Ultra-micro gap inductor
By designing a groove and an integrated terminal block with an ultra-micro air gap structure in the inductor, the problems of terminal block centering and core damage during the assembly process of the MCSHC series inductors have been solved, realizing an inductor device with high bonding strength and adjustable inductance.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- SUZHOU MORE CHANCE ELECTRONICS CO LTD
- Filing Date
- 2025-04-14
- Publication Date
- 2026-07-10
AI Technical Summary
The existing MCSHC series inductors have problems during assembly, such as the inability to center the terminal pieces, easy damage to the magnetic core at the bevel angle, leakage flux due to air gap, and reduced bonding strength.
The design incorporates a groove at the bottom of the first iron core and an integrated bending and forming of the terminal piece. An ultra-micro air gap structure is formed by bonding with glue. Combined with the magnetic permeability adjustment of the core material, the sensitivity value is adjusted to avoid damage from extrusion assembly and ensure that the terminal piece is centered.
It effectively reduces the defect rate of finished products, improves the bonding strength between the magnetic core and the terminal piece, makes the magnetic gap approach zero, and enhances the stability of the inductor structure and the ability to adjust the inductance value.
Smart Images
Figure CN224480857U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of inductor components, and in particular to an ultra-micro gap inductor. Background Technology
[0002] An inductor is a component that converts electrical energy into magnetic energy and stores it. When no current flows through an inductor, it will attempt to impede the flow of current when the circuit is closed; when current flows through an inductor, it will attempt to maintain a constant current when the circuit is open. Inductors are also known as chokes, reactors, or dynamic reactors.
[0003] The existing MCSHC series inductors have the following specific structure: Figure 1 As shown, it consists of two iron cores 1 and 2 and a terminal piece 3. During assembly, the terminal piece and the magnetic core are assembled by pressing the two ends of the terminal piece. In actual operation, the following problems may occur:
[0004] 1. The centering position of the terminal piece cannot be guaranteed;
[0005] 2. When assembling the two ends of the crimped terminal piece, at the bevel of the magnetic core (such as...) Figure 1 The area indicated by the arrow is prone to damage;
[0006] 3. During fixing, the top iron core and the terminal piece need to be fixed with a mixture of glass beads and glue, which creates a certain air gap at the joint surface, resulting in magnetic leakage. As the inductance decreases, the air gap increases, and the joint strength of the upper and lower magnetic cores will also decrease, which requires special control. Utility Model Content
[0007] In order to overcome the above-mentioned defects of the prior art, the present invention provides an ultra-micro gap inductor to solve the problems existing in the background art.
[0008] This utility model provides the following technical solution: an ultra-micro gap inductor, comprising:
[0009] The first iron core has a groove at its bottom;
[0010] The second iron core has a rectangular structure;
[0011] The terminal piece is an integrated bending and forming device, which includes a horizontal piece and two assembly pieces. Both assembly pieces are L-shaped, and their side widths are greater than the width of the horizontal piece. The two assembly pieces are symmetrically arranged at both ends of the horizontal piece to form a space for receiving the second iron core.
[0012] The second iron core is horizontally inserted onto the two assembly plates, so that the assembly plates are supported by the second iron core. The first iron core is snapped onto the terminal plate and the groove matches the horizontal plate to form a complete inductor structure.
[0013] Preferably, the gap between the assembled first iron core and the second iron core is bonded with glue, and the glue uses ultra-fine particles to reduce the gap between the first iron core and the second iron core, forming an ultra-fine gas system structure.
[0014] Preferably, the outer surface of the second iron core is designed to be smooth and flat.
[0015] Preferably, the transverse piece is centered on the two assembly pieces.
[0016] Preferably, the groove corresponds to and is adapted to the horizontal piece. When the groove and the horizontal piece are fitted together, the front and rear ends of the bottom of the first iron core also match and contact the top of the assembly piece.
[0017] Preferably, a gap is formed between the two assembly pieces.
[0018] Preferably, the bottom of the second iron core is provided with a protrusion, the length of which is adapted to the gap so that the protrusion is just embedded in the gap, and the thickness of the protrusion is equal to the thickness of the assembly piece.
[0019] Preferably, both the first iron core and the second iron core are made of high-performance alloy materials.
[0020] Preferably, the terminal piece is made of copper material and is electroplated.
[0021] Compared with the prior art, the beneficial effects of this utility model are as follows:
[0022] 1. This utility model allows for assembly by moving the terminal piece and the magnetic core in the front-back and left-right directions, replacing the extrusion assembly of the prior art. This effectively avoids damage to the oblique angle of the second iron core, reduces the defect rate of the finished product, and ensures that the terminal piece is in the center position with the cooperation of the groove and the cross piece.
[0023] 2. When fixing the assembled inductor structure of this utility model, it is only necessary to apply glue to the gap between the terminal piece and the magnetic core, and then press them tightly together with tools before baking. At the same time, the inductor structure adjusts the inductance value by changing the permeability of the magnetic core material, so that the air gap between the magnetic core and the terminal piece approaches zero, which not only improves the bonding strength, but also requires no special control. Attached Figure Description
[0024] Figure 1 This is a schematic diagram of an existing inductor.
[0025] Figure 2 This is a schematic diagram of the inductive explosion structure of Embodiment 1 of this utility model.
[0026] Figure 3 This is a schematic diagram of the inductor assembly structure of Embodiment 1 of this utility model.
[0027] Figure 4 This is a schematic diagram of the inductive explosion structure of Embodiment 2 of this utility model.
[0028] Figure 5 This is a schematic diagram of the inductor assembly structure of Embodiment 2 of this utility model.
[0029] Figure 6 This is a saturation current test curve of this utility model.
[0030] Figure 7 This is a temperature rise current test curve of this utility model.
[0031] Figure 8 This is a comparison chart of the saturation current test curves of this utility model and the prior art.
[0032] The attached figures are labeled as follows: 1, first iron core; 11, groove; 2, second iron core; 21, protrusion; 3, terminal piece; 31, cross piece; 32, assembly piece; 33, gap. Detailed Implementation
[0033] The preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, so that the advantages and features of the present invention can be more easily understood by those skilled in the art, thereby providing a clearer and more definite definition of the scope of protection of the present invention.
[0034] Example 1
[0035] A type of micro-gap inductor, such as Figure 1-3 As shown, it includes: a first iron core 1, a second iron core 2, and a terminal piece 3. Specifically, the first iron core 1 has a groove 11 at its bottom, which is located in the middle of the first iron core 1 to ensure that the terminal piece 3 is centered; the second iron core 2 has a rectangular structure.
[0036] The terminal piece 3 is integrally bent and formed to avoid damage to the magnetic core during assembly with the magnetic core, reduce the defect rate of the finished product, and ensure the flatness of the bottom of the product. The terminal piece 3 includes a horizontal piece 31 and two assembly pieces 32.
[0037] Furthermore, both assembly pieces 32 are L-shaped, and their side widths are greater than the width of the horizontal piece 31. The greater side width of the assembly piece 32 reduces the DC impedance, facilitating the assembly and positioning of the magnetic core, while also increasing the bottom area of the sub-piece 3 to improve the welding strength of the product. The bottom surface of the assembly piece 32 does not require specific specifications; it can be greater than, less than, or equal to the width of the horizontal piece 31.
[0038] Two assembly pieces 32 are symmetrically arranged at both ends of the cross piece 31 to form a space for mounting the second iron core 2.
[0039] During assembly, the second iron core 2 is horizontally inserted onto the two mounting pieces 32, so that the mounting pieces 32 are supported by the second iron core 2. The first iron core 1 is fastened onto the terminal piece 3 and the groove 11 matches the horizontal piece 31 to form a complete inductor structure.
[0040] The gap between the first iron core 1 and the second iron core 2 after assembly is bonded with glue. The glue uses ultra-fine particles to reduce the gap between the first iron core 1 and the second iron core 2, forming an ultra-fine gas system structure.
[0041] Assembly can be performed by moving the terminal pieces and magnetic core in the front-back and left-right directions, replacing the extrusion assembly of the existing technology. This effectively avoids damage to the oblique angle of the second iron core, reduces the defect rate of the finished product, and ensures that the terminal pieces are in the center position with the cooperation of the groove and the cross piece.
[0042] When fixing the assembled inductor structure, it is only necessary to apply glue to the gap between the terminal piece and the magnetic core, press them tightly together with a tool, and then cure them in an oven. At the same time, the inductor structure adjusts the inductance value by changing the permeability of the magnetic core material, so that the air gap between the magnetic core and the terminal piece approaches zero, which not only improves the bonding strength, but also requires no special control.
[0043] The assembled dimensions of the inductor are 10.0±0.2mm in length, 5.8±0.2mm in width, and 2.6±0.2mm in height. Its saturation current was tested at 0~80A as follows... Figure 6 As shown in Table 1 below:
[0044] Table 1
[0045] The heating current was tested at a current range of 0~40A. Figure 7 As shown.
[0046] The saturation current of the inductors in this application and those in the prior art were compared under current conditions ranging from 0 to 70 A. Figure 8 As shown in Table 2 below:
[0047]
[0048] Table 2
[0049] like Figure 8 As shown in Table 2, when the current is large (above 50A), the inductor of this application can better carry the overcurrent than the inductors of the prior art (MCSHV series), preventing the back-end MOS or IC components from burning out.
[0050] In this embodiment, the outer surface of the second iron core 2 is designed to be smooth and flat, which reduces the difficulty of assembly and ensures the flatness of the product.
[0051] In this embodiment, the groove 11 corresponds to and is adapted to the horizontal piece 31. When the groove 11 and the horizontal piece 31 are fitted together, the bottom front and rear ends of the first iron core 1 also match and contact the top of the assembly piece 32, which further improves the flatness of the product.
[0052] In this embodiment, a gap 33 is formed between the two assembly pieces 32.
[0053] In this embodiment, both the first iron core 1 and the second iron core 2 are made of high-performance alloy materials. The terminal piece 3 is made of copper and electroplated, with the electroplating material being nickel or tin.
[0054] Example 2
[0055] A type of micro-gap inductor, such as Figure 4-5 As shown, it includes: a first iron core 1, a second iron core 2, and a terminal piece 3. Specifically, the first iron core 1 has a groove 11 at its bottom, which is located in the middle of the first iron core 1 to ensure the centered position of the terminal piece 3; the second iron core 2 has a rectangular structure; the terminal piece 3 is integrally bent to avoid damage to the magnetic core during assembly with the magnetic core, reduce the defect rate of the finished product, and ensure the flatness of the bottom of the product. The terminal piece 3 includes a horizontal piece 31 and two assembly pieces 32. The two assembly pieces 32 have an L-shaped structure and are symmetrically arranged at both ends of the horizontal piece 31 to form a space for supporting the second iron core 2.
[0056] During assembly, the second iron core 2 is horizontally inserted onto the two mounting pieces 32, so that the mounting pieces 32 are supported by the second iron core 2. The first iron core 1 is fastened onto the terminal piece 3 and the groove 11 matches the horizontal piece 31 to form a complete inductor structure.
[0057] Assembly can be performed by moving the terminal pieces and magnetic core in the front-back and left-right directions, replacing the extrusion assembly of the existing technology. This effectively avoids damage to the oblique angle of the second iron core, reduces the defect rate of the finished product, and ensures that the terminal pieces are in the center position with the cooperation of the groove and the cross piece.
[0058] In this embodiment, the width of the two assembly pieces 32 is greater than the width of the horizontal piece 31, and the horizontal piece 31 is centrally located on the two assembly pieces 32. The width of the assembly pieces 32 being greater than the width of the horizontal piece 31 reduces the DC impedance and facilitates the assembly and positioning of the magnetic core. At the same time, the bottom area of the terminal piece 3 is increased to improve the welding strength of the product.
[0059] In this embodiment, the groove 11 corresponds to and is adapted to the horizontal piece 31. When the groove 11 and the horizontal piece 31 are fitted together, the bottom front and rear ends of the first iron core 1 also match and contact the top of the assembly piece 32, which further improves the flatness of the product.
[0060] In this embodiment, a gap 33 is formed between the two assembly pieces 32.
[0061] In this embodiment, the outer surface of the second iron core 2 is designed to be smooth and flat, and a protrusion 21 is provided at the bottom of the second iron core 2. The length of the protrusion 21 is adapted to the gap 33 so that the protrusion 21 is just embedded in the gap 33. The thickness of the protrusion 21 is equal to the thickness of the assembly piece 32. After assembly, the complete inductor structure is a rectangular structure, which improves the flatness of the inductor's appearance and the flatness of the product.
[0062] In this embodiment, both the first iron core 1 and the second iron core 2 are made of high-performance alloy materials. The terminal piece 3 is made of copper and electroplated, with the electroplating material being nickel or tin.
[0063] Several points should be noted: First, in the description of this application, it should be noted that, unless otherwise specified and limited, the terms "installation", "connection" and "linkage" should be interpreted broadly, and can be mechanical or electrical connection, or internal connection between two components, or direct connection. "Up", "down", "left", "right", etc. are only used to indicate relative positional relationship. When the absolute position of the described object changes, the relative positional relationship may change.
[0064] The above description is only a preferred embodiment of the present utility model. The protection scope of the present utility model is not limited to the above embodiments. Any equivalent modifications or changes made by those skilled in the art based on the content disclosed in the present utility model should be included in the protection scope recorded in the claims.
Claims
1. An ultra-micro gap inductor, characterized in that, include: The first iron core (1) has a groove (11) at its bottom; The second iron core (2) has a rectangular structure; Terminal piece (3), integrally bent and formed, includes a horizontal piece (31) and two assembly pieces (32). Both assembly pieces (32) are L-shaped, and their side widths are greater than the width of the horizontal piece (31). The two assembly pieces (32) are symmetrically arranged at both ends of the horizontal piece (31) to form a space for mounting the second iron core (2). The second iron core (2) is horizontally inserted onto the two assembly pieces (32), so that the assembly pieces (32) are supported by the second iron core (2). The first iron core (1) is fastened onto the terminal piece (3) and the groove (11) matches the cross piece (31) to form a complete inductor structure.
2. The ultra-micro gap inductor according to claim 1, characterized in that: The gap between the assembled first iron core (1) and the second iron core (2) is bonded with glue. The glue uses ultra-fine particles to reduce the gap between the first iron core (1) and the second iron core (2), forming an ultra-fine gas system structure.
3. The ultra-micro gap inductor according to claim 1, characterized in that: The outer surface of the second iron core (2) is designed to be smooth and flat.
4. The ultra-micro gap inductor according to claim 1, characterized in that: The horizontal piece (31) is centered on the two assembly pieces (32).
5. The ultra-micro gap inductor according to claim 1, characterized in that: The groove (11) corresponds to and is adapted to the horizontal piece (31). When the groove (11) and the horizontal piece (31) are fitted together, the bottom front and rear ends of the first iron core (1) also match and contact the top of the assembly piece (32).
6. The ultra-micro gap inductor according to claim 1, characterized in that: A gap (33) is formed between the two assembly pieces (32).
7. The ultra-micro gap inductor according to claim 6, characterized in that: The bottom of the second iron core (2) is provided with a protrusion (21), the length of which is adapted to the gap (33) so that the protrusion (21) is just embedded in the gap (33), and the thickness of the protrusion (21) is equal to the thickness of the assembly piece (32).
8. An ultra-micro gap inductor according to any one of claims 1-7, characterized in that: Both the first iron core (1) and the second iron core (2) are made of high-performance alloy materials.
9. An ultra-micro gap inductor according to any one of claims 1-7, characterized in that: The terminal piece (3) is made of copper material and is electroplated.