One-piece surface-mount power inductor
By employing a pre-fabricated sealed compression molding technology for T-cores and U-cores, the problem of easy damage to the coil insulation layer was solved, resulting in higher material utilization and improved inductance performance.
Patent Information
- Application Number
- CN202423237374.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-12-27
- Publication Date
- 2025-11-28
- Estimated Expiration
- 2034-12-27
AI Technical Summary
In the current process of cold pressing, the insulation layer of the coil in the integrally molded inductor is easily damaged by pressure, which can lead to short circuits in the coil and low material utilization.
The T-core and U-core are prefabricated and formed by sealing and high-temperature pressing. The protrusions on the T-core act as a buffer to protect the coil, prevent damage to the insulation layer, and improve the material density and permeability.
This effectively prevents the coil from short-circuiting due to pressure, improves material utilization and inductor performance, reduces resistance, and increases space utilization.
Smart Images
Figure CN223612168U_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The utility model relates to electronic component technical field, concretely relates to integrally-formed surface mount technology (SMT) power inductor. BACKGROUND
[0002] The integrally-formed inductor is due to the development of computer mainboard technology and power supply technology: the CPU frequency is higher and higher, so it has high requirements on stable power supply and filtering, and the integrally-formed inductor solves this problem, can work for a long time under the condition of large current, and can supply stable power for CPU, of course, the main function of inductor is filtering, and the integrally-formed inductor is also good in this respect. Good material properties and special design make the inductor structure more stable and the impedance lower, so it has higher efficiency.
[0003] The integrally-formed inductor comprises a seat body and a winding body, the seat body is formed by embedding the winding body into metal magnetic powder and pressure casting, SMD pins are directly formed on the surface of the seat body, and the inductor has higher inductance and smaller leakage inductance than traditional inductors; the inductor is designed in SMD structure, so that the inductor is not damaged during use and the production efficiency is improved. The integrally-formed inductor has a full-closed structure, good magnetic shielding effect, can effectively reduce electromagnetic interference, and is used in the fields of vehicle, military, medical treatment, aerospace and the like with high reliability requirements.
[0004] At present, the integrally-formed inductor is mostly welded on the coil by spot welding first, then the coil is placed in a mold, the mold is filled with powder, and the powder is cold-pressed to form a protective shell wrapping the coil after pressure is added. Since the cold-pressing needs to solidify the powder in the mold by a large pressure, when the powder in the mold is pressed, the coil in the middle of the powder is also subjected to a large pressure, and the insulating layer of the coil is prone to damage under the large pressure, and after the insulating layer is damaged, the copper wires of the coil are short-circuited. TECHNICAL PROBLEM
[0005] In view of the above technical problems, the technical scheme provides an integrally-formed SMT power inductor, the protective body adopts T-core and U-core which are prefabricated, when the T-core and the U-core are sealed and pressed after assembly, only a small pressure is needed, and then the T-core and the U-core are sealed and formed by high-temperature pressing, the boss on the T-core can buffer the pressure when the inductor is pressed, so as to protect the coil and avoid the coil being pressed, the damage of the insulating layer of the coil caused by high pressure can be effectively avoided, and the short circuit of the coil can be effectively avoided, and the above problems can be effectively solved.
[0006] The utility model discloses a technical scheme as follows:
[0007] The integrated patch power inductor comprises a protective body, a coil arranged in the middle of the protective body, and electrode pads arranged at both ends of the coil and fixed on the surface of the protective body; the protective body comprises a T-core and a U-core, a boss in the middle of the T-core is inserted into a gap in the center of the coil, and the end of the T-core is in contact with the inner surface of the U-core to wrap and fix the coil from all directions; the protective body is arranged at the position where the electrode pads pass through, and a notch corresponding to the electrode pads is arranged at the position; the electrode pads are fixed in the notch in the protective body after passing through the protective body; and the T-core and the U-core are sealed and formed after assembly.
[0008] Further, the T-core is provided with a T-shaped cover with a boss in the middle, the U-core is provided with a U-shaped cover with a notch in the middle, the coil is sleeved on the boss of the T-shaped cover and arranged in the notch of the U-shaped cover; and the T-core and the U-core are heat-pressed after assembly.
[0009] Further, the shape of the boss in the middle of the T-core is consistent with the shape of the gap in the middle of the coil, and the size of the boss is less than or equal to the size of the gap.
[0010] Further, the gravity of the coil is less than or equal to the friction force between the coil and the boss, so that the coil is optimally sized to not fall off the boss in the middle of the T-core due to its own gravity.
[0011] Further, the coil is made of round wire, and welding points are arranged at both ends of the round wire, respectively.
[0012] Further, the coil is made of single coil or double coil; when the coil is single coil, the electrode pads are narrow terminal or / and wide terminal; when the coil is double coil, the electrode pads are narrow terminal; and the narrow terminal or / and wide terminal are arranged at intervals.
[0013] Further, the coil is made of flat wire, and the flat wire is bent at both ends to form electrode pads; after the protective layer and the insulating layer of the flat wire are removed at the positions where the electrode pads are formed, an electroplated layer is added.
[0014] Further, the electrode pads pass through the protective body and are fixed by being bent along the direction of the notch; after the electrode pads are fixed in the notch, the surface of the electrode pads is flush with the surface of the protective body. Advantages
[0015] Compared with the prior art, the integrated patch power inductor has the following advantages:
[0016] The protection body of the technical scheme adopts the T-core and U-core which are prefabricated in advance, and when the T-core and U-core are sealed and compressed after being assembled, only a small pressure needs to be given, and then the T-core and U-core are compressed at high temperature, so that the sealing and forming of the T-core and U-core can be realized; meanwhile, the boss on the T-core can buffer the pressure when the inductor is pressed, so as to protect the coil and avoid the coil being pressed; the damage of the insulation layer caused by the large pressure on the coil can be effectively avoided, so that the situation of short circuit of the coil is avoided.
[0017] In the technical scheme, the powder material density of the T-core and U-core in the prefabrication process or in the later hot-pressing forming is higher than that in the cold pressing, so that the material utilization rate of the T-core and U-core is improved, the performance of the protection body is more stable, and the initial permeance is high. When the initial permeance of the protection body is high, the inductor with the same inductance value can be made of a coil with shorter copper wire, so that the space utilization rate inside the inductor is increased, the space inside the magnetic material is larger, the wire diameter can be thicker, the resistance DCR is lower, the saturation current is higher, and the unit product volume is smaller. Relatively, in the case of the same powder material, an inductor with a higher inductance value can be made. BRIEF DESCRIPTION OF DRAWINGS
[0018] Figure 1 It is a whole structure schematic view of embodiment 1 in the utility model.
[0019] Figure 2 It is a sectional view of Figure 1 .
[0020] Figure 3 It is a front view of Figure 2 .
[0021] Figure 4 It is a structure schematic view of T-core in embodiment 1 in the utility model.
[0022] Figure 5 It is a structure schematic view of U-core in embodiment 1 in the utility model.
[0023] Figure 6 It is a structure schematic view of coil in embodiment 1 in the utility model.
[0024] Figure 7 It is a structure schematic view of electrode sheet in embodiment 1 in the utility model.
[0025] Figure 8 It is a whole structure schematic view of embodiment 2 in the utility model.
[0026] Figure 9It is a structure schematic view of the coil in the embodiment 2 of the utility model.
[0027] Figure 10 It is a structure schematic view of the electrode sheet in the embodiment 2 of the utility model.
[0028] Figure 11 It is a whole structure schematic view of the embodiment 3 of the utility model.
[0029] Figure 12 It is Figure 11 A sectional view.
[0030] Figure 13 It is Figure 12 An elevation view.
[0031] Figure 14 It is a structure schematic view of the coil in the embodiment 3 of the utility model.
[0032] The mark in the drawing is: 1-protective body, 11-T-core, 12-U-core, 13-groove, 2-coil, 21-welding point, 3-electrode sheet. DETAILED DESCRIPTION
[0033] The technical scheme in the embodiments of the utility model will be clearly and completely described below with the drawings in the embodiments of the utility model. The described embodiments are only a part of the embodiments of the utility model, not all. The various modifications and improvements of the technical scheme of the utility model made by the ordinary people in the art without departing from the design concept of the utility model shall fall into the protection scope of the utility model. Embodiment 1
[0034] As Figures 1 to 7 Shown, integrally formed patch type power inductance, including protective body 1, the protective body 1 includes T-core 11 and U-core 12, the T-core 11 adopts T-shaped cover with boss in the middle, the U-core 12 adopts U-shaped cover with recess in the middle.
[0035] The middle part of the protective body 1 is provided with a coil 2, the boss shape in the middle part of the T-core 11 is consistent with the shape of the gap in the middle part of the coil 2, and the boss size is less than or equal to the gap size; in the embodiment, the coil 2 is a circular coil, the boss in the middle part of the T-core 11 is a circular boss corresponding to the shape of the gap in the middle part of the coil 2; (in addition to circular, the coil can also be square, oval, etc.). The size of the boss is slightly smaller than the size of the coil 2, the gravity of the coil 2 is less than or equal to the friction force between the coil 2 and the boss, and the optimal size is that the coil 2 does not fall due to its own gravity after being sleeved on the boss in the middle part of the T-core 11.
[0036] Coil 2 is fitted onto the protrusion of the T-shaped cover. After the protrusion in the middle of T-core 11 is inserted into the gap in the center of coil 2, its end contacts the inner surface of U-core 12, thus fixing coil 2 in the groove of the U-shaped cover; so that the protective body 1 completely wraps the inner and outer sides of coil 2.
[0037] The joint between T-core11 and U-core12 can be sealed and fixed in various ways, such as by glue or by compression molding. In this embodiment, the joint between T-core11 and U-core12 is formed by thermoforming.
[0038] Electrode plates 3 are provided at both ends of the coil 2. The coil 2 is made of round wire and is a single coil. Soldering points 21 are provided at both ends of the round wire, and the two soldering points 21 are fixed and electrically connected to the electrode plates 3 respectively. In this embodiment, since the coil 2 is a single coil, only two soldering points 21 are led out and soldered to the electrode plates 3 for fixation; therefore, the electrode plates 3 can be made of narrow terminals and / or wide terminals as required.
[0039] After the electrode sheet 3 penetrates the protective body 1, it is fixed to the surface of the protective body 1. The protective body 1 is located at the position where the electrode sheet 3 is set, and a slot 13 corresponding to the size and shape of the electrode sheet 3 is provided. The electrode sheet 3 passes through the protective body 1, is bent and fixed along the direction of the slot 13, and fits and is fixed in the slot 13 of the protective body 1. When the electrode sheet 3 is fixed in the slot 13, the surface of the electrode sheet 3 is flush with the surface of the protective body 1.
[0040] An insulating layer is provided on the outer layer of the protective body 1, except for the electrode sheet 3. An electroplated layer is provided at the welding position of the electrode sheet 3. Example 2
[0041] like Figures 8 to 10 As shown, in addition to the single coil of round wire used in embodiment 1, this scheme can also be a double coil of round wire. When the coil 2 is a double coil of round wire, the electrode plate 3 uses narrow terminals; narrow terminals and / or wide terminals are spaced apart.
[0042] The other structures in this embodiment, as well as the positional and connection relationships between them, are the same as those in Embodiment 1, and will not be repeated here. Example 3
[0043] like Figures 11 to 14 As shown, in addition to using round wire for coil 2 in Embodiments 1 and 2, this solution can also use flat wire for single or double coils. When coil 2 is a flat wire coil, electrode plates can be welded to both ends of the flat wire, or the ends of the flat wire can be directly bent to form electrode plates. The protective layer and insulation layer of the flat wire are removed at the location where the electrode plates are formed, and an electroplated layer is provided.
[0044] The other structures in this embodiment, as well as the positional and connecting relationships between the structures, are the same as in Embodiment 1, and thus are not repeated here.
Claims
1. A one-piece molded surface mount power inductor, comprising a protective body (1), a coil (2) disposed in the middle of the protective body (1), and electrode plates (3) disposed at both ends of the coil (2), the electrode plates (3) penetrating the protective body (1) and being fixed to the surface of the protective body (1); characterized in that: The protective body (1) includes a T-core (11) and a U-core (12). After the boss in the middle of the T-core (11) is inserted into the gap in the center of the coil (2), the end contacts the inner surface of the U-core (12) to wrap and fix the inner and outer sides of the coil (2) in all directions. The protective body (1) is located at the position where the electrode sheet (3) is oriented, and a slot (13) corresponding to the electrode sheet (3) is provided. After the electrode sheet (3) passes through the protective body (1), it is fitted and fixed in the groove of the protective body (1). The T-core (11) and U-core (12) are sealed and formed after assembly.
2. The integrally molded surface mount power inductor according to claim 1, characterized in that: The T-core (11) adopts a T-shaped cover with a protrusion in the middle, and the U-core (12) adopts a U-shaped cover with a groove in the middle. The coil (2) is sleeved on the protrusion of the T-shaped cover and installed in the groove of the U-shaped cover.
3. The integrally molded surface mount power inductor according to claim 2, characterized in that: The shape of the boss in the middle of the T-core (11) is consistent with the shape of the gap in the middle of the coil (2), and the size of the boss is less than or equal to the size of the gap.
4. The integrally molded surface mount power inductor according to claim 3, characterized in that: The weight of the coil (2) is less than or equal to the friction between the coil (2) and the boss, and the optimal size is such that the coil (2) will not fall off due to its own weight after being placed on the boss in the middle of the T-core (11).
5. The integrally molded surface mount power inductor according to claim 1, characterized in that: The coil (2) is made of round wire, and welding points (21) are provided at both ends of the round wire. The welding points (21) are fixed and electrically connected to the electrode sheet (3).
6. The integrally molded surface mount power inductor according to claim 5, characterized in that: The coil (2) is a single coil or a double coil; when the coil (2) is a single coil, the electrode plate (3) is a narrow terminal and / or a wide terminal; when the coil (2) is a double coil, the electrode plate (3) is a narrow terminal; the narrow terminal and / or the wide terminal are spaced apart.
7. The integrally molded surface mount power inductor according to claim 1, characterized in that: The coil (2) is made of flat wire. The two ends of the flat wire are bent to form electrode plates (3). After removing the protective layer and insulation layer of the flat wire at the position where the electrode plates (3) are formed, an electroplating layer is added.
8. The integrally molded surface-mount power inductor according to claim 1, 5, 6, or 7, characterized in that: The electrode sheet (3) extends out of the protective body (1) and is bent and fixed along the direction of the groove (13). When the electrode sheet (3) is fixed in the groove, the surface of the electrode sheet (3) is flush with the surface of the protective body (1).