Flat wire inductor structure with integrated protective shell and base

Abstract

The utility model relates to the technical field of inductors, in particular to a flat wire inductor structure with a protective shell and a base integrated. The inductor comprises an inductor body, the inductor body comprises a magnetic core and a winding, the magnetic core is wrapped in an integrated structure, and the integrated structure comprises a base which is located below the magnetic core and comprises a shell and a false needle arranged at the bottom of the shell; the periphery of the shell is concave downwards to form a groove for placing the magnetic core, and the middle part of the shell is convex upwards to form a butt joint port matched with the protection shell for fixation; the protective shell is located above the magnetic core, and a sealing cavity for protecting the magnetic core is formed by the butt joint opening and the base. Wherein the windings are wound on the two sides of the integrated structure respectively and are separated by a partition plate located in the middle of the integrated structure; the winding is formed by vertically winding a flat wire, and a leading-out wire of the winding is connected with the false needle on the base. According to the utility model, the base and the protective shell are integrally connected through an injection molding process, traditional tedious assembly steps are abandoned, the production process is obviously simplified, and the labor and time cost is reduced.

Description

TECHNICAL FIELD

[0001] The utility model relates to the technical field of inductor, specifically relates to a flat wire inductor structure of shell and base integration. BACKGROUND

[0002] In the traditional flat wire inductor product, the shell and the base are often in a separated state, and the shell winding is first assembled during production, then assembled with the base, and the lead-out wire is hung to the base false needle, the process is complicated and the connection strength is insufficient. To solve this problem, the existing patent such as CN212659410U proposes to use a shell to isolate the ferrite magnetic core and the enameled round winding wire, which improves the insulation performance and protects the magnetic core from extrusion, but still faces challenges such as complicated coil assembly, low production efficiency, high cost and limited inductance performance. In addition, the traditional inductor is also difficult to meet the high standard demand of modern electronic equipment in terms of heat dissipation, electromagnetic compatibility and size adaptability. SUMMARY

[0003] The technical problem to be solved by the utility model is to overcome the shortcomings of the prior art and provide a flat wire inductor structure of shell and base integration.

[0004] The technical scheme adopted by the utility model is as follows:

[0005] A flat wire inductor structure of shell and base integration, comprising an inductor body, the inductor body comprising a magnetic core and a winding, the magnetic core being wrapped in an integrated structure, the integrated structure comprising:

[0006] A base is located below the magnetic core and comprises a shell and a false needle arranged at the bottom of the shell; the periphery of the shell is concave to form a groove for placing the magnetic core, and the middle part of the shell is convex to form a docking port for fixing the shell;

[0007] A shell is located above the magnetic core and forms a sealed cavity for protecting the magnetic core through the docking port and the base;

[0008] The winding is wound on both sides of the integrated structure and is separated by a partition plate in the middle part of the integrated structure; the winding is formed by flat wire vertical winding, and the lead-out wire of the winding is connected to the false needle on the base.

[0009] The technical scheme is characterized in that the base and the half of the shell are integrally connected by one-time molding through an injection molding process, the complicated steps of accurately assembling the coil to the base one by one in the traditional process are abandoned, the production process is greatly simplified, and the labor and time costs are reduced.Specifically, the magnetic core is wrapped in the groove of the base and fixed by the shell through the butt joint, forming a sealed cavity, which not only ensures the stability of the magnetic core, but also prevents external environmental interference (such as dust, moisture, etc.), prolonging the service life of the inductor; the flat wire is vertically wound, compared with the traditional round wire winding, the flat wire can be arranged more closely, reducing the gap between the windings, thereby improving the efficiency and performance of the inductor; the flat wire also has better heat dissipation performance for reducing the temperature of the inductor during work; the lead-out wire of the winding is directly connected with the false needle on the base to simplify the electrical connection process and improve the reliability of the connection.

[0010] In addition, the flat wire inductor structure with an integrated shell and base according to the utility model has the following additional technical features:

[0011] According to an embodiment of the utility model, the magnetic core is a square ring with a circumferential arc shape, the groove and the shell are provided with an arc surface matched with the magnetic core, and the arc surface is closely combined with the magnetic core.

[0012] In the technical scheme, the magnetic core adopts a square ring with a circumferential arc shape for optimizing the magnetic circuit, reducing the magnetic resistance, and making the distribution of the magnetic field in the magnetic core more uniform; the arc surface provided by the groove and the shell is closely combined with the magnetic core, which not only ensures the stability of the magnetic core in the structure, but also enhances the heat conduction between the magnetic core and the surrounding material; the close combination reduces the thermal resistance between the magnetic core and the surrounding environment, which is conducive to heat dissipation and prevents the magnetic core from being damaged or degraded in performance due to overheating.

[0013] According to an embodiment of the utility model, the winding is provided with two groups, which are wound along the long edges of the integrated structure; the lead-out wire of the winding is located at the bottom of the shell and is electrically connected with the adjacent false needle.

[0014] In the technical scheme, because the long edges provide more winding space, it is conducive to the operation of the winding machine and the positioning of the winding; the lead-out wire is located at the bottom of the shell and is directly connected with the false needle, simplifying the processing process of the lead-out wire; in the assembly process, the lead-out wire is more easily connected with the external circuit, and the stability of the connection is ensured.

[0015] According to an embodiment of the utility model, the shell of the base is provided with four downward legs around, and the false needle is located inside the four legs.

[0016] In the technical solution, the base can be fixed more firmly on the mounting surface through the supporting leg, preventing movement or tilting due to vibration or external force during the operation of the inductor. The supporting leg not only provides support, but also forms a protective area around the dummy needle, preventing external objects or impurities from contacting the dummy needle and ensuring the stability of the electrical connection.

[0017] According to an embodiment of the present application, the sealing cavity formed by the base and the shell has the same shape as the magnetic core.

[0018] According to an embodiment of the present application, the middle part of the butt joint is hollow, and the winding is wound between the base and the shell through the hollow butt joint.

[0019] The technical solution of the present application uses a hollow butt joint to wind the winding directly between the base and the shell, without occupying additional space, thereby achieving compactness of the inductor structure.

[0020] Compared with the prior art, the present application has the following advantages:

[0021] (1) The base and the shell are integrally connected by injection molding process, eliminating the traditional complicated assembly steps, significantly simplifying the production process, and reducing labor and time costs.

[0022] (2) The magnetic core is wrapped in the groove of the base and fixed by the shell, forming a sealed cavity, ensuring the stability of the magnetic core, preventing external environmental interference, and prolonging the service life of the inductor. BRIEF DESCRIPTION OF DRAWINGS

[0023] Fig. 1 is an assembly drawing of the present application.

[0024] Fig. 2 is a structural schematic view of the base.

[0025] Fig. 3 is a perspective view of the present application.

[0026] In the figure: 1, base; 11, shell; 12, groove; 13, butt joint; 14, dummy needle; 2, magnetic core; 3, shell; 4, winding; 5, partition. DETAILED DESCRIPTION

[0027] 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 a part of the embodiments of the present application, not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0028] Embodiment 1

[0029] As Figs. 1-3 shown in the embodiment, a flat wire inductance structure with integrated shell and base is provided, which comprises an inductance body including a magnetic core 2 and a winding 4, the magnetic core 2 is wrapped in an integrated structure, the integrated structure comprises:

[0030] a base 1 located below the magnetic core 2, which comprises a shell 11 and a false needle 14 arranged at the bottom of the shell 11; the periphery of the shell 11 is concave to form a groove 12 for placing the magnetic core 2, and the middle part of the shell 11 is convex to form a docking port 13 for fixing the shell 3;

[0031] a shell 3 located above the magnetic core 2, which forms a sealed cavity for protecting the magnetic core 2 through the docking port 13 and the base 1;

[0032] wherein the winding 4 is wound on both sides of the integrated structure and is separated by a partition 5 located in the middle part of the integrated structure; the winding 4 is vertically wound by flat wire, and the lead wire of the winding 4 is connected to the false needle 14 on the base 1.

[0033] As Figs. 1-3 shown in the embodiment, the base 1 and half of the shell 3 are formed by injection molding process at one time to realize the integrated connection of the two, which abandons the complicated steps of accurately assembling the coil to the base 1 one by one in the traditional process, greatly simplifies the production process, and reduces the labor and time cost. Specifically, the magnetic core 2 is wrapped in the groove 12 of the base 1 and fixed by the shell 3 through the docking port 13 to form a sealed cavity, which not only ensures the stability of the magnetic core 2, but also prevents external environmental interference (such as dust, moisture, etc.), prolongs the service life of the inductance; the flat wire is vertically wound, compared with the traditional round wire winding, the flat wire can be arranged more closely, reducing the gap between the windings 4, thereby improving the efficiency and performance of the inductance; the flat wire also has better heat dissipation performance for reducing the temperature of the inductance during work; the lead wire of the winding 4 is directly connected to the false needle 14 on the base 1 to simplify the electrical connection process and improve the reliability of the connection.

[0034] In addition, the flat wire inductance structure with integrated shell and base according to the above-mentioned utility model has the following additional technical features:

[0035] According to an embodiment of the utility model, the magnetic core 2 is a square ring with a periphery arc, the groove 12 and the shell 3 are provided with an arc surface matched with the magnetic core 2, and the arc surface is tightly combined with the magnetic core 2.

[0036] In the technical solution, the magnetic core 2 adopts a square ring with a peripheral arc shape, which is used for optimizing the magnetic circuit, reducing the magnetic resistance, and making the distribution of the magnetic field in the magnetic core 2 more uniform; the arc surface provided by the groove 12 and the protective shell 3 is closely attached to the magnetic core 2, which not only ensures the stability of the magnetic core 2 in the structure, but also enhances the heat conduction between the magnetic core 2 and the surrounding material; the close attachment reduces the thermal resistance between the magnetic core 2 and the surrounding environment, which is beneficial to heat dissipation and prevents the magnetic core 2 from being overheated and degraded or damaged.

[0037] According to an embodiment of the present application, the winding 4 is provided with two groups, which are wound along the long edges of the integrated structure; the lead-out wire of the winding 4 is located at the bottom of the shell 11 and is electrically connected with the adjacent dummy needle 14.

[0038] In the technical solution, because the long edges provide larger winding space, it is beneficial to the operation of the winding machine and the positioning of the winding 4; the lead-out wire is located at the bottom of the shell 11 and is directly connected with the dummy needle 14, which simplifies the processing process of the lead-out wire; in the assembly process, the lead-out wire is more easily connected with the external circuit, and the stability of the connection is ensured.

[0039] According to an embodiment of the present application, the shell 11 of the base 1 is provided with downward legs around, and the dummy needle 14 is located inside the four legs.

[0040] In the technical solution, the base 1 can be more firmly fixed on the mounting surface through the legs, preventing movement or tilting due to vibration or external force during the operation of the inductor. The legs not only provide support, but also form a protection area around the dummy needle 14, preventing external objects or impurities from contacting the dummy needle 14 and ensuring the stability of the electrical connection.

[0041] According to an embodiment of the present application, the sealing cavity formed by the base 1 and the protective shell 3 has the same shape as the magnetic core 2.

[0042] According to an embodiment of the present application, the middle part of the butt joint 13 is hollow, and the winding 4 winds the base 1 and the protective shell 3 into one through the hollow butt joint 13.

[0043] The technical solution winds the winding 4 directly between the base 1 and the protective shell 3 through the hollow butt joint 13, without occupying additional space, which is used to realize the compactness of the inductor structure; the winding 4 generates heat during operation, and the hollow butt joint 13 is used to reduce the operating temperature of the inductor.

[0044] The use process of the above embodiment is as follows:

[0045] As Figs. 1-3As shown, during processing, the base 1 and half of the shell 3 are formed at one time by an injection molding process, realizing integrated connection of the two, forming a sealed cavity, protecting the magnetic core 2 from external environmental interference and preventing overheating damage. The shell 11 of the base 1 is provided with downward legs around the periphery, providing stable support to prevent the inductor from moving or tilting, while protecting the dummy needle 14 from contact with external objects or impurities; the hollow butt joint 13 not only facilitates winding of the winding 4, but also helps to dissipate heat and reduce operating temperature.

[0046] As shown in Figs. 1-3 As shown, during use, the magnetic core 2 is placed in the groove 12 of the base 1, and then the shell 3 is buckled on the base 1; the peripheral arc of the magnetic core 2 closely fits the arc surface of the groove 12 and the shell 3, optimizing the magnetic circuit and enhancing heat conduction; the flat wire winding 4 is wound on the base 1 and the shell 3, the winding 4 is arranged closely in a vertical winding manner, reducing the gap and improving efficiency; the winding 4 is divided into two groups and wound along the long side of the integrated structure, with the lead wire located at the bottom of the shell 11 and directly electrically connected with the adjacent dummy needle 14, simplifying the connection process.

[0047] Although the utility model is described in detail by referring to the attached drawings and in combination with the preferred embodiments, the utility model is not limited thereto. Without departing from the spirit and essence of the utility model, those skilled in the art can make various equivalent modifications or replacements to the embodiments of the utility model, and these modifications or replacements should be within the scope of the utility model. Any person skilled in the art can easily think of changes or replacements within the technical range disclosed by the utility model, which should be covered within the protection scope of the utility model. Therefore, the protection scope of the utility model should be subject to the protection scope of the claims.

Claims

1. A flat wire inductor structure of a housing and base integrated type, comprising an inductor body including a magnetic core (2) and a winding (4), characterized in that, The magnetic core (2) is wrapped in an integrated structure, which comprises: A base (1) below the magnetic core (2) comprises a shell (11) and a dummy needle (14) arranged at the bottom of the shell (11); the periphery of the shell (11) is concave downward to form a groove (12) for placing the magnetic core (2), and the middle of the shell (11) is convex upward to form a docking interface (13) for fixing the protective shell (3); The protective shell (3) is above the magnetic core (2) and forms a sealed cavity for protecting the magnetic core (2) with the base (1) through the docking interface (13); Wherein, the winding (4) is wound on both sides of the integrated structure and is separated by a partition (5) in the middle of the integrated structure; the winding (4) is made of flat wire vertical winding, and the lead-out wire of the winding (4) is connected with the dummy needle (14) on the base (1).

2. The flat wire inductor structure of claim 1, wherein the housing is integrated with the base. The magnetic core (2) is a square ring with an arc-shaped periphery, the groove (12) and the protective shell (3) are provided with an arc surface matched with the magnetic core (2), and the arc surface is closely combined with the magnetic core (2).

3. The flat wire inductor structure of claim 1, wherein the housing is integrated with the base. The winding (4) is provided with two groups, which are wound along the long edges of the integrated structure; the lead-out wire of the winding (4) is located at the bottom of the shell (11) and is electrically connected with the adjacent dummy needle (14).

4. The flat wire inductor structure of claim 1, wherein the housing is integrated with the base. The shell (11) of the base (1) is provided with four downward legs, and the dummy needle (14) is located inside the four legs.

5. The flat wire inductor structure of claim 1 or 4, wherein the housing is integrated with the base. The sealed cavity formed by the base (1) and the protective shell (3) has the same shape as the magnetic core (2).

6. The flat wire inductor structure of claim 1, wherein the housing is integrated with the base. The middle of the docking interface (13) is hollow, and the winding (4) is wound into an integrated structure through the hollow docking interface (13).

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