Aluminum brazing inductor structure

Abstract

The utility model discloses an aluminum brazing inductor structure. The structure comprises a magnetic core; the coil sleeves the outer side of the magnetic core; the two aluminum bars are connected to the two ends of the coil respectively; the tin layers are arranged at the ends, away from the coil, of the aluminum bars in a covering mode, the aluminum bars form a solder area through the tin layers so as to be connected with an external wire, in the production process of the aluminum brazing inductor structure, the ends of the two aluminum bars of the coil need to be covered with the tin layers, and in the follow-up welding process of the aluminum bars and the external wire, the tin layers at the ends of the aluminum bars can rapidly form the solder area. After welding forming, air holes, cracks and the like in a welding flux area are few, and the fusion depth is high, so that the connection strength between the aluminum bar and an external electric wire is obviously improved. And the tin layer covers the end part of the aluminum bar, so that the welding speed of the aluminum bar and the external wire is high, and the production efficiency is high.

Description

Technical Field

[0001] This application relates to the field of inductor technology, and in particular to an aluminum brazed inductor structure. Background Technology

[0002] An inductor is an electronic component used to handle current in a circuit. Inductors are widely used in electronic equipment fields such as industrial control, automotive electronics, new energy, and high-current switching regulators. As electronic equipment develops towards higher performance and higher density, the installation and performance requirements for inductors are constantly increasing, and existing connection methods between aluminum busbars and external wires are insufficient to meet these ever-growing demands.

[0003] The existing connection between aluminum busbars and external wires is made by welding. Existing welding methods include direct welding, which means that after the aluminum busbars and external wires come into contact, they are directly connected by laser welding or other welding techniques. This welding method can produce defects such as porosity, inclusions, and cracks, which will reduce the connection strength and durability between the aluminum busbars and external wires.

[0004] Therefore, it is necessary to propose an aluminum brazed inductor structure to improve the connection strength between the aluminum busbar and the external wires, which has become an important technical problem that needs to be solved urgently. Utility Model Content

[0005] This application provides an aluminum brazed inductor structure, which aims to solve the problem of insufficient connection strength between aluminum busbars and external wires in the prior art.

[0006] To achieve the above objectives, this application proposes an aluminum brazing inductor structure, comprising: a magnetic core; a coil, the coil being fitted around the outside of the magnetic core; two aluminum busbars, the two aluminum busbars being connected to the two ends of the coil respectively; and a tin layer, the tin layer being applied to the end of the aluminum busbars away from the coil, the aluminum busbars forming a solder area through the tin layer, thereby connecting to external wires.

[0007] In some embodiments, the device further includes a textured area, which is disposed at the end of the aluminum busbar away from the coil, and a tin layer is applied to the textured area.

[0008] In some embodiments, it further includes: a main mounting plate, which is disposed at one end of the coil and has through holes for aluminum busbars to pass through;

[0009] A secondary mounting plate is located at the other end of the coil.

[0010] In some embodiments, the magnetic core includes:

[0011] Two motherboards are installed, one on the main mounting plate and the other on the secondary mounting plate.

[0012] The connecting core is located between the two main boards, and the coil is fitted onto the outer circumference of the connecting core.

[0013] In some embodiments, it also includes:

[0014] The first positioning component is installed at intervals on the main mounting plate and the secondary mounting plate, and the first positioning component is used to limit the main board;

[0015] The second positioning element is installed at intervals on the main mounting plate and the secondary mounting plate, and is used to position the coil.

[0016] In some embodiments, the first positioning element includes:

[0017] Circumferential positioning end, which is connected to the main mounting plate or the secondary mounting plate;

[0018] Axial positioning end, which is connected to the circumferential positioning end.

[0019] In some embodiments, it also includes:

[0020] The housing has an open mounting cavity inside, where the magnetic core and coil are located.

[0021] The potting compound is placed in the mounting cavity.

[0022] In some embodiments, it also includes:

[0023] Multiple heat-conducting components are provided on the outer circumference of the coil.

[0024] This application proposes an aluminum brazed inductor structure, comprising: a magnetic core, a coil, two aluminum busbars, and a tin layer. The coil is fitted around the outside of the magnetic core; the two aluminum busbars are respectively connected to both ends of the coil; the tin layer is applied to the ends of the aluminum busbars furthest from the coil, forming a solder area through the tin layer, thereby connecting to external wires. During the production of the aluminum brazed inductor structure, the two aluminum busbars of the coil need to have a tin layer applied to their ends. During the subsequent welding process between the aluminum busbars and external wires, the tin layer at the ends of the aluminum busbars can quickly form a solder area. After welding, the solder area has fewer pores and cracks, and the penetration depth is high, significantly increasing the connection strength between the aluminum busbars and the external wires. Furthermore, because the tin layer is applied to the ends of the aluminum busbars, the welding speed between the aluminum busbars and external wires is fast, resulting in high production efficiency. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort, wherein:

[0026] Figure 1 This is a three-dimensional structural diagram of an aluminum brazed inductor structure in one embodiment of this application;

[0027] Figure 2 for Figure 1 Enlarged view of part A in the middle;

[0028] Figure 3 This is a schematic diagram of the aluminum brazed inductor structure and the tin-clad laminate in one embodiment of this application;

[0029] Figure 4 This is a three-dimensional structural diagram of the coil in one embodiment of this application;

[0030] Figure 5 This is a three-dimensional structural diagram of the magnetic core in one embodiment of this application;

[0031] Figure 6 This is a three-dimensional structural diagram of an aluminum brazed inductor in one embodiment of this application. Detailed Implementation

[0032] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0033] It should be noted that all directional indicators (such as up, down, left, right, front, back, etc.) in the embodiments of this application are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicator will also change accordingly.

[0034] It should also be noted that when a component is described as "fixed to" or "set on" another component, it can be directly on the other component or there may be an intervening component present. When a component is described as "connected to" another component, it can be directly connected to the other component or there may be an intervening component present.

[0035] Furthermore, the use of terms such as "first" and "second" in this application is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. Additionally, the technical solutions of the various embodiments can be combined with each other, but only on the basis of being achievable by those skilled in the art. When the combination of technical solutions is contradictory or impossible to implement, such a combination of technical solutions should be considered non-existent and not within the scope of protection claimed in this application.

[0036] See Figure 1 and Figure 6 As shown, this application proposes an aluminum brazing inductor structure, including: a magnetic core; a coil 1, the coil 1 being fitted onto the outside of the magnetic core; two aluminum busbars 2, the two aluminum busbars 2 being connected to the two ends of the coil 1 respectively; a tin layer 4, the tin layer 4 being applied to the end of the aluminum busbars 2 away from the coil 1, the aluminum busbars 2 forming a solder area 13 through the tin layer 4, thereby connecting to an external wire 14.

[0037] The coil 1 and the magnetic core constitute the inductor structure. The aluminum busbar 2 and the external wire 14 form a wiring structure. The aluminum busbar 2 connects to the coil 1, and the external wire 14 introduces external current, which is then introduced into the coil 1 through the two aluminum busbars 2. The tin layer 4 is the core component of the aluminum brazed inductor structure. The tin layer 4 can effectively enhance the connection strength between the aluminum busbar 2 and the external wire 14.

[0038] Specifically, in the production process of the aluminum brazed inductor structure, the two aluminum busbars 2 of the coil 1 need to be covered with a tin layer 4 at their ends. During the subsequent welding process between the aluminum busbars 2 and the external wires 14, the tin layer 4 at the ends of the aluminum busbars 2 can quickly form a solder area 13. After welding, the solder area 13 has fewer pores and cracks, and the penetration depth is high, which significantly increases the connection strength between the aluminum busbars 2 and the external wires 14. Furthermore, because the tin layer 4 is applied to the ends of the aluminum busbars 2, the welding speed between the aluminum busbars 2 and the external wires 14 is fast, resulting in high production efficiency.

[0039] Preferably, in this embodiment, an ultrasonic aluminum-tin soldering machine is used to weld the aluminum busbar 2 to the external wire 14. By setting the welding parameter combination, such as welding time, ultrasonic frequency, and temperature, ultrasonic aluminum-tin soldering can be performed to achieve a high-quality welding effect. Compared with traditional soldering, the ultrasonic soldering solder area 13 is full, without problems such as missed soldering or cold solder joints.

[0040] The coil 1 is made of film-wrapped flat aluminum wire, and the two aluminum busbars 2 are 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. However, aluminum has low strength, so a tin layer 4 needs to be applied to its ends to ensure the stability of the connection between the coil 1 and the external wire 14.

[0041] See Figure 1 and Figure 4 As shown, in some embodiments, it further includes: a rough surface area 21, which is disposed at the end of the aluminum busbar 2 away from the coil 1. The rough surface area 21 is formed by polishing the aluminum busbar 2. Specifically, the rough surface area 21 refers to the rough surface of the aluminum busbar 2 at this location. The tin layer 4 is coated on the rough surface area 21. The rough surface area 21 increases the specific surface area of ​​the aluminum busbar 2, which is beneficial for adsorbing the tin layer 4.

[0042] In this embodiment, the polishing area at the end of the aluminum busbar 2 is formed by polishing the end of the aluminum busbar 2 on a polishing machine. The preferred polishing length is 10-20mm. After polishing, the surface of the end of the aluminum busbar 2 is rough, forming a rough surface area 21. After polishing, the waste debris needs to be blown away with an air gun.

[0043] See Figure 1 , Figure 2 and Figure 3 As shown, in some embodiments, the system further includes: a main mounting plate 3, disposed at one end of the coil 1, and having a through hole 31 for the aluminum busbar 2 to pass through; and a secondary mounting plate 6, disposed at the other end of the coil 1. The main mounting plate 3 and the secondary mounting plate 6 form a mounting structure for better fixing the coil 1. The through hole 31 on the main mounting plate 3 allows the aluminum busbar 2 to pass through. During the tinning process, the tinning plate 10 has a wire hole for the aluminum busbar 2 to be inserted. After the aluminum busbar 2 is inserted, the main mounting plate 3 can seal the wire hole to prevent solder from splashing onto the coil 1 and other inductor structures, ensuring the safe conduct of the tinning process.

[0044] In this embodiment, the cross-sectional area of ​​the through hole 31 is slightly larger than the area of ​​the aluminum busbar 2, so as to facilitate the insertion of the aluminum busbar 2 into the through hole 31. The aluminum busbar 2 has a certain degree of flexibility and can be bent to be inserted into the through hole 31. The through hole 31 plays a certain positioning and fixing role in the tinning or soldering process, and is used to position and fix the position of the aluminum busbar 2 to avoid excessive bending of the aluminum busbar 2 from affecting the coil structure of the coil 1.

[0045] See Figure 1 , Figure 3 and Figure 5 As shown, in some embodiments, the magnetic core includes: two main boards 7, one main board 7 mounted on a main mounting plate 3 and the other main board 7 mounted on a secondary mounting plate 6; and a connecting core 11 disposed between the two main boards 7, with a coil 1 fitted onto the outer periphery of the connecting core 11. The two main boards 7 and the connecting core 11 constitute the magnetic core, and the main boards 7 and the connecting core 11 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.

[0046] See Figure 1 and Figure 3As shown, in some embodiments, it further includes: a first positioning member, which is spaced apart and installed on the main mounting plate 3 and the sub-mounting plate 6, and is used to limit the position of the main board 7; the first positioning member is used to position the main board 7 so that the main board 7 is fixedly connected to the main mounting plate 3 or the sub-mounting plate 6. A second positioning member, which is spaced apart and installed on the main mounting plate 3 and the sub-mounting plate 6, is used to position the coil 1. The second positioning member is used to position the coil 1. Through the above structural design, the inductor structure can be stabilized, the inductor performance can be stabilized, and the inductor structure can be better matched with the overall machine working efficiency.

[0047] See Figure 1 and Figure 3 As shown, in some embodiments, the first positioning element includes: a circumferential positioning end 9, which is connected to the main mounting plate 3 or the sub-mounting plate 6; the circumferential positioning end 9 is used to position the circumferential position of the motherboard 7, and is arranged circumferentially at intervals on the main mounting plate 3 or the sub-mounting plate 6, forming a mounting space for the motherboard 7 on the same plane, in which the motherboard 7 is placed, with the circumferential positioning end 9 contacting the side of the motherboard 7. An axial positioning end 8 is connected to the circumferential positioning end 9. The axial positioning end 8 restricts one degree of freedom of movement of the motherboard 7 in its thickness direction, and the main mounting plate 3 or the sub-mounting plate 6 restricts another degree of freedom of movement of the motherboard 7 in its thickness direction, thereby locking the axial position of the motherboard 7. The axial positioning end 8 contacts the end face of the motherboard 7. It can be understood that the circumferential positioning end 9 and the axial positioning end 8 have a certain degree of elasticity so that the motherboard 7 can be inserted into the mounting space formed by the circumferential positioning end 9.

[0048] See Figure 1 and Figure 6 As shown, in some embodiments, the system further includes: a housing 12, with a mounting cavity open at one end, where the magnetic core and coil 1 are located; the housing 12 is the structural basis of the inductor structure and can support other components in the inductor structure. A potting compound 15 is disposed in the mounting cavity. The potting compound 15 is formed by mixing and filling a potting material with a curing agent. The potting material is room temperature vulcanizing silicone rubber or silicone gel. After preparing the potting material, it is mixed with the curing agent at a 1:1 ratio for potting. After curing, the potting compound 15 is formed and used to fix the various structures within the mounting cavity. Preferably, a base coating is provided between the potting compound 15 and the housing 12 to enhance the adhesion between the housing 12 and the potting compound 15.

[0049] See Figure 1 and Figure 3As shown, in some embodiments, the coil 1 further includes multiple heat-conducting elements 5, with multiple heat-conducting elements 5 disposed on the outer peripheral surface of the coil 1. The heat-conducting elements 5 are used to improve heat conduction efficiency. Since the heat transfer efficiency of the heat-conducting elements 5 is better than that of the potting compound 15, by providing heat-conducting elements 5 between the coil 1 and the outer casing 12, the heat generated on the coil 1 can be more easily transferred to the outer casing 12 and dissipated from the outer casing 12. Preferably, the heat-conducting elements 5 are made of ceramic material.

[0050] The above description is only a part or preferred embodiment of this application. Neither the text nor the drawings should limit the scope of protection of this application. All equivalent structural transformations made using the content of this application's specification and drawings under the overall concept of this application, or direct / indirect applications in other related technical fields, are included within the scope of protection of this application.

Claims

1. An aluminum brazed inductor structure, characterized in that, include: magnetic core; Coil (1), the coil (1) is fitted onto the outside of the magnetic core; Two aluminum busbars (2) are connected to the two ends of the coil (1), respectively. A tin layer (4) is applied to one end of the aluminum busbar (2) away from the coil (1). The aluminum busbar (2) forms a solder area (13) through the tin layer (4), thereby connecting to an external wire (14).

2. The aluminum brazed inductor structure according to claim 1, characterized in that, Also includes: The rough surface area (21) is located at one end of the aluminum busbar (2) away from the coil (1), and the tin layer (4) is applied to the rough surface area (21).

3. The aluminum brazed inductor structure according to claim 1, characterized in that, Also includes: The main mounting plate (3) is disposed at one end of the coil (1) and the main mounting plate (3) is provided with a through hole (31) for the aluminum busbar (2) to pass through. A secondary mounting plate (6) is disposed at the other end of the coil (1).

4. The aluminum brazed inductor structure according to claim 3, characterized in that, The magnetic core includes: Two motherboards (7), one of which is mounted on the main mounting plate (3) and the other is mounted on the sub-mounting plate (6); A connecting core (11) is disposed between the two main boards (7), and the coil (1) is fitted onto the outer circumference of the connecting core (11).

5. The aluminum brazed inductor structure according to claim 4, characterized in that, Also includes: A first positioning element is installed at intervals between the main mounting plate (3) and the sub-mounting plate (6), and the first positioning element is used to limit the main board (7). The second positioning element is installed at an interval between the main mounting plate (3) and the auxiliary mounting plate (6), and the second positioning element is used to position the coil (1).

6. The aluminum brazed inductor structure according to claim 5, characterized in that, The first positioning element includes: Circumferential positioning end (9), the circumferential positioning end (9) is connected to the main mounting plate (3) or the auxiliary mounting plate (6); Axial positioning end (8), which is connected to the circumferential positioning end (9).

7. The aluminum brazed inductor structure according to claim 1, characterized in that, Also includes: The outer casing (12) has a mounting cavity with an opening at one end, and the magnetic core and the coil (1) are both located in the mounting cavity; A potting compound (15) is disposed in the mounting cavity.

8. The aluminum brazed inductor structure according to claim 1, characterized in that, Also includes: Multiple heat-conducting elements (5) are provided on the outer peripheral surface of the coil (1).

Images