mounting surface 25 of the first composite part 24. In the welding process, the end surface opposite to the mounting surface 25 of the first composite part 24 is in close contact with the aluminum bar 3, and the welding wire is welded at the position of the groove, so that the welding process is simple, and the molten solder is more easily flowed into the first composite part 24 and the aluminum bar 3 to form a solder layer. In summary, by setting the groove, the contact area between the composite terminal 2 and the solder layer is increased, and the setting of the solder is beneficial to quickly form a solder layer between the composite terminal 2 and the aluminum bar 3.

[0053] Referring to Figure 1 and Figure 3As shown, in some embodiments, the composite terminal 2 further includes: a first side 26, which is disposed on both sides of the first composite portion 24; the first composite portion 24 is electrically connected to the aluminum busbar 3 of the coil 1; and a second side 27, which is disposed on both sides of the second composite portion 23, with the first side 26 and the second side 27 on the same side being coplanar. The second composite portion 23 needs to be electrically connected to an external current. To ensure the accuracy of the installation position, it is necessary to ensure that the second side 27 of the second composite portion 23 on the same side is coplanar with the first side 26 of the first composite portion 24.

[0054] See Figure 4 , Figure 5 , Figure 6 and Figure 7 As shown, in some embodiments, the system further includes: a main mounting plate 13, disposed at one end of the coil 1; and a secondary mounting plate 12, disposed at the other end of the coil 1. The main mounting plate 13 and the secondary mounting plate 12 form a mounting structure for better fixing the coil 1 and effectively determining the position of the coil 1 inside the housing 4. A main board 14 is disposed on the side of the main mounting plate 13 and the secondary mounting plate 12 away from the coil 1. A connecting core 17 is disposed at one end of one main board 14 and at the other end of another main board 14. The coil 1 is fitted onto the outside of the connecting core 17. The two main boards 14 and the connecting core 17 constitute a magnetic core. The main boards 14 and the connecting core 17 are connected as one unit by adhesive. Through the above-described magnetic core structure design, it is beneficial to increase the magnetic flux area of ​​the magnetic core, further improve the performance of the magnetic core, and enable the magnetic core to better match the overall working efficiency of the machine.

[0055] See Figure 6 and Figure 7 As shown, in some embodiments, the system further includes a mounting member 15, which is spaced apart from the main mounting plate 13 and the sub-mounting plate 12. The mounting member 15 is used to fix the main board 14. The mounting member 15 includes a positioning part and a limiting part, with an included angle between the positioning part and the limiting part. The positioning part and the limiting part form an L-shaped snap-fit, which is used to better fix the main board 14. Preferably, the included angle between the positioning part and the limiting part is 90°. Preferably, the main mounting plate 13 and the sub-mounting plate 12 are also provided with mounting members 15 for mounting coil 1. The structure of the mounting member 15 for mounting coil 1 is the same as that of the mounting member 15 for mounting main board 14, and the structure of the mounting member 15 for mounting coil 1 will not be described in detail here.

[0056] See Figure 6 and Figure 7As shown in some embodiments, further comprising: a connecting seat 7, the connecting seat 7 is installed on the main mounting plate 13, the connecting seat 7 is provided with a positioning hole 16 for the aluminum row 3 and the composite terminal 2 to pass through; the positioning hole 16 is used to fix the position of the aluminum row 3 and the composite terminal 2, and ensure that the first connecting hole 11 can coincide with the second mounting hole, the first connecting hole 11 is provided on the connecting seat 7; the second connecting hole 21 is provided on the composite terminal 2, and the second connecting hole 21 is adapted to the first connecting hole 11. The first connecting hole 11 and the second connecting hole 21 are used to introduce external current, specifically, the access contact of the external lead is arranged between the first connecting hole 11 and the second connecting hole 21, and then the second connecting hole 21 is connected with the first connecting hole 11 through a bolt, so that the access contact can fully contact the composite terminal 2, thereby facilitating the introduction of external current.

[0057] Referring to Figure 4 , Figure 5 and Figure 6 As shown in some embodiments, further comprising: a potting glue body 5, the potting glue body 5 is arranged in the installation cavity; the potting material is mixed with a curing agent to be filled to form, the potting material is room temperature vulcanized silicone rubber or organic silicon gel, after the potting material is arranged, the potting material is mixed with the curing agent at a ratio of 1:1, and then the potting can be carried out, and the curing agent forms the potting glue body 5 after curing, which is used to fix various structures in the installation cavity. Preferably, a primer layer is arranged between the potting glue body 5 and the shell 4, which is used to enhance the adhesion between the shell 4 and the potting glue body 5. The heat conducting piece 10 is arranged between the potting glue body 5 and the coil 1. The heat conducting piece 10 is located in the installation cavity. The heat conducting piece 10 is used to improve the heat conduction efficiency. Since the heat transfer efficiency of the heat conducting piece 10 is better than that of the potting glue body 5, by arranging the heat conducting piece 10 between the coil 1 and the shell 4, the heat generated on the coil 1 can be more easily transferred to the shell 4. And radiated from the shell 4. Preferably, the heat conducting piece 10 is made of ceramic material.

[0058] Referring to Figure 4 , Figure 5 , Figure 6 and Figure 8 As shown in some embodiments, further comprising: a third connecting hole 8, the third connecting hole 8 is arranged on the shell 4; the third connecting hole 8 is used to install the shell 4 into the whole machine; and a positioning pin 6, the positioning pin 6 is arranged on the shell 4. The positioning pin 6 plays a positioning role, which facilitates the installation of the shell 4.

[0059] Referring to Figure 4 , Figure 5 and Figure 8In some embodiments, the heat dissipation member 9 is arranged on the outer wall of the housing 4. The heat dissipation members 9 form a wind cooling heat dissipation structure. Cold air flows through the air channel between the heat dissipation members 9, taking away the heat from the heat dissipation members 9 and the housing 4, thereby rapidly cooling the housing 4. The heat dissipation member 9 is preferably a heat dissipation plate.

[0060] The above description is merely some or preferred embodiments of the present application, and neither the text nor the drawings can limit the scope of protection of the present application. Any equivalent structural transformation made by using the content of the present application specification and drawings, or direct / indirect application in other related technical fields is included in the scope of protection of the present application.

Claims

1. An inductance of a copper-aluminum composite terminal structure, characterized by, The application relates to a coil assembly. The coil assembly comprises: a shell (4) provided with an open-end installation cavity; a magnetic core arranged in the shell (4) and located in the installation cavity; a coil (1) sleeved on the outer side of the magnetic core and located in the installation cavity; an aluminum bar (3) connected with the coil (1); a composite terminal (2) connected with the aluminum bar (3); 2. The inductance of a copper-aluminum composite terminal structure according to claim 1, characterized by a solder layer arranged between the composite terminal (2) and the aluminum bar (3), and the composite terminal (2) is connected with the aluminum bar (3) through the solder layer. The composite terminal (2) comprises: a first composite part (24) connected with the aluminum bar (3) and provided with an installation surface (25); a second composite part (23) integrally formed with the first composite part (24) and provided with an installation surface (25); 3. The inductance of a copper-aluminum composite terminal structure according to claim 2, characterized in that a copper layer arranged on the installation surface (25). The composite terminal (2) further comprises:

4. The inductance of a copper-aluminum composite terminal structure according to claim 2, wherein a cutting groove (22) arranged on the end surface of the first composite part (24) opposite to the installation surface (25). The composite terminal (2) further comprises: a first side surface (26) arranged on the two sides of the first composite part (24); 5. The inductance of a copper-aluminum composite terminal structure according to claim 1, wherein a second side surface (27) arranged on the two sides of the second composite part (23), and the first side surface (26) and the second side surface (27) on the same side are coplanar. The application further relates to a coil assembly. The coil assembly comprises: a main installation plate (13) arranged at one end of the coil (1); a secondary installation plate (12) arranged at the other end of the coil (1); 6. The inductance of a copper-aluminum composite terminal structure according to claim 5, characterized by a main plate (14) arranged on the side of the main installation plate (13) and the secondary installation plate (12) away from the coil (1); a connecting core (17) with one end connected with one main plate (14) and the other end connected with the other main plate (14), and the coil (1) is sleeved on the outer side of the connecting core (17).

7. The inductance of a copper-aluminum composite terminal structure according to claim 5, wherein The coil assembly further comprises: an installation piece (15) arranged between the main installation plate (13) and the secondary installation plate (12), and the installation piece (15) is used for fixing the main plate (14). The coil assembly further comprises: a connecting seat (7) arranged on the main installation plate (13) and provided with a positioning hole (16) through which the aluminum bar (3) and the composite terminal (2) pass; 8. The inductance of a copper-aluminum composite terminal structure according to claim 1, characterized by a first connecting hole (11) arranged on the connecting seat (7); a second connecting hole (21) arranged on the composite terminal (2) and matched with the first connecting hole (11). The coil assembly further comprises: a pouring glue body (5) arranged in the installation cavity. A heat conducting member (10) is arranged between the potting glue (5) and the coil (1).

9. The inductance of a copper-aluminum composite terminal structure according to claim 1, wherein Further comprising: A third connecting hole (8) is arranged on the shell (4). A positioning pin (6) is arranged on the shell (4).

10. The inductance of a copper-aluminum composite terminal structure according to claim 1, wherein Further comprising: A heat dissipation member (9) is arranged on the outer wall surface of the shell (4).

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