Copper-iron co-fired inductor

Abstract

The utility model belongs to the inductance technical field discloses a copper iron co -firing inductance, including copper sheet, first magnetic core and second magnetic core, copper sheet includes connecting portion and electrode portion, and the connecting portion and electrode portion surround and form the hollow part, first magnetic core is equipped with the positioning portion, first magnetic core is equipped with two positioning slots, and the positioning portion fills in the hollow part, and the electrode portion is limited in the positioning slot, and the side wall of electrode portion side away from the hollow part is flush with the side wall of first magnetic core, and the bottom wall of electrode portion is flush with the bottom wall of first magnetic core, second magnetic core is integrally formed with first magnetic core and covers connecting portion and positioning portion. Through setting up the positioning portion and the positioning slot, guarantee the finished product magnetic core characteristic unchangeable, avoid the magnetic core structure near the electrode portion to appear the problem of cracking, improve the quality of the magnetic core.

Description

Technical Field

[0001] This utility model relates to the field of inductor technology, and in particular to a copper-iron co-fired inductor. Background Technology

[0002] Copper-iron co-fired inductors (copper sheet inductors) are inductors obtained by placing copper sheets of different shapes into a forming die, filling them with metallic magnetic powder, and pressing them to form a magnetic core structure. The copper sheet can be designed in various shapes to meet specific application requirements, but to ensure electrode connection, its overall shape is generally U-shaped, with the two ends of the U-shaped copper sheet forming the electrodes. Considering copper loss and high current handling requirements, the DCR (Direct Current Resistance) of the copper sheet is generally designed to be relatively low. This results in a larger cross-sectional area of ​​the copper sheet, i.e., increased copper sheet thickness, and a corresponding increase in stress required during the pressing of the magnetic powder. To facilitate the subsequent lead-out of the electrode portion at the ends of the copper sheet to the outside of the inductor, the magnetic powder forming the core is thinner at the electrodes of the copper sheet. This results in a lower density of the core near the electrodes during subsequent pressing. Simultaneously, the copper sheet expands and deforms during the magnetic powder pressing process. Under high stress, the core is prone to cracking at the electrodes of the copper sheet. Some manufacturers also use a secondary processing technique, filling powder into the mold in batches and pressing it into shape to obtain a complete inductor. This results in the magnetic powder with a lower density around the electrode being squeezed twice, which greatly increases the risk of cracking of the magnetic core on the electrode surface. Utility Model Content

[0003] The purpose of this invention is to provide a copper-iron co-fired inductor that eliminates the magnetic powder area that is prone to cracking, thereby avoiding cracking problems in the magnetic core structure.

[0004] To achieve this objective, the present invention adopts the following technical solution: a copper-iron co-fired inductor, comprising a copper sheet, a first magnetic core, and a second magnetic core. The copper sheet is U-shaped, and includes a connecting portion and electrode portions located at both ends of the connecting portion. The connecting portion and the two electrode portions form a hollow portion. The first magnetic core has a positioning portion and two positioning grooves, which are symmetrically arranged on both sides of the positioning portion. The positioning grooves are formed on the sidewall of the first magnetic core and penetrate through the bottom wall of the first magnetic core. The positioning portion fills the hollow portion. The electrode portions are confined within the positioning grooves, and the sidewall of the electrode portion facing away from the hollow portion is flush with the sidewall of the first magnetic core, and the bottom wall of the electrode portion is flush with the bottom wall of the first magnetic core. The second magnetic core is integrally formed with the first magnetic core and covers the connecting portion and the positioning portion.

[0005] Preferably, there are two copper sheets, which are arranged opposite each other in the horizontal direction, and two positioning parts are arranged corresponding to the copper sheets.

[0006] Preferably, the top surface of the first magnetic core located between the two positioning portions is flush with the top surface of the copper sheet.

[0007] Preferably, the electrode portion has a protrusion that protrudes from one side of the copper sheet along the width direction of the copper sheet, and the protrusion is flush with the sidewall of the first magnetic core.

[0008] Preferably, the electrode portion has a first bend at the end away from the connection portion, the first bend extending horizontally toward the hollow portion, the bottom surface of the first magnetic core has a groove, and the first bend is located in the groove and flush with the bottom wall of the first magnetic core.

[0009] Preferably, the electrode portion has a second bend at the end away from the connecting portion, the second bend extending horizontally away from the hollow portion, the first magnetic core has a blocking portion, the blocking portion and the positioning portion cooperate to form a limiting groove matching the shape of the copper sheet, the positioning groove is connected to the limiting groove, the copper sheet is limited in the limiting groove, and the side wall of the second bend portion away from the hollow portion is flush with the outer side wall of the blocking portion.

[0010] Preferably, the electrode portion has a sidewall flush with the sidewall of the first magnetic core; and / or, the electrode portion has a protruding portion connected to the bottom wall of the first magnetic core, which protrudes from the surface of the first magnetic core.

[0011] Preferably, the outer peripheral wall of the second magnetic core is flush with the outer peripheral wall of the first magnetic core.

[0012] Preferably, the minimum thickness of the copper sheet is greater than or equal to 1 mm.

[0013] The beneficial effects of this invention are as follows: The magnetic core employs a two-stage processing technique. In the first stage, magnetic powder is pressed to form the first magnetic core. After a copper sheet is installed onto the first magnetic core, magnetic powder is filled again and pressed to form the second magnetic core. The first and second magnetic cores are integrally formed to obtain a complete magnetic core structure, with the electrode portion of the copper sheet exposed on the core surface. By setting a positioning part and a positioning groove, the positioning part fills the hollow portion of the copper sheet, effectively positioning the copper sheet and preventing displacement during the second processing, thus ensuring the characteristics of the finished magnetic core remain unchanged. The electrode portion of the copper sheet is confined within the positioning groove, allowing the outer and bottom walls of the electrode portion to be flush with the outer and bottom walls of the first magnetic core. This removes the thin layer of core structure originally covering the electrode portion surface, ensuring that no magnetic powder on the outer and bottom walls of the electrode portion bears the secondary pressing force, thereby preventing cracking of the core structure near the electrode portion and effectively improving the quality of the magnetic core. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the structure of the copper-iron co-fired inductor according to an embodiment of the present invention;

[0015] Figure 2 This is a schematic diagram of the structure of the first magnetic core according to the first embodiment of this utility model;

[0016] Figure 3 This is a schematic diagram of the structure of the copper sheet in the first embodiment of this utility model;

[0017] Figure 4 This is a schematic diagram of the installation of the copper sheet according to the first embodiment of this utility model;

[0018] Figure 5 This is a schematic diagram of the installation of the copper sheet according to the second embodiment of this utility model;

[0019] Figure 6 This is a schematic diagram of the installation of the copper sheet according to the third embodiment of this utility model.

[0020] In the picture:

[0021] 100. Copper sheet; 110. Connecting part; 120. Electrode part; 121. Protrusion; 122. First bend; 123. Second bend; 130. Hollowed-out part;

[0022] 200, First magnetic core; 210, Positioning part; 220, Positioning groove; 230, Groove; 240, Enclosing part; 300, Second magnetic core. Detailed Implementation

[0023] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, not the entire structure.

[0024] In the description of this utility model, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0025] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0026] In the description of this embodiment, the terms "upper," "lower," "right," etc., refer to the orientation or positional relationship shown in the accompanying drawings. They are used only for ease of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model. In addition, the terms "first" and "second" are only used for distinction in description and have no special meaning.

[0027] Reference Figures 1 to 6 As shown, a copper-iron co-fired inductor according to an embodiment of this application includes a copper sheet 100, a first magnetic core 200, and a second magnetic core 300. The copper sheet 100 is U-shaped and includes a connecting portion 110 and electrode portions 120 located at both ends of the connecting portion 110. The connecting portion 110 and the two electrode portions 120 surround a hollow portion 130. The first magnetic core 200 has a rectangular cross-section. A positioning portion 210 is provided on one side of the first magnetic core 200. The positioning portion 210 is a protrusion structure protruding from one side of the first magnetic core 200. The height of the protrusion 121 is greater than or equal to the width of the copper sheet 100. The first magnetic core 200 has two positioning grooves 220. The two positioning grooves 220 are disposed on two opposite sidewalls of the first magnetic core 200 and symmetrically disposed on both sides of the positioning portion 210. The positioning grooves 220 penetrate the bottom wall of the first magnetic core 200. The positioning portion 210 fills the hollow portion 300. The hollow portion 130 and the electrode portion 120 are confined within the positioning groove 220. The side wall of the electrode portion 120 facing away from the hollow portion 130 is flush with the side wall of the first magnetic core 200, and the bottom wall of the electrode portion 120 is flush with the bottom wall of the first magnetic core 200. At this time, the outer side wall and the bottom wall of the electrode portion 120 are exposed to the first magnetic core 200. The second magnetic core 300 is integrally formed with the first magnetic core 200 and covers the connecting portion 110 and the positioning portion 210. The first magnetic core 200 and the second magnetic core 300 form a complete magnetic core structure.

[0028] Understandably, the magnetic core employs a two-stage processing technique. The first stage involves pressing magnetic powder to form a first magnetic core 200. After installing a copper sheet 100 onto the first magnetic core 200, magnetic powder is filled again and pressed to form a second magnetic core 300. The first and second magnetic cores 200 are integrally formed to obtain a complete magnetic core structure, with the electrode portion 120 of the copper sheet 100 exposed on the core surface. By providing a positioning portion 210 and a positioning groove 220, the positioning portion 210 fills the hollow portion 130 of the copper sheet 100, effectively positioning the copper sheet 100 and preventing displacement during the second stage of processing, thus ensuring the core's structural characteristics remain unchanged. The electrode portion 120 of the copper sheet 100 is confined in the positioning groove 220, so that the outer and bottom walls of the electrode portion 120 can be flush with the outer and bottom walls of the first magnetic core 200. This removes the thin magnetic core structure that originally covered the surface of the electrode portion 120, ensuring that no magnetic powder on the outer and bottom walls of the electrode portion 120 bears secondary pressing force, thereby avoiding cracking of the magnetic core structure near the electrode portion 120 and effectively improving the quality of the magnetic core.

[0029] It should be noted that the magnetic core structure may selectively coat the outer wall or bottom wall of the electrode section 120 with insulating varnish according to the actual connection requirements. For example, if the magnetic core structure needs to be soldered from the side, the bottom wall surface of the electrode section 120 exposed to the first magnetic core 200 will be coated with varnish. Conversely, if the magnetic core structure needs to be soldered from the bottom, the side wall surface of the electrode section 120 exposed to the first magnetic core 200 will be coated with varnish. If both the side wall and bottom wall of the copper sheet 100 need to be soldered, no varnish will be applied. This is specifically noted here and will not be repeated hereafter.

[0030] Among them, the minimum thickness of copper sheet 100 is greater than or equal to 1 mm.

[0031] When the copper sheet 100 is thin, directly exposing its outer wall and bottom to the first magnetic core 200 may result in poor bonding between the copper sheet 100 and the magnetic core, leading to loosening of the copper sheet 100. Limiting the thickness of the copper sheet 100 to more than 1 mm ensures that the portion of the copper sheet 100 not exposed to the first magnetic core 200 is tightly covered with sufficient magnetic powder, thereby improving the structural stability of the copper sheet 100.

[0032] Furthermore, the outer peripheral wall of the second magnetic core 300 is flush with the outer peripheral wall of the first magnetic core 200. At this time, the first magnetic core 200 and the second magnetic core 300 form a complete block-shaped magnetic core structure.

[0033] Setting the outer peripheral walls of the second magnetic core 300 and the first magnetic core 200 flush can increase the height of the complete magnetic core structure, compensate for the height loss due to removing the magnetic powder at the bottom of the copper sheet 100, and make the overall height and shape of the magnetic core consistent with traditional magnetic cores. This allows users to directly use existing molds for processing, reduces the production cost of the magnetic core structure, and ensures the compatibility of the magnetic core structure with existing circuits.

[0034] Reference Figure 1 and Figure 2 As shown, it can be understood that there are two copper sheets 100, which are arranged opposite each other in the horizontal direction, and two positioning parts 210 are arranged corresponding to the copper sheets 100.

[0035] In some embodiments, two copper sheets 100 are disposed inside the magnetic core to form a coupled inductor, which can reduce resistance loss and improve the practicality of the magnetic core structure. At the same time, the two copper sheets 100 are integrated into the same magnetic core, reducing material usage and lowering costs.

[0036] Reference Figure 4 As shown, it can be understood that the top surface of the first magnetic core 200 located between the two positioning portions 210 is flush with the top surface of the copper sheet 100. And along the length direction of the copper sheet 100 (i.e. the extension direction of the connecting portion 110), the length of the top surface of the first magnetic core 200 between the two positioning portions 210 is equal to the length of the copper sheet 100.

[0037] Setting the top surface of the first magnetic core 200 flush with the top surface of the copper sheet 100 ensures that the top surface of the connection structure between the first magnetic core 200 and the copper sheet 100 is flat during the secondary powder filling and pressing process. It also limits the top of the copper sheet 100 to prevent slight displacement of the two copper sheets 100 due to compression during powder filling and pressing, thus ensuring the quality of the magnetic core structure.

[0038] Reference Figure 3 As shown, it can be understood that the electrode part 120 is provided with a protrusion 121. The protrusion 121 protrudes from one side of the copper sheet 100 along the width direction of the copper sheet 100. At this time, the shape of the electrode part 120 is L-shaped. The protrusion 121 is flush with the side wall of the first magnetic core 200 and the electrode part 120 is exposed and flush with the side wall of the first magnetic core 200.

[0039] By providing the protrusion 121, the area of ​​the outer wall of the electrode portion 120 exposed to the first magnetic core 200 can be increased, which facilitates subsequent soldering and improves the electrical connection stability of the magnetic core structure.

[0040] Reference Figure 5 As shown, it can be understood that the electrode part 120 is provided with a first bending part 122 at the end away from the connecting part 110. The first bending part 122 extends horizontally toward the hollow part 130. At this time, the copper sheet 100 has a square shape with a notch at the bottom. The bottom surface of the first magnetic core 200 is provided with a groove 230. The first bending part 122 is limited to the groove 230 and is flush with the bottom wall of the first magnetic core 200.

[0041] By providing the first bending portion 122, the area of ​​the bottom wall of the portion of the electrode portion 120 exposed to the first magnetic core 200 can be increased, facilitating subsequent soldering and improving the electrical connection stability of the magnetic core structure. The first bending portion 122 is confined within the groove 230 and flush with the bottom wall of the first magnetic core 200, preventing the first bending portion 122 from protruding from the bottom surface of the magnetic core, thus avoiding structural instability, or from being recessed into the bottom wall of the first magnetic core 200, thus preventing cracking around the first bending portion 122. Simultaneously, the inwardly bent first bending portion 122 can also form a locking structure with the electrode portion 120 and the connecting portion 110, improving the tightness of the connection between the copper sheet 100 and the first magnetic core 200.

[0042] Reference Figure 6 As shown, it can be understood that the electrode part 120 is provided with a second bending part 123 at the end away from the connecting part 110. The second bending part 123 extends horizontally away from the hollow part 130. At this time, the copper sheet 100 has a Z-shaped shape. The first magnetic core 200 is provided with a blocking part 240. The blocking part 240 and the positioning part 210 are located on the same side of the first magnetic core 200. The blocking part 240 and the positioning part 210 cooperate to form a limiting groove that matches the shape of the copper sheet 100. The positioning groove 220 is connected to the limiting groove. The copper sheet 100 is limited in the limiting groove. The side wall of the second bending part 123 away from the hollow part 130 is flush with the outer side wall of the blocking part 240. That is, the outer side wall of the second bending part 123 is the outer side wall of the electrode part 120 exposed in the first magnetic core 200.

[0043] When the copper sheet 100 is shaped like a "Z", the portion of the electrode part 120 that is higher than the second bend 123 is not easily covered by magnetic powder during the secondary powder filling and pressing process, which can easily lead to cracking. By setting up the enclosure part 240, which works in conjunction with the positioning part 210, the copper sheet 100 can be positioned and locked, further improving the installation stability of the copper sheet 100. Moreover, the outer wall of the outwardly bent second bend 123 is flush with the enclosure part 240, meaning that the enclosure part 240 itself covers the side wall of the electrode part 120 except for the second bend 123. The side wall of the electrode part 120 can be directly covered without secondary powder filling and pressing, which facilitates subsequent secondary processing.

[0044] It should be noted that since the secondary powder filling and pressing is performed from top to bottom on the basis of the first magnetic core 200, that is, the second magnetic core 300 is located above the first magnetic core 200, and the copper sheet 100 itself is located in the limiting groove, in order to cover the copper sheet 100, the blocking part 240 and the positioning part 210 are both provided on the top surface of the first magnetic core 200, so that the limiting groove is formed on the top surface of the first magnetic core 200, thereby facilitating the secondary powder filling and pressing. After the magnetic core is pressed and formed, the magnetic core can be rotated 90° so that the part of the second bending part 123 exposed in the first magnetic core 200 is rotated to the bottom of the inductor before use. This is specifically mentioned here to avoid misunderstanding.

[0045] Furthermore, the electrode portion 120 has a sidewall flush with the sidewall of the first magnetic core 200; or, the electrode portion 120 has a bottomwall flush with the bottom wall of the first magnetic core 200 with a protruding portion; or, the electrode portion 120 has an exposed protruding portion that is connected to both the sidewall and the bottom wall of the first magnetic core 200, and the protruding portion protrudes from the surface of the first magnetic core 200.

[0046] By providing a protrusion that extends beyond the surface of the magnetic core structure, the pressure resistance requirements of the magnetic core structure when it is connected to electricity in some embodiments can be met, thereby further improving the practicality of the magnetic core structure.

[0047] Obviously, the above embodiments of this utility model are merely examples for clearly illustrating the present utility model, and are not intended to limit the implementation of the present utility model. Those skilled in the art can make various obvious changes, readjustments, and substitutions without departing from the protection scope of this utility model. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this utility model should be included within the protection scope of the claims of this utility model.

Claims

1. A copper-iron co-fired inductor, characterized in that, include: A copper sheet (100) is U-shaped. The U-shaped copper sheet (100) includes a connecting part (110) and electrode parts (120) located at both ends of the connecting part (110). The connecting part (110) and the two electrode parts (120) surround and form a hollow part (130). A first magnetic core (200) is provided with a positioning part (210) and two positioning grooves (220). The two positioning grooves (220) are symmetrically arranged on both sides of the positioning part (210). The positioning grooves (220) are opened on the side wall of the first magnetic core (200) and penetrate the bottom wall of the first magnetic core (200). The positioning part (210) is filled in the hollow part (130). The electrode part (120) is limited to the positioning groove (220). The side wall of the electrode part (120) facing away from the hollow part (130) is flush with the side wall of the first magnetic core (200). The bottom wall of the electrode part (120) is flush with the bottom wall of the first magnetic core (200). The second magnetic core (300) is integrally formed with the first magnetic core (200) and covers the connecting part (110) and the positioning part (210).

2. The copper-iron co-fired inductor of claim 1, wherein, Two copper sheets (100) are provided, and the two copper sheets (100) are arranged opposite each other in the horizontal direction. Two positioning parts (210) are provided corresponding to the copper sheets (100).

3. The co-fired copper inductor of claim 2, wherein, The top surface of the first magnetic core (200) located between the two positioning parts (210) is flush with the top surface of the copper sheet (100).

4. The co-fired copper inductor of claim 1 or 2, wherein, The electrode portion (120) is provided with a protrusion (121), which protrudes from one side of the copper sheet (100) along the width direction of the copper sheet (100), and the protrusion (121) is flush with the side wall of the first magnetic core (200).

5. The co-fired copper inductor of claim 1 or 2, wherein, The electrode portion (120) has a first bending portion (122) at one end away from the connecting portion (110). The first bending portion (122) extends horizontally toward the hollow portion (130). The bottom surface of the first magnetic core (200) has a groove (230). The first bending portion (122) is located in the groove (230) and is flush with the bottom wall of the first magnetic core (200).

6. The co-fired copper inductor of claim 1, wherein, The electrode portion (120) has a second bend portion (123) at one end away from the connecting portion (110). The second bend portion (123) extends horizontally away from the hollow portion (130). The first magnetic core (200) has a blocking portion (240). The blocking portion (240) and the positioning portion (210) cooperate to form a limiting groove that matches the shape of the copper sheet (100). The positioning groove (220) communicates with the limiting groove. The copper sheet (100) is limited in the limiting groove. The side wall of the second bend portion (123) away from the hollow portion (130) is flush with the outer side wall of the blocking portion (240).

7. The copper-iron co-fired inductor according to claim 1 or 6, characterized in that, The electrode portion (120) has a sidewall flush with the sidewall of the first magnetic core (200); and / or, the electrode portion (120) has a protrusion connected to the bottom wall of the first magnetic core (200) flush with the bottom wall, the protrusion protruding from the surface of the first magnetic core (200).

8. The co-fired copper inductor of claim 1, wherein, The outer peripheral wall of the second magnetic core (300) is flush with the outer peripheral wall of the first magnetic core (200).

9. The co-fired copper inductor of claim 1, wherein, The minimum thickness of the copper sheet (100) is greater than or equal to 1 mm.

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