T-shaped magnetic core, inductor and electronic product

Abstract

The utility model provides a kind of T-type magnetic core, inductance and electronic product, T-type magnetic core has board part and the column part of self board part extension, wherein, the number of column part is two, two column parts are distributed along first direction, the two side walls of board part in first direction are all formed protruding and form protruding to board part back, the two opposite sides of protruding are respectively formed first gap with the side wall of being located, T-type magnetic core also has retaining wall part, retaining wall part and column part are all located in the first side of board part, retaining wall part is surrounded in the outer periphery of column part, each column part is formed with retaining wall part, board part between one limit cavity, limit cavity has limit perimeter wall, limit cavity has second gap in the side wall close to itself and second gap penetrates the side wall, so that two limit cavities are mirror image symmetry distribution.Electronic product is equipped with inductance, inductance includes above-mentioned T-type magnetic core, T-type magnetic core has the advantages that structural strength is high, and the crack of inductance finished product after hot-pressing forming can be avoided.

Description

Technical Field

[0001] This utility model relates to the field of electronic product technology, specifically to a T-shaped magnetic core, an inductor provided with the T-shaped magnetic core, and an electronic product containing the aforementioned inductor. Background Technology

[0002] T-core type inductors are widely used in circuits due to their small size and high saturation. The manufacturing process of existing T-core type inductors is as follows: First, a T-core is formed by cold pressing magnetic powder; then, a coil is wound on the T-core, or the coil is wound first and then assembled with the T-core; then, the assembly structure of the T-core and coil is placed in a molding mold, filled with magnetic powder, and finally hot-pressed to form the inductor.

[0003] like Figure 1 As shown, the existing T-shaped magnetic core 91 has a plate portion 911 and a post portion 912 extending from the plate portion 911. Two wire-hanging notches 9112 are provided on one side of the plate portion 9112, and a protrusion 9111 is formed between the two wire-hanging notches 9112. The wire-hanging notches 9112 are used to accommodate the leads 921 of the coil 92 and, together with the protrusion 9111, limit the coil 92 to prevent it from rotating around the post portion 912. The main body 922 of the coil 92 is fitted onto the post portion 912 to prevent the coil 92 from shifting position during hot pressing. However, this T-shaped magnetic core 91 has the following defects:

[0004] First, after the coil 92 is assembled with the T-shaped magnetic core 91, the lead 921 portion of the coil 92 needs to be bent to the side of the plate portion 911 facing away from the post portion 912 (e.g., Figure 2 As shown in the figure, since the inductor is small in size, the thickness of the board 911 is usually thin, which makes the board 911 prone to breakage due to insufficient structural strength during the bending process of the pin 921.

[0005] Secondly, since the assembly structure of coil 92 and T-shaped magnetic core 91 is placed into the molding mold, magnetic powder needs to be filled. During this process, uneven magnetic powder filling density occurs around coil 92, resulting in cavitation during hot pressing and ultimately causing cracks in the finished inductor. Summary of the Invention

[0006] To address the aforementioned problems, the primary objective of this invention is to provide a T-shaped magnetic core with high structural strength that can prevent cracking in the finished inductor product after hot pressing.

[0007] The second objective of this invention is to provide an inductor having the aforementioned T-shaped magnetic core.

[0008] The third objective of this invention is to provide an electronic product having the aforementioned inductor.

[0009] To achieve the first objective of this utility model, this utility model provides a T-shaped magnetic core having a plate portion and column portions extending from the plate portion. The number of column portions is two, and the two column portions are distributed along a first direction. The two sidewalls of the plate portion in the first direction protrude away from the plate portion to form protrusions. The two oppositely arranged sidewalls of the protrusions respectively form a first notch with the sidewalls where they are located. The T-shaped magnetic core also has a retaining wall portion. The retaining wall portion and the column portions are both located on the first side of the plate portion. The retaining wall portion surrounds the outer periphery of the column portions. Each column portion forms a limiting cavity with the retaining wall portion and the plate portion. The limiting cavity has a limiting peripheral wall. The limiting cavity has a second notch at its sidewall near itself, and the second notch penetrates the sidewall, so that the two limiting cavities are distributed in a mirror symmetrical manner.

[0010] As can be seen from the above, the design of the retaining wall enhances the structural strength of the plate, preventing cracking and breakage of the plate during coil bending. On the other hand, the formed limiting cavity can work with the column and protrusion to better limit and support the coil, preventing the coil position from shifting during subsequent hot pressing and ensuring the quality of the finished inductor. At the same time, the design of the retaining wall combined with the limiting cavity can better ensure the density and uniformity of the magnetic powder filling around the coil, preventing cracks from appearing in the finished inductor.

[0011] A preferred embodiment is that the partial wall surface opposite to the second notch of the limiting peripheral wall is a first arc surface, and the first arc surface protrudes away from the column; or the partial wall surface opposite to the second notch of the limiting peripheral wall is a surface group, the surface group including a plane and two second arc surfaces, the plane being located between the two second arc surfaces, and the second arc surfaces protruding away from the column.

[0012] As can be seen from the above, the contour shape of the limiting peripheral wall is diverse, which can be adapted to coil bodies with different winding shapes, expand the application range of T-type magnetic cores, and improve the practicality of T-type magnetic cores.

[0013] Another preferred option is that the cross-section of the column is circular, elliptical, racetrack-shaped, rounded rectangle, or rectangular.

[0014] As can be seen from the above, the shape of the post can be varied and adjusted according to the coil body with different winding shapes, which has diversity, thereby expanding the application range of T-type magnetic cores, improving the practicality and production flexibility of T-type magnetic cores, and at the same time ensuring that the post can better fit close to the inner ring of the coil body, ensuring coupling efficiency and reducing magnetic leakage.

[0015] Another preferred option is to have a chamfered structure at the junction of the protrusion and the sidewall.

[0016] As can be seen from the above, this design can reduce stress concentration at the junction of the protrusion and the sidewall, and further prevent cracking at the junction of the protrusion and the sidewall during the bending process of the coil leads.

[0017] Another preferred embodiment is that, along the axial direction of the column, the height of the column is equal to the depth of the limiting cavity; or, along the axial direction, the height of the column is greater than the depth of the limiting cavity; or, along the axial direction, the height of the column is less than the depth of the limiting cavity.

[0018] As can be seen from the above, the relationship between the height of the column and the depth of the limiting cavity can be adjusted according to the powder filling requirements of the inductor to meet different production process requirements and improve the practicality of the T-shaped magnetic core.

[0019] A further proposed solution is to provide a limiting step in each limiting cavity. The limiting step is located near the second notch and along the second direction. The limiting step is located between the limiting peripheral wall and the protrusion. The limiting step is connected to the limiting peripheral wall and the plate. The side of the limiting step facing the column is the limiting surface. The height of the limiting step is less than the height of the column.

[0020] A further proposed solution is that the limiting steps within the two limiting cavities are centrally symmetrically distributed or mirror-symmetrically distributed.

[0021] As can be seen from the above, the limiting step can support the pin with the higher position of the coil, avoiding deformation, collapse, misalignment, etc. caused by insufficient powder density and / or insufficient suspension around the pin during the hot pressing process, thereby ensuring the forming quality of the inductor.

[0022] To achieve the second objective of this utility model, this utility model provides an inductor comprising two coils, each coil having a body and two leads. The inductor further includes a powder coating layer and the aforementioned T-shaped magnetic core. The two coils correspond one-to-one with two limiting cavities, with the body located within the corresponding limiting cavity and sleeved on the column portion. The limiting peripheral wall surrounds the outer periphery of the body. The lead of each coil extends out of the T-shaped magnetic core from the second notch, bends through the corresponding first notch, and then bends and overlaps on the second side of the plate portion opposite to the column portion. At least a portion of the powder coating layer fills the limiting cavity, the first notch, and the second notch. The coils, the T-shaped magnetic core, and the powder coating layer are formed into an inductor through a hot-pressing molding process.

[0023] As can be seen from the above, the inductor with the above-mentioned T-shaped magnetic core has a low probability of developing cracks on its surface and / or inside after molding, and the molding quality is high.

[0024] A further option is to make the height of the column greater than or equal to the height of the main body.

[0025] As can be seen from the above, this design can ensure the coupling efficiency between the coil winding and the post, and reduce magnetic leakage.

[0026] To achieve the third objective of this utility model, this utility model provides an electronic product, including a printed circuit board, wherein the aforementioned inductor is mounted on the printed circuit board.

[0027] As can be seen from the above, electronic products equipped with the aforementioned inductors operate reliably and stably. Attached Figure Description

[0028] Figure 1 This is a structural diagram of an existing T-shaped magnetic core.

[0029] Figure 2 This is a structural diagram of the existing T-shaped magnetic core and coil assembly.

[0030] Figure 3 This is a structural diagram of the first embodiment of the T-shaped magnetic core of this utility model.

[0031] Figure 4 This is a structural diagram of the T-shaped magnetic core and coil after assembly in the first embodiment of the T-shaped magnetic core of this utility model.

[0032] Figure 5 This is another structural diagram of the T-shaped magnetic core of this utility model.

[0033] Figure 6 This is a structural diagram of the T-shaped magnetic core and coil after assembly, according to the second embodiment of the T-shaped magnetic core of this utility model.

[0034] Figure 7 This is a structural diagram of the second embodiment of the T-shaped magnetic core of this utility model.

[0035] Figure 8 This is a structural diagram from a first-view perspective of the inductor embodiment of this utility model after it has been formed.

[0036] Figure 9 This is a structural diagram from a second perspective after the inductor embodiment of this utility model has been formed.

[0037] The present invention will be further described below with reference to the accompanying drawings and embodiments. Detailed Implementation

[0038] First embodiment of T-shaped magnetic core

[0039] Reference Figure 3 and Figure 4 The T-shaped magnetic core 1 has a plate portion 11, a column portion 12, and a retaining wall portion 13.

[0040] The sidewall of the plate portion 11 has a protrusion 111, which protrudes away from the plate portion 11 in the first direction X, such that the two oppositely arranged sides of the protrusion 111 respectively form a first notch 112 with the sidewall of the plate portion 11. That is, the opposite sides of the protrusion 111 each have a first notch 112, and the distribution direction of the two first notches 112 is basically perpendicular to the first direction X. One first notch 112 is used to accommodate one pin of the coil 2; wherein, in the first direction X, the height of the protrusion 111 protruding from the sidewall is preferably greater than the thickness of the pin of the coil 2, so as to avoid unnecessary exposure of the coil 2 after the inductor is formed. As in this embodiment, in the distribution direction of the two first notches 112, the first notch 112 penetrates the side of the plate portion 11 away from the protrusion 111, so as to increase the gap between the first notch 112 and the pin of the coil 2, so that the magnetic powder can better fill the first notch 112 when the powder coating layer is filled later.

[0041] Furthermore, a chamfer structure 1111 is provided at the junction of the protrusion 111 and the side wall of the plate portion 11. This chamfer structure is preferably a rounded corner structure, but other chamfer structures, such as a beveled corner structure, are also possible. The chamfer structure can reduce stress concentration at the junction of the protrusion 111 and the side wall of the plate portion 11, and prevent cracking of the coil 2 lead during bending due to stress at the junction of the protrusion 111 and the side wall.

[0042] The column 12 extends from the plate 11 and is basically perpendicular to the plate 11. The column 12 is used to cooperate with the body 21 of the coil 2, so that the body 21 of the coil 2 can be sleeved on the column 12, thereby allowing the column 12 to cooperate with the protrusion 111 to limit the coil 2 to a certain extent, preventing the T-shaped magnetic core 1, coil 2, etc. from shifting position during hot pressing.

[0043] Both the retaining wall portion 13 and the column portion 12 are located on the first side of the plate portion 11, wherein the outer periphery of the retaining wall portion 13 is substantially flush with the outer periphery of the plate portion 11. The retaining wall portion 13 surrounds the outer periphery of the column portion 12, and a limiting cavity 130 is formed between the retaining wall portion 13, the column portion 12, and the plate portion 11. The limiting cavity 130 is used to accommodate the main body 21 portion of the coil 2. The limiting cavity 130 has a limiting peripheral wall 131, at least a portion of the contour of the limiting peripheral wall 131 is in contact with the contour of the main body 21 of the coil 2 to further limit the coil 2 and prevent the coil 2 from rotating around the column portion 12. The contouring limiter forms a second notch 132 on the side wall of the plate portion 11 (i.e. the side wall with the protrusion 111). The second notch 132 penetrates the cavity wall of the limiting cavity 130 at this side wall, so that the two pins (pin A and pin B) of the coil 2 can extend out of the T-shaped magnetic core 1 through the second notch 132, so that the pins of the coil 2 can first be bent into the first notch 112, and then the part of the pins extending out of the first notch 112 is bent and attached to the second side of the plate portion 11 facing away from the column portion 12.

[0044] By designing the baffle section 13, the structural strength of the plate section 11 is enhanced, preventing cracking or chipping of the plate section 11 during bending of the coil 2 leads. Furthermore, the cooperation of the limiting cavity 130 with the column section 12 and the protrusion 111 better limits and supports the coil 2, effectively preventing positional displacement of the coil 2 during subsequent hot pressing and ensuring the quality of the finished inductor. Moreover, the design of the baffle section 13 combined with the limiting cavity 130 better ensures the density and uniformity of the magnetic powder filling around the coil 2, preventing cracks in the finished inductor.

[0045] In this embodiment, there are two pillars 12, distributed along the first direction X. Correspondingly, there are two protrusions 111. Along the first direction X, the plate portion 11 has two oppositely arranged sidewalls, and one protrusion 111 is located on one sidewall. It is understood that each protrusion 111 has a first notch 112 on both opposite sides. A retaining wall portion 13 surrounds the outer periphery of the two pillars 12, thus forming two limiting cavities 130, which are arranged in a mirror-symmetrical manner. This design allows the T-shaped magnetic core 1 to be assembled with two coils 2 simultaneously, improving the design and usage flexibility of the T-shaped magnetic core 1, enabling it to meet different usage requirements, expanding its application range, and further enhancing its practicality.

[0046] The limiting peripheral wall 131 has a partial wall surface 1311 opposite to the second notch 132 in the first direction X. In this embodiment, the partial wall surface 1311 is a first arc surface, and the first arc surface protrudes away from the column portion 12. It is understood that in some embodiments, the partial wall surface 1311 may also be a group of surfaces, such as... Figure 5 As shown, the surface assembly includes a plane 13111 and two second arc surfaces 13112. The plane 13111 is positioned directly opposite the second notch 132 in the first direction X and is substantially parallel to the sidewall of the plate portion 11 with the protrusion 111. Furthermore, the plane 13111 is located between the two second arc surfaces 13112, and the second arc surfaces 13112 protrude away from the column portion 12. It can be seen that the contour shape of the limiting peripheral wall 131 can be diverse, so that the T-shaped magnetic core 1 can be adapted to the body 21 of the coil 2 with different winding shapes, thereby expanding the applicability of the T-shaped magnetic core 1 and improving its practicality.

[0047] In this embodiment, the cross-section of the post 12 is circular; it is understood that the cross-section of the post 12 can also be other shapes, so that the shape of the post 12 matches the shape of the body 21 of the coil 2, thereby ensuring that the post 12 can better fit close to the inner coil of the body 21 of the coil 2, ensuring coupling efficiency and reducing magnetic leakage. For example, as Figure 5As shown, in other embodiments, the cross-section of the column 12 can be a rounded rectangle; in some embodiments, the cross-section of the column 12 can also be elliptical, racetrack-shaped, or rectangular, etc. It is evident that the shape of the column 12 can be varied and adjusted according to the different winding shapes of the coil 2 body 21, exhibiting diversity, thereby expanding the application range of the T-type magnetic core 1 and improving its practicality and production flexibility.

[0048] Furthermore, in this embodiment, the height of the column 12 along the axial direction is equal to the depth of the limiting cavity 130; however, depending on the powder filling requirements of the inductor, production process requirements, etc., the height of the column 12 may be greater than the depth of the limiting cavity 130, or the height of the column 12 may be less than the depth of the limiting cavity 130.

[0049] In summary, the structural design of the T-shaped magnetic core 1 makes it less prone to cracking or chipping of the plate portion 11 of the T-shaped magnetic core 1 during the bending process of the coil 2 pins. At the same time, it can also improve the filling density and uniformity of the magnetic material, prevent cracks from appearing on the surface and / or inside of the finished inductor, and improve the forming quality of the inductor.

[0050] Second embodiment of T-shaped magnetic core

[0051] Combination Figure 6 and Figure 7 The difference between this embodiment and the first embodiment of the T-shaped magnetic core is that, in this embodiment:

[0052] Each limiting cavity 130 is provided with a limiting step portion 133, and the limiting step portion 133 is located near the second notch 132. Along the second direction (i.e., the distribution direction of the two first notches 112 on the same side wall of the plate portion 11), the limiting step portion 133 is located between the limiting peripheral wall 131 and the protrusion 111, and the limiting step portion 133 is connected to the limiting peripheral wall 131 and the plate portion 11. Among them, the side of the limiting step portion 133 facing the column portion 12 is the limiting surface 1331, so that when the main body 21 of the coil 2 is installed in the limiting cavity 130, the limiting surface 1331 can fit the main body 21 of the coil 2, thereby improving the filling density and filling uniformity of the magnetic powder.

[0053] Furthermore, the height of the limiting step is less than the height of the column 12, and the height of the limiting step is less than the height of the pin with the higher position of the coil 2 (such as pin A). The limiting step can support the pin with the higher position of the coil 2 (such as pin A), thereby avoiding pin deformation, collapse, misalignment, etc., caused by insufficient powder density around the pin and / or suspension (such as when filling with magnetic powder, the magnetic powder cannot reliably fill the gap between pin A and plate 11) during the hot pressing process, thus ensuring the molding quality of the inductor.

[0054] In this embodiment, the two limiting step portions 133 are centrally symmetrically distributed; of course, depending on the winding method of the two coils 2, the two limiting step portions 133 can also be arranged in a mirror symmetrical distribution.

[0055] Inductor Example

[0056] Combination Figures 1 to 9 The inductor 100 includes a coil 2, a powder coating layer 101, and a T-shaped magnetic core 1. The T-shaped magnetic core 1 can be the T-shaped magnetic core 1 described in the first or second embodiment of the above-mentioned T-shaped magnetic core. There are two coils 2, and the two coils 2 correspond one-to-one with the two limiting cavities 130 of the T-shaped magnetic core 1. As can be seen from the foregoing, the coil 2 includes a body 21 and two pins (pin A and pin B).

[0057] When the inductor 100 is formed, the main body 21 of the wound coil 2 is first inserted into a limiting cavity 130 corresponding to the T-shaped magnetic core 1, and the main body 21 is fitted onto the column portion 12 in the limiting cavity 130, so that the limiting peripheral wall 131 fits the outer periphery of the main body 21 and cooperates with the column portion 12 to limit the coil 2.

[0058] Next, the two leads of coil 2 are bent so that one lead of coil 2 passes through the T-shaped magnetic core 1 from the second notch 132 of the limiting cavity 130. Then, the lead is bent once so that it passes through a corresponding first notch 112. Finally, the lead is bent a second time so that the end of the lead is attached to the second side of the plate 11 opposite to the post 12. The height of the post 12 is greater than or equal to the height of the main body 21 to ensure the coupling efficiency between the coil winding and the post 12 and reduce magnetic leakage.

[0059] Next, the assembly structure of coil 2 and T-shaped magnetic core 1 is implanted into the molding die, and magnetic powder is filled into the molding die to form a powder coating layer 101, wherein at least a portion of the powder coating layer 101 fills the limiting cavity 130, the first notch 112 and the second notch 132. For example, in some embodiments, the powder coating layer 101 only fills the limiting cavity 130, the second notch 132, the first notch 112 and other areas, and the powder coating layer 101 is flush with the top of the retaining wall portion 13; for example, in some embodiments, in addition to filling the limiting cavity 130, the second notch 132, the first notch 112 and other areas, the powder coating layer 101 also forms a layer of powder on the top of the retaining wall portion 13 and the column portion 12.

[0060] Finally, the coil 2, T-shaped magnetic core 1 and powder coating layer 101 are hot-pressed using a molding die to form inductor 100.

[0061] It should be noted that, due to differences in the materials of the T-shaped magnetic core 1, the powder coating layer 101, the hot pressing process, and the molding parameters, the structure of the inductor 100 after hot pressing exhibits the following characteristics:

[0062] The first method involves dissecting the inductor 100 after hot pressing to reveal the outlines of its components, such as the outline of the T-shaped magnetic core 1, the outline of the powder coating layer 101, and the interface between the T-shaped magnetic core 1, the coil 2, and the powder coating layer 101.

[0063] The second type is that when the inductor 100 after hot pressing is dissected, the outlines of each component cannot be clearly seen or the outlines of each component are blurry and difficult to define, and the interfaces between the components are blurry.

[0064] However, since the inductor 100 after hot pressing is still made by the T-shaped magnetic core 1, the probability of cracks appearing on the surface and / or inside after molding is low, and the molding quality is high.

[0065] Electronic Product Examples

[0066] The electronic product includes a printed circuit board, on which the inductor described in the above-described inductor embodiment is mounted. The inclusion of this inductor ensures reliable and stable operation of the electronic product.

[0067] Finally, it should be emphasized that the above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. For those skilled in the art, the present utility model can have various changes and modifications. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A T-shaped magnetic core, having a plate portion and a post portion extending from said plate portion, characterized in that: The number of columns is two, and the two columns are distributed along a first direction; The plate portion has two sidewalls that protrude away from the plate portion to form protrusions, and the two oppositely arranged sides of the protrusions respectively form a first notch with the sidewalls on which they are located. The T-shaped magnetic core also has a retaining wall portion, which and the column portion are both located on the first side of the plate portion. The retaining wall portion surrounds the outer periphery of the column portion. Each column portion forms a limiting cavity with the retaining wall portion and the plate portion. The limiting cavity has a limiting peripheral wall. The limiting cavity has a second notch near its own side wall and the second notch penetrates the side wall, so that the two limiting cavities are distributed in a mirror symmetrical manner.

2. The T-shaped magnetic core according to claim 1, characterized in that: The partial wall surface of the limiting peripheral wall opposite to the second notch forms a first arc surface, and the first arc surface protrudes away from the column portion; or The partial wall surface opposite to the second notch of the limiting peripheral wall is a surface group. The surface group includes a plane and two second arc surfaces. The plane is located between the two second arc surfaces, and the second arc surfaces protrude away from the column portion.

3. The T-shaped magnetic core according to claim 1, characterized in that: The cross-section of the column is circular, elliptical, racetrack-shaped, rounded rectangle, or rectangular.

4. The T-shaped magnetic core according to claim 1, characterized in that: The junction between the protrusion and the sidewall is provided with a chamfered structure.

5. The T-shaped magnetic core according to claim 1, characterized in that: Along the axial direction of the column, the height of the column is equal to the depth of the limiting cavity; or Along the axial direction, the height of the column is greater than the depth of the limiting cavity; or Along the axial direction, the height of the column is less than the depth of the limiting cavity.

6. The T-shaped magnetic core according to any one of claims 1 to 5, characterized in that: Each of the limiting cavities is provided with a limiting step portion. The limiting step portion is located near the second notch and along the second direction. The limiting step portion is located between the limiting peripheral wall and the protrusion. The limiting step portion is connected to the limiting peripheral wall and the plate portion. The side of the limiting step portion facing the column portion is the limiting surface. The height of the limiting step portion is less than the height of the column portion.

7. The T-shaped magnetic core according to claim 6, characterized in that: The limiting steps within the two limiting cavities are centrally symmetrically distributed or mirror-symmetrically distributed.

8. An inductor comprising two coils, said coils having a body and two leads, characterized in that: The inductor further includes a powder coating layer and a T-shaped magnetic core as described in any one of claims 1 to 7; The two coils correspond one-to-one with the two limiting cavities. The main body is located in the corresponding limiting cavity and is sleeved on the column. The limiting peripheral wall surrounds the outer periphery of the main body. The pin of each coil passes through the T-shaped magnetic core from the second notch, bends through the corresponding first notch, and then bends and overlaps the second side of the plate facing away from the column. At least a portion of the powder coating layer is filled in the limiting cavity, the first gap and the second gap, and the coil, the T-shaped magnetic core and the powder coating layer form the inductor through a hot press forming process.

9. The inductor of claim 8, wherein: The height of the column portion is greater than or equal to the height of the main body.

10. An electronic product comprising a printed circuit board, characterized in that The printed circuit board is mounted with the inductor of claim 8 or 9.

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