Multilayer pre-pressed core hot-pressing integrated inductor

Abstract

This utility model discloses a multilayer pre-compressed magnetic core thermo-pressed integrated inductor, relating to the field of electronic component technology. It includes a magnetically conductive block body with a cavity inside, and an anti-vibration mounting base inside the cavity. Electrode sheets are secured to the top two sides of the mounting base, and a stabilizing mechanism is provided on the outer side of the electrode sheets. A coil is placed in the center of the mounting base, and the coil leads are flattened into square connection terminals, which are welded to the outer side of the electrode sheets. The side ends of the electrode sheets extend to the outer side of the magnetically conductive block body. Grooves are provided on both sides of the upper part of the magnetically conductive block body, and the side ends of the electrode sheets are thermo-pressed into folded feet and fitted into the grooves. This utility model effectively solves the problems of high short-circuit risk and poor structural stability in traditional round wire multilayer inductors, improving the overall performance of the inductor.

Description

Technical Field

[0001] This utility model relates to the field of electronic component technology, and in particular to a multilayer pre-pressed magnetic core thermo-pressed integrated inductor. Background Technology

[0002] The current product design uses a multi-layer round wire coil to achieve a high number of turns and large inductance, paired with a pre-pressed magnetic core. The main advantages are: the round wire leads are flattened and welded to the lead sheet to ensure a firm connection terminal; the pre-pressed magnet is placed in the coil and then hot-pressed to avoid friction between the coil and the magnetic core, thus avoiding the risk of short circuits, and achieving a high number of turns and high inductance. Traditionally, the round wire coil is spot-welded to the material sheet and directly placed into the mold cavity with powder added and hot-pressed. During the hot-pressing process, the powder and coil are squeezed under great force, which can easily cause short circuits.

[0003] Meanwhile, the traditional spot welding method limits the connection strength between the coil and the sheet metal. During subsequent packaging and use, the connection is prone to loosening due to vibration or temperature changes, affecting the long-term stability of the inductor. Utility Model Content

[0004] This invention proposes a multi-layer pre-pressed magnetic core hot-pressed integrated inductor, which solves the problems of high short-circuit risk and poor structural stability of traditional round wire multi-layer magnetic core integrated inductors.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A multilayer preloaded magnetic core thermo-pressed integrated inductor includes a magnetically conductive block body. A cavity is formed inside the magnetically conductive block body, and a shock-resistant mounting base is provided inside the cavity. Electrode sheets are limited and snapped onto both sides of the top of the mounting base, and a stabilizing mechanism is provided on the outer side of the electrode sheets. A coil is placed in the center of the mounting base, and the coil pins are flattened into square connecting terminals. The connecting terminals are welded to the outer side of the electrode sheets, and the side ends of the electrode sheets extend to the outer side of the magnetically conductive block body. Grooves are provided on both sides of the upper part of the magnetically conductive block body, and the side ends of the electrode sheets are thermo-pressed into folded feet and fitted into the grooves.

[0007] Preferably, the magnetic block body is integrally formed by die-casting of metal magnetic powder and coil and electrode sheet.

[0008] Preferably, the cavity is provided with multiple sets of first slots, and the bottom of the mounting base is provided with a second slot corresponding to the first slot, and U-shaped spring pieces are inserted into the first slot and the second slot.

[0009] Preferably, the top of the mounting base is provided with multiple sets of limiting blocks, and the electrode sheet is provided with limiting holes that match the limiting blocks.

[0010] Preferably, the stabilizing mechanism includes a limiting groove, a slide rail, and a fixing plate, and the limiting groove is provided on both sides of the mold cavity, and the slide rail is provided on both sides inside the limiting groove.

[0011] Preferably, one end of the electrode sheet is hot-pressed and bent to fit against the inner wall of the limiting groove, and the side of the electrode sheet is provided with a fixing plate that matches the slide rail for sliding connection and limiting.

[0012] Preferably, a limiting rod is provided in the middle of the mounting base, and the limiting rod is slidably engaged with the pre-compressed magnetic core inside the coil.

[0013] Compared with the prior art, the beneficial effects of this utility model are:

[0014] 1. This multilayer pre-loaded magnetic core thermo-pressed integrated inductor uses flattened leads of the round wire coil as external connection terminals of the inductor. This design not only enhances the shock resistance of the leads and the circuit board, but also improves the reliability of the connection. The flattened lead connection terminals can better adapt to the surface mount soldering process, reduce connection loosening caused by vibration or temperature changes, and thus ensure the long-term stability of the inductor.

[0015] 2. Before assembling the coil, the internal magnetic core is pre-pressed. Through pre-pressing, a stable structural framework is formed inside the magnetic core, which reduces the compression of the coil by the powder during hot pressing and the friction between the coil and the magnetic core, thus reducing the risk of short circuit. At the same time, hot pressing molding process is used instead of traditional cold pressing molding. During hot pressing molding, heating softens the magnetic powder and coil material, reducing the pressure required for molding, thereby avoiding coil deformation and short circuit problems caused by high pressure.

[0016] 3. Electrode plates are secured to the top two sides of the mounting base via limiting blocks and limiting holes. A limiting rod is provided in the middle of the mounting base to effectively limit the movement of the coil during hot pressing and prevent damage to the coil, thus ensuring the coil remains stable during hot pressing. In addition, a U-shaped spring is provided at the bottom of the mounting base. The elastic support of the U-shaped spring helps to avoid the risk of coil deformation and short circuit caused by excessive hot pressing pressure. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of this utility model.

[0018] Figure 2 This is a top cross-sectional view of the magnetic block body of this utility model.

[0019] Figure 3 This is a schematic diagram of the exploded structure of this utility model.

[0020] Figure 4This is a schematic diagram of the mounting base and limiting rod structure of this utility model.

[0021] Figure 5 This is a schematic diagram of the U-shaped spring and the second slot structure of this utility model.

[0022] The following are the labels in the diagram: 1. Magnetic block body; 2. Mold cavity; 3. Mounting base; 4. Electrode sheet; 5. Coil; 6. Connecting terminal; 7. Groove; 8. First slot; 9. Second slot; 10. U-shaped spring sheet; 11. Limiting block; 12. Limiting hole; 13. Limiting groove; 14. Slide rail; 15. Fixing plate; 16. Limiting rod. Detailed Implementation

[0023] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.

[0024] Example 1

[0025] Reference Figures 1-5 This utility model provides a technical solution: a multi-layer pre-compressed magnetic core thermo-pressed integrated inductor, including a magnetic block body 1, a cavity 2 inside the magnetic block body 1, and an anti-vibration mounting base 3 inside the cavity 2. Electrode sheets 4 are limited and snapped onto the top two sides of the mounting base 3, and a stabilizing mechanism is provided on the outer side of the electrode sheets 4. A coil 5 is placed in the middle of the mounting base 3, and the pin ends of the coil 5 are flattened into square connection terminals 6. The connection terminals 6 are welded to the outer side of the electrode sheets 4, and the side ends of the electrode sheets 4 extend to the outer side of the magnetic block body 1. Grooves 7 are provided on both sides above the magnetic block body 1, and the side ends of the electrode sheets 4 are thermo-pressed into folded feet and attached to the inside of the grooves 7.

[0026] Reference Figure 1 The magnetic block body 1 is formed by die casting of metal magnetic powder and coil 5 and electrode sheet 4 into one piece.

[0027] In specific implementation, a multilayer pre-compressed magnetic core hot-pressed integrated inductor, when used in traditional round wire multilayer inductors, typically involves spot welding a round wire coil 5 to an electrode sheet 4 and then directly placing it into a mold cavity 2. The combination of the round wire coil 5 and the traditional spot welding method results in limited connection strength between the coil 5 and the electrode sheet 4. During subsequent packaging and use, the connection is easily loosened due to vibration or temperature changes, affecting the long-term stability of the inductor. Next, magnetic powder is poured in for cold pressing. While this structure achieves inductor manufacturing to some extent, the high pressure between the powder and the round wire coil 5 during cold pressing causes deformation of the coil 5, increasing friction between the coil 5 and the magnetic core and increasing the risk of short circuits. Such short circuits not only reduce inductor performance but may also cause circuit failures. Therefore, the main risk of traditional integrated spot-welded coil 5 placed in a mold cavity 2, filled with powder, and cold-pressed is the high cold pressing pressure and the risk of short circuits due to the pressure between the powder and the coil 5.

[0028] Example 2

[0029] Reference Figure 3 , Figure 5 This embodiment is an optimization based on the first embodiment. The cavity 2 is provided with multiple sets of first slots 8, and the bottom of the mounting base 3 is provided with a second slot 9 corresponding to the first slot 8. U-shaped spring pieces 10 are inserted into the first slot 8 and the second slot 9. The top of the mounting base 3 is provided with multiple sets of limiting blocks 11, and the electrode sheet 4 is provided with limiting holes 12 that match the limiting blocks 11. The limiting holes 12 and the limiting blocks 11 limit the electrode sheet 4, ensuring the stability of the internal structure of the magnetic block body 1.

[0030] Reference Figure 2 , Figure 4 The stabilizing mechanism includes a limiting groove 13, a slide rail 14, and a fixing plate 15. The limiting groove 13 is provided on both sides of the mold cavity 2, and the slide rail 14 is provided on both sides inside the limiting groove 13. One end of the electrode sheet 4 is hot-pressed and bent to fit against the inner wall of the limiting groove 13. The side of the electrode sheet 4 is provided with a fixing plate 15 that matches the slide rail 14 and is slidably connected to limit it, further ensuring the stability of the electrode sheet 4. The electrode sheet 4 is usually made of tin-plated iron sheet. The tin layer has good solderability and certain corrosion resistance, as well as good rust prevention. The mounting base 3 is provided with a limiting rod 16 in the middle, and the limiting rod 16 is matched with the pre-compressed magnetic core inside the coil 5 and is slidably engaged.

[0031] In specific implementation, a multi-layer pre-loaded magnetic core thermo-pressed integrated inductor is designed. When using this innovative multi-layer pre-loaded magnetic core thermo-pressed integrated inductor structure, firstly, the lead end of the coil 5 is flattened into a square connection terminal 6. The flattened connection terminal 6 can be more securely welded to the outside of the electrode sheet 4, reducing connection loosening caused by vibration or temperature changes. Next, the U-shaped spring piece 10 at the bottom of the mounting base 3 is inserted into the first slot 8 and the second slot 9 respectively. Since the mold cavity 2 has multiple sets of first slots 8, the mounting base 3 is installed inside the mold cavity 2. During the thermo-pressing process, the U-shaped spring piece 10... The coil 5 is subjected to zero pressure displacement, and because it has elastic support, it can further avoid the risk of deformation and short circuit caused by excessive hot pressing pressure. Secondly, because the mounting base 3 is provided with a limiting block 11 at the top, the bent electrode 4 is then snapped onto the outside of the limiting block 11 through the limiting hole 12. The side end of the electrode 4 is tightly attached to the inner wall of the limiting groove 13. Then, the fixing plate 15 is manually inserted into the limiting groove 13, so that the fixing plate 15 moves along the inner wall of the slide 14 and limits and fixes the side end of the tightly attached electrode 4, further ensuring that the coil 5 can remain stable during the hot pressing process.

[0032] Subsequently, the magnetic core inside coil 5 is pre-pressed into a flat wire. The pre-pressed magnetic core effectively reduces the direct contact area between coil 5 and magnetic powder during hot pressing, thereby reducing the risk of short circuits caused by extrusion. Next, the pre-pressed coil 5 is placed outside the limiting rod 16. Then, metallic magnetic powder (such as iron-silicon-chromium powder) is filled into the mold cavity 2. The metallic magnetic powder is then hot-pressed from top to bottom to make it tightly cover the coil 5 and the electrode sheet 4. A groove 7 is formed on the outside of the formed magnetic block body 1. The other end of the electrode sheet 4 extends to the outside of the magnetic block body 1 and is hot-pressed into a folded foot that fits into the groove 7. Through the above operations, the pre-pressed magnetic core solves the problem of powder extrusion and avoids short circuits. Hot pressing solves the problem of high pressure in traditional cold pressing and further improves its overall performance.

[0033] The above are merely preferred embodiments of this utility model, but the scope of protection of this utility model is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in this utility model, based on the technical solution and inventive concept of this utility model, should be included within the scope of protection of this utility model.

Claims

1. A multilayer pre-pressed magnetic core thermo-pressed integrated inductor, comprising a magnetically conductive block body (1), characterized in that, The magnetic block body (1) has a cavity (2) inside, and an anti-vibration mounting base (3) is provided inside the cavity (2). Electrode pieces (4) are limited and snapped on both sides of the top of the mounting base (3), and a stabilizing mechanism is provided on the outside of the electrode pieces (4). A coil (5) is placed in the middle of the mounting base (3), and the pins of the coil (5) are flattened into square connecting terminals (6). The connecting terminals (6) are welded to the outside of the electrode pieces (4), and the side ends of the electrode pieces (4) extend to the outside of the magnetic block body (1). Grooves (7) are provided on both sides of the top of the magnetic block body (1), and the side ends of the electrode pieces (4) are hot-pressed into folded feet and attached to the inside of the grooves (7).

2. The multilayer pre-pressed magnetic core hot-pressed integrated inductor according to claim 1, characterized in that, The magnetic block body (1) is formed by die casting of metal magnetic powder and coil (5) and electrode sheet (4) into one piece.

3. The multilayer pre-pressed magnetic core hot-pressed integrated inductor according to claim 1, characterized in that, The mold cavity (2) is provided with multiple sets of first slots (8), and the bottom of the mounting base (3) is provided with a second slot (9) corresponding to the first slot (8). U-shaped spring pieces (10) are inserted into the first slot (8) and the second slot (9).

4. The multilayer pre-pressed magnetic core hot-pressed integrated inductor according to claim 1, characterized in that, The mounting base (3) is provided with multiple sets of limiting blocks (11) on its top, and the electrode sheet (4) is provided with limiting holes (12) that match the limiting blocks (11).

5. The multilayer pre-pressed magnetic core hot-pressed integrated inductor according to claim 1, characterized in that, The stabilizing mechanism includes a limiting groove (13), a slide (14), and a fixing plate (15). The mold cavity (2) is provided with limiting grooves (13) on both sides, and the limiting grooves (13) are provided with slides (14) on both sides inside.

6. The multilayer pre-pressed magnetic core hot-pressed integrated inductor according to claim 5, characterized in that, One end of the electrode sheet (4) is hot-pressed and bent to fit the inner wall of the limiting groove (13), and the side of the electrode sheet (4) is provided with a fixing plate (15) that matches the slide (14) and is slidably connected to it, and is limited thereto.

7. The multilayer pre-pressed magnetic core hot-pressed integrated inductor according to claim 1, characterized in that, The mounting base (3) is provided with a limiting rod (16) in the middle, and the limiting rod (16) is matched with the pre-compressed magnetic core inside the coil (5) in a sliding engagement.

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