Tcore-based integrally-formed cylindrical inductor structure

Abstract

The utility model discloses an integrally formed cylinder inductor structure based on Tcore. The integrally formed cylinder inductor structure based on Tcore comprises a Tcore magnet, a coil, an outer magnet and an extraction electrode, the coil is wound on the Tcore magnet, the positive pole and the negative pole of the coil are respectively connected with the extraction electrodes, the Tcore magnet, the coil and the extraction electrodes form a magnetic core, the outer magnet is integrally formed and wraps the outer side of the magnetic core, and the outer magnet is of a cylindrical structure. Compared with an existing square outer magnet, the cylindrical outer magnet structure is adopted, the space utilization rate of the inner magnetic core is improved, miniaturization of the inductor is achieved, the shock resistance and the mechanical strength of the inductor structure are improved through the cylindrical outer magnet structure, the manufacturing process is simplified, and the manufacturing cost is reduced. And the size of the outer magnet required by the Tcore with the same size is smaller, so that raw materials required in molding are reduced, and the manufacturing cost is reduced.

Description

Technical Field

[0001] This utility model relates to the field of inductor technology, and in particular to a one-piece molded cylindrical inductor structure based on Tcore. Background Technology

[0002] With the rapid development of the global economy and technology, the inductor industry has ushered in new growth opportunities. Demand in traditional downstream applications is gradually recovering, while emerging markets such as communications, industrial control, new energy vehicles, artificial intelligence (AI), and data centers are experiencing a surge in demand. This rapid growth in downstream markets has brought unprecedented development opportunities to the inductor industry. Against this backdrop, inductor miniaturization has become a key trend in the industry, especially with the increasing demand in compact electronic devices, making the miniaturization and high reliability of inductor components increasingly urgent. While traditional molded inductors can meet performance requirements, their large size makes it difficult to meet the space-efficient utilization requirements of modern automotive electronic devices.

[0003] Existing miniaturized inductors, based on Tcore (T-shaped magnetic core) structures, are all shaped into square structures. However, square inductors, due to their sharp edges, are easily damaged when subjected to impacts, have insufficient impact resistance, and are difficult to adapt to harsh working environments.

[0004] Therefore, a new inductor structure is urgently needed. Utility Model Content

[0005] In view of the above problems, this utility model is proposed to provide a Tcore-based integral cylindrical inductor structure that overcomes or at least partially solves the above problems.

[0006] This invention provides a Tcore-based integral cylindrical inductor structure, comprising: a Tcore magnet, a coil, an outer magnet, and lead-out electrodes; the coil is wound around the Tcore magnet, and the positive and negative poles of the coil are respectively connected to the lead-out electrodes; the Tcore magnet, the coil, and the lead-out electrodes form a magnetic core; the outer magnet is integrally formed and covers the outside of the magnetic core, and the outer magnet has a cylindrical structure.

[0007] Optionally, the outer magnet is integrally formed by pressing crystal powder.

[0008] Optionally, the crystal powder is nanocrystalline powder or iron-nickel alloy crystal powder.

[0009] Optionally, the lead-out electrode extends to the outside of the outer magnet, and the lead-out direction of the lead-out electrode is opposite to the extension direction of the positive and negative poles of the coil.

[0010] Optionally, a receiving groove is provided at the end face of the external magnet corresponding to the area of ​​the lead-out electrode, and the lead-out electrode is disposed in the receiving groove.

[0011] Optionally, the Tcore magnet includes a base and a central column. The central column is located in the middle region of the base. Two right-angled slots are symmetrically formed at one end of the base. The coil is wound around the outside of the central column. The lead-out electrodes, which are connected to the positive and negative poles of the coil, are respectively attached to the two slots.

[0012] Optionally, the Tcore magnet is made of a soft magnetic alloy.

[0013] Optionally, the structure of the central column can be a cylinder, an elliptical cylinder, or a racetrack structure, which facilitates the winding of the coil; the base can be a circle, an offset circle, an ellipse, a racetrack structure, or a concentric structure.

[0014] Optionally, the inner side of the hollow groove includes a first end face that fits against the lead-out electrode and a second end face that is perpendicular to the first end face, wherein the width of the first end face is twice the width of the lead-out electrode, and the width of the second end face is 1.5 times the thickness of the lead-out electrode.

[0015] Optionally, the distance between the outer edge of the coil and the outer edge of the outer magnet is not less than 0.1 mm.

[0016] The technical solution provided in this embodiment of the utility model has at least the following technical effects or advantages:

[0017] The Tcore-based integrated cylindrical inductor structure described in this embodiment of the invention adopts a cylindrical outer magnet structure. Compared with the existing square outer magnet, it reduces space occupation, improves the space utilization of the internal magnetic core, and realizes the miniaturization of the inductor. In addition, the cylindrical outer magnet structure improves the impact resistance and mechanical strength of the inductor structure, simplifies the manufacturing process, and requires a smaller outer magnet volume for the same Tcore volume, reducing the raw materials required in molding and lowering manufacturing costs.

[0018] The above description is merely an overview of the technical solution of this utility model. In order to better understand the technical means of this utility model and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of this utility model more obvious and understandable, specific embodiments of this utility model are given below. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this utility model, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the integrated cylindrical inductor structure based on Tcore described in this utility model;

[0021] Figure 2 This is a schematic diagram of the front connection between the Tcore magnet and the coil;

[0022] Figure 3 This is a schematic diagram showing the connection between the Tcore magnet and the coil on the back.

[0023] Explanation of reference numerals in the attached figures:

[0024] 1. Tcore magnet; 2. Coil; 3. Lead-out electrode; 4. External magnet; 11. Base; 12. Hollowed-out slot; 13. Central column. Detailed Implementation

[0025] Exemplary embodiments of the present disclosure will now be described in more detail with reference to the accompanying drawings.

[0026] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. The accompanying drawings show preferred embodiments of the present invention. The present invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to make the disclosure of the present invention more thorough and complete.

[0027] Unless otherwise specified, all raw materials, instruments and equipment used in this invention can be purchased from the market or prepared by existing methods.

[0028] Figure 1 This is a schematic diagram of a Tcore-based integral cylindrical inductor structure provided in an embodiment of this utility model. (See attached diagram.) Figure 1As shown, the integrated cylindrical inductor structure based on Tcore includes a Tcore magnet 1, a coil 2, an outer magnet 4, and lead-out electrodes 3. The coil 2 is wound around the Tcore magnet 1, and the positive and negative poles of the coil 2 are respectively connected to the lead-out electrodes 3. The Tcore magnet 1, the coil 2, and the lead-out electrodes 3 form a magnetic core. The outer magnet 4 is integrally formed and covers the outside of the magnetic core. The outer magnet 4 has a cylindrical structure.

[0029] In this embodiment of the present invention, the outer magnet 4 is integrally formed by pressing crystal powder. The crystal powder is nano-crystalline powder or iron-nickel alloy powder, etc., preferably nano-crystalline powder, which can reduce losses and improve working efficiency. It can be selected according to the actual application requirements, and this embodiment of the present invention does not limit it.

[0030] In this embodiment of the invention, the lead-out electrode 3 extends to the outside of the outer magnet 4, which facilitates electrical connection with external components. The lead-out direction of the lead-out electrode 3 is opposite to the extension direction of the positive and negative poles of the coil 2, which allows the lead-out electrode 3 to be folded at the end face of the outer magnet 4 (e.g., the bottom face of the outer magnet 4 in this embodiment) to save space and facilitate soldering to external electrodes such as those on a PCB board.

[0031] The end face of the external magnet 4 has a receiving groove (not shown) corresponding to the area of ​​the lead-out electrode 3. The lead-out electrode 3 is disposed in the receiving groove. The height of the lead-out electrode 3 can be the same as the height of the end face of the external magnet 4, or it can be lower or higher than the height of the end face of the external magnet 4. It can be selected according to the actual application requirements. This utility model embodiment does not limit this.

[0032] Figure 2 This is a schematic diagram showing the front connection between Tcore magnet 1 and coil 2. Figure 3 This is a schematic diagram showing the connection between the Tcore magnet 1 and coil 2 on the back. Figure 2-3 As shown, the Tcore magnet 1 includes a base 11 and a central column 13. The central column 13 is located in the middle region of the base 11. Two right-angled slots 12 are symmetrically opened at one end of the base 11. The coil 2 is wound around the outside of the central column 13. The lead-out electrodes 3, which are connected to the positive and negative poles of the coil 2, are respectively attached to the two slots 12.

[0033] The Tcore magnet 1 is made of a soft magnetic alloy. Depending on the actual application requirements, different magnetic powder particle sizes and soft magnetic alloys composed of insulating resin can be selected. This embodiment of the utility model does not limit this.

[0034] In this embodiment of the utility model, the structure of the central column 13 is a cylinder, an elliptical cylinder, or a racetrack structure, which facilitates the winding of the coil 2; the base 11 is a circle, an offset circle, an ellipse, a racetrack structure, or a concentric structure.

[0035] In some embodiments of this utility model, the base 11 and the central column 13 may be integrally formed.

[0036] The inner side of the hollow groove 12 includes a first end face that fits against the lead-out electrode 3 and a second end face that is perpendicular to the first end face. The width A of the first end face is twice the width of the lead-out electrode 3, and the width B of the second end face is 1.5 times the thickness of the lead-out electrode 3. The redundant space left by the first end face and the second end face prevents the lead-out electrode 3 from sliding out of the hollow groove 12.

[0037] In this embodiment of the utility model, the outer magnet 4 and the magnetic core can be integrally formed when the outer magnet 4 is pressed, or the outer magnet 4 can be integrally formed and then assembled with the magnetic core.

[0038] In this embodiment of the utility model, the coil 2 is composed of copper wire wrapped with enameled film, which has better electrical signal transmission capability, and the enameled film has a certain degree of insulation protection; the coil 2 can be wound in a reverse winding method or a horizontal winding method.

[0039] In this embodiment of the present invention, the material of the lead electrode 3 is metallic copper or a copper alloy. When the material of the lead electrode 3 is a copper alloy, it can be, for example, a copper-tin alloy, a copper-nickel alloy, a copper-zinc alloy, phosphor bronze, etc., whichever is selected according to the actual application requirements. This embodiment of the present invention does not limit this.

[0040] In this embodiment of the utility model, the distance between the outer edge of the coil 2 and the outer edge of the outer magnet 4 is not less than 0.1 mm. By completely covering the magnetic core with the outer magnet 4, functional damage or short circuit faults caused by exposure are avoided.

[0041] The Tcore-based integrated cylindrical inductor structure described in this embodiment adopts a cylindrical outer magnet 4 structure. Compared with the existing square outer magnet 4, it reduces space occupation, improves the space utilization of the internal magnetic core, and realizes the miniaturization of the inductor. Moreover, the cylindrical outer magnet 4 structure improves the impact resistance and mechanical strength of the inductor structure, simplifies the manufacturing process, and requires a smaller outer magnet volume for the same Tcore volume, reducing the raw materials required in molding and lowering the manufacturing cost.

[0042] Numerous specific details are set forth in the specification provided herein. However, it will be understood that embodiments of the present invention may be practiced without these specific details. In some instances, well-known methods, structures, and techniques have not been shown in detail so as not to obscure the understanding of this specification.

[0043] Similarly, it should be understood that, in order to simplify this disclosure and aid in understanding one or more of the various aspects of the invention, in the above description of exemplary embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof. However, this method of disclosure should not be construed as reflecting an intention that the claimed invention requires more features than expressly recited in each claim. Rather, as reflected in the claims, the inventive aspect lies in fewer than all features of a single foregoing disclosed embodiment. Therefore, the claims following the detailed description are hereby expressly incorporated into that detailed description, wherein each claim itself is a separate embodiment of the invention.

[0044] It should be noted that the above embodiments are illustrative of the present invention and not restrictive of the present invention, and that those skilled in the art can devise alternative embodiments without departing from the scope of the appended claims.

Claims

1. A one-piece molded cylindrical inductor structure based on Tcore, characterized in that, The Tcore-based integral cylindrical inductor structure includes: a Tcore magnet, a coil, an outer magnet, and lead-out electrodes; the coil is wound on the Tcore magnet, and the positive and negative poles of the coil are respectively connected to the lead-out electrodes; the Tcore magnet, the coil, and the lead-out electrodes form a magnetic core; the outer magnet is integrally formed and covers the outside of the magnetic core; the outer magnet has a cylindrical structure.

2. The integrally formed cylindrical inductor structure based on Tcore according to claim 1, characterized in that: The outer magnet is integrally formed by pressing crystal powder.

3. The integrally molded cylindrical inductor structure based on Tcore according to claim 2, characterized in that: The crystal powder is either nanocrystalline powder or iron-nickel alloy crystal powder.

4. The integrally formed cylindrical inductor structure based on Tcore according to claim 1, characterized in that: The lead-out electrode extends to the outside of the outer magnet, and the lead-out direction of the lead-out electrode is opposite to the extension direction of the positive and negative poles of the coil.

5. The integrally molded cylindrical inductor structure based on Tcore according to claim 4, characterized in that: A receiving groove is provided on the end face of the external magnet corresponding to the area of ​​the lead-out electrode, and the lead-out electrode is disposed in the receiving groove.

6. The integrally molded cylindrical inductor structure based on Tcore according to claim 1, characterized in that: The Tcore magnet includes a base and a central column. The central column is located in the middle region of the base. Two right-angled slots are symmetrically opened at one end of the base. The coil is wound around the outside of the central column. The lead-out electrodes connected to the positive and negative poles of the coil are respectively attached to the two slots.

7. The integrally molded cylindrical inductor structure based on Tcore according to claim 6, characterized in that: The Tcore magnet is made of a soft magnetic alloy.

8. The integrally molded cylindrical inductor structure based on Tcore according to claim 6, characterized in that: The central column has a cylindrical, elliptical, or racetrack-like structure; the base is circular, offset circular, elliptical, racetrack-like, or concentric.

9. The integrally molded cylindrical inductor structure based on Tcore according to claim 6, characterized in that: The inner side of the hollow groove includes a first end face that fits against the lead-out electrode and a second end face that is perpendicular to the first end face. The width of the first end face is twice the width of the lead-out electrode, and the width of the second end face is 1.5 times the thickness of the lead-out electrode.

10. The integrally formed cylindrical inductor structure based on Tcore according to claim 1, characterized in that: The distance between the outer edge of the coil and the outer edge of the outer magnet is not less than 0.1 mm.

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