A winding mold for a flat wire inductor
By designing a downward-sloping groove bottom structure with inclined straight lines and arc-shaped wire inlet slots, the problem of excessive friction in traditional winding dies was solved, achieving high-quality winding and efficient production, and extending the service life of the dies.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- DONGGUAN NACHUANG ELECTROMECHANICAL TECH CO LTD
- Filing Date
- 2025-08-12
- Publication Date
- 2026-07-14
AI Technical Summary
Traditional winding dies cause excessive friction between the wire and the bottom of the groove, resulting in scratches on the wire and poor winding quality.
The bottom of the inclined straight wire inlet groove and the inclined circular arc wire inlet groove are designed to slope downward relative to the horizontal plane, reducing the coefficient of friction to 0.01-0.03. The wire is in partial contact inside the groove, reducing friction.
It effectively reduces wire scratches, improves winding quality and electrical performance consistency, increases production efficiency by 20-30%, and extends mold life.
Smart Images
Figure CN224501683U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of inductor manufacturing technology, and in particular to a winding mold for flat wire inductors. Background Technology
[0002] See patent document CN2018101027048, which discloses a filter extrusion molding winding module, which includes a base and a cover that is installed in conjunction with the base. The base is provided with a material loading groove for holding a carrier that needs to be wound and a wire inlet groove located next to the material loading groove for wire to pass through. The wire inlet groove has a straight section and an arc section connected to the straight section. The cover can be closed on the top of the wire inlet groove to form a wire inlet channel. The base is provided with a wire blocking insert for blocking the wire end of the wire entering along the wire inlet channel from winding in a circle and a driving mechanism for driving the wire blocking insert to move up and down. The wire blocking insert is placed on the side end of the arc section of the wire inlet groove, and the blocking flange formed on the side of the wire blocking insert is connected to the arc section of the wire inlet groove. Because the wire inlet groove of the wire module consists of a horizontal straight section and a horizontal arc section, the wire slides along the bottom of the groove throughout the entire process, resulting in a friction coefficient as high as 0.15-0.25. This can cause scratches on the wire. Therefore, traditional winding dies have the problem of excessive contact friction. Summary of the Invention
[0003] The technical problem to be solved by this utility model is to provide a winding mold for flat wire inductors, which solves the problem of excessive contact friction in the past.
[0004] To solve the above-mentioned technical problems, this utility model discloses a winding mold for flat wire inductors, including a base. The base has a horizontal straight inlet groove arranged along the wire conveying direction and a mounting hole that communicates with the end of the horizontal straight inlet groove. A winding insert for supporting the workpiece is embedded in the mounting hole. An inclined straight inlet groove and an inclined arc inlet groove are formed between the winding insert and the base. The beginning of the inclined straight inlet groove communicates with the end of the horizontal straight inlet groove, and the end of the inclined straight inlet groove communicates with the beginning of the inclined arc inlet groove. The winding insert has a limiting groove for inserting external workpieces, and the end of the inclined arc inlet groove communicates with the limiting groove. The bottom of the inclined straight inlet groove and the bottom of the inclined arc inlet groove are both inclined downward relative to the horizontal plane.
[0005] Among them, the angle between the bottom of the inclined straight inlet slot and the inclined circular arc inlet slot and the horizontal plane is 5° to 15°.
[0006] The width of the horizontal straight inlet slot is equal to the width of the inclined straight inlet slot.
[0007] The limiting groove of the winding insert is a rectangular groove or a circular groove.
[0008] It also includes a cover plate that can slide laterally relative to the base, the cover plate having a horizontal covering part and an inclined covering part fixedly connected in sequence.
[0009] The inclined covering part includes a straight covering part that is inclined downward and an arc covering part that is fixed to the straight covering part and inclined downward; in the mold closed state, the horizontal covering part covers the horizontal straight wire inlet groove to form a horizontal straight wire inlet channel, the straight covering part covers the inclined straight wire inlet groove to form an inclined straight wire inlet channel, and the arc covering part covers the inclined arc wire inlet groove to form an inclined arc wire inlet channel.
[0010] Among them, the top surface of the winding insert extends upward to form a limiting protrusion for restricting the sliding position of the cover plate.
[0011] The base has a sliding groove arranged horizontally on its top, and a cover plate is inserted into the sliding groove. The cover plate has an elongated hole, and the base has a threaded hole aligned axially with the elongated hole. The winding mold also includes a locking screw. The outer periphery of the locking screw is fitted with a locking nut, a spring, and a pressing block arranged sequentially from top to bottom. The top end of the spring abuts against the locking nut, the bottom end of the spring abuts against the pressing block, and the bottom surface of the pressing block abuts against the cover plate. The pressing block has a through hole through which the locking screw passes.
[0012] The bottom of the limiting groove has a first channel arranged vertically and located on the side of the outlet at the end of the inclined arc inlet groove.
[0013] The bottom of the limiting groove has a second channel arranged vertically and located at the intersection of the inclined straight inlet groove and the inclined circular arc inlet groove.
[0014] Compared with the prior art, the embodiments of this utility model have the following beneficial effects:
[0015] (1) By setting the bottom of both the inclined straight inlet groove and the inclined arc inlet groove to be inclined downward, the friction coefficient is reduced to 0.01-0.03. This structural design changes the contact between the wire and the bottom of the groove from complete adhesion to partial contact, effectively reducing the contact area. That is, when the wire is in the horizontal straight inlet groove, the wire is attached to the bottom of the groove. When the wire enters the inclined straight inlet groove, the wire changes from being attached to the bottom of the groove to being attached to the side wall. When the wire enters the inclined arc inlet groove, the wire is mainly guided by the groove wall. The change in the direction of the contact force reduces sliding friction and solves the problem of excessive contact area in the past.
[0016] (2) The downward-sloping groove bottom structure allows the wire to naturally "suspend" in the groove during the conveying process, reducing the direct friction between the wire and the groove bottom and avoiding surface scratches. It is particularly suitable for precision inductor manufacturing with high surface quality requirements, effectively improving the winding quality. The inclined wire inlet groove structure makes the tension of the wire more uniform during the winding process, reducing the phenomenon of uneven winding tightness caused by uneven friction, and improving the electrical performance consistency of inductor products.
[0017] (3) Friction reduction can be achieved simply by changing the angle of the groove, without the need for additional friction reduction devices. It has the characteristics of wide applicability. The friction reduction effect can increase the winding speed by 20-30%, reduce downtime caused by wire jamming, and significantly improve overall production efficiency. The low friction design reduces mold wear, extends service life, and reduces mold replacement frequency and maintenance costs. Attached Figure Description
[0018] To more clearly illustrate the technical solutions in the embodiments of this utility model, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0019] Figure 1 This is a schematic diagram of the winding mold in this utility model;
[0020] Figure 2 This is an exploded view of the winding mold in this utility model;
[0021] Figure 3 This is a structural schematic diagram of the winding mold from another perspective in this utility model;
[0022] Figure 4 for Figure 3 Sectional view at point AA;
[0023] Figure 5 This is a schematic diagram of the cover plate in this utility model;
[0024] Figure 6 This is a schematic diagram of the winding insert in this utility model. Detailed Implementation
[0025] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0026] The terms "first," "second," etc., in the specification, claims, and accompanying drawings of this utility model are used to distinguish different objects, not to describe a specific order. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion. For example, a process, method, apparatus, product, or end that includes a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to these processes, methods, products, or ends.
[0027] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of the present invention. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.
[0028] This utility model discloses a specific embodiment of a winding mold for flat wire inductors. Please see [link to relevant documentation]. Figures 1 to 2 As shown, the device includes a base 1, which has a horizontal straight inlet groove 11 arranged along the wire conveying direction and a mounting hole 12 that communicates with the end of the horizontal straight inlet groove 11. A winding insert 2 for carrying a workpiece is embedded in the mounting hole 12. An inclined straight inlet groove 21 and an inclined arc inlet groove 22 are formed between the winding insert 2 and the base 1. The beginning of the inclined straight inlet groove 21 communicates with the end of the horizontal straight inlet groove 11, and the end of the inclined straight inlet groove 21 communicates with the beginning of the inclined arc inlet groove 22. The winding insert 2 has a limiting groove 20 for inserting an external workpiece, and the end of the inclined arc inlet groove 22 communicates with the limiting groove 20.
[0029] Combination Figure 3 and Figure 4In this embodiment, the wire inlet channel formed by the base 1 and the winding insert 2 includes two key parts: first, an inclined straight wire inlet groove 21, whose beginning smoothly connects to the end of the horizontal straight wire inlet groove 11; second, an inclined arc wire inlet groove 22, whose beginning connects to the end of the inclined straight wire inlet groove 21. The winding insert 2 has a limiting groove 20 for fixing the workpiece. This limiting groove 20 can be rectangular or circular. The end of the inclined arc wire inlet groove 22 directly communicates with the limiting groove 20. As an improvement, the bottoms of both the inclined straight wire inlet groove 21 and the inclined arc wire inlet groove 22 are inclined downwards relative to the horizontal plane. The design feature of these two wire inlet channels is that their bottoms are both inclined downwards relative to the horizontal plane. This unique structure can significantly reduce the contact pressure between the wire and the bottom of the groove.
[0030] In this embodiment, the inclination angle of the bottom of the inclined straight inlet groove 21 and the inclined arc inlet groove 22 is carefully designed and preferably controlled between 5° and 15°. This angle range ensures smooth wire feeding and effectively reduces friction. At the same time, the width of the horizontal straight inlet groove 11 and the inclined straight inlet groove 21 is consistent to ensure that the wire is not subjected to additional stress or deformation in the transition area.
[0031] To enhance the adjustability of the winding die, the winding die is also equipped with a laterally sliding cover plate 3 assembly. The cover plate 3 consists of a horizontal covering part 31 and an inclined covering part, wherein the inclined covering part is further subdivided into a straight covering part 32 inclined downwards and an arc covering part 33 connected thereto. When the cover plate 3 is in the closed state, the horizontal covering part 31 covers the horizontal straight wire inlet groove 11 to form a closed horizontal straight wire inlet channel, the straight covering part 32 covers the inclined straight wire inlet groove 21 to form an inclined straight wire inlet channel, and the arc covering part 33 covers the inclined arc wire inlet groove 22 to form an inclined arc wire inlet channel.
[0032] Combination Figure 5 To precisely control the sliding position of the cover plate 3, an upwardly extending limiting protrusion 23 is specially provided on the top of the winding insert 2. Simultaneously, a horizontally arranged sliding groove 13 is provided on the top of the base 1, along which the cover plate 3 can move. For convenient adjustment and fixation, an elongated hole 34 is provided on the cover plate 3, and a threaded hole 14 is provided at a corresponding position on the top of the base 1. The mold adopts an innovative locking mechanism, including a locking screw 41, a locking nut 42, a spring 43, and a clamping block 44. The spring 43 is compressed between the locking nut 42 and the clamping block 44. Adjusting the screw allows for elastic clamping of the cover plate 3. This design ensures both a secure fixation and allows for fine-tuning.
[0033] Combination Figure 6To further optimize wire guiding, two vertical channels are added to the bottom of the limiting groove 20: the first channel 201 is located on the side of the outlet at the end of the inclined arc wire inlet groove 22, and the second channel 202 is located at the intersection of the inclined straight wire inlet groove 21 and the inclined arc wire inlet groove 22. These auxiliary channels can effectively guide the wire direction and prevent deviation during winding.
[0034] In this embodiment, the winding mold reduces the coefficient of friction to 0.01-0.03 by setting the bottom of both the inclined straight inlet groove 21 and the inclined arc inlet groove 22 to a downward-sloping structure. This structural design changes the contact between the wire and the bottom of the groove from complete adhesion to partial contact, effectively reducing the contact area. Specifically, when the wire is in the horizontal straight inlet groove 11, it adheres to the bottom of the groove. When the wire enters the inclined straight inlet groove 21, it changes from adhering to the bottom to adhering to the side wall. When the wire enters the inclined arc inlet groove 22, it is mainly guided by the groove wall. The change in the direction of the contact force reduces sliding friction and solves the problem of excessive contact area in the past. The downward-sloping groove bottom structure allows the wire to naturally "float" within the groove during transport, reducing direct friction between the wire and the groove bottom and preventing surface scratches. This is particularly suitable for precision inductor manufacturing where high surface quality is required, effectively improving winding quality. The inclined inlet groove structure ensures more uniform wire tension during winding, reducing uneven winding tightness caused by friction and improving the consistency of electrical performance of inductor products. Friction reduction is achieved simply by changing the groove angle, eliminating the need for additional friction-reducing devices. This makes it widely applicable, and the friction-reducing effect can increase winding speed by 20-30%, reducing downtime caused by wire jamming and significantly improving overall production efficiency. The low-friction design reduces mold wear, extends service life, and lowers mold replacement frequency and maintenance costs.
[0035] The beneficial effects of this winding die are mainly reflected in the following aspects: First, the unique downward-sloping groove bottom design significantly reduces the coefficient of friction from the traditional 0.15-0.25 to 0.01-0.03, greatly reducing the risk of scratches on the wire surface; second, the adjustable cover plate 3-component and locking mechanism allow the die to adapt to the processing requirements of wires of different specifications; third, the added guide channel and limiting structure significantly improve winding accuracy; finally, the entire system has a simple and reliable structure, is easy to maintain, and has a long service life. These improvements make this die particularly suitable for the mass production of high-quality flat wire inductors, improving production efficiency while ensuring product quality.
[0036] Finally, it should be noted that the winding mold for a flat wire inductor disclosed in this utility model embodiment is only a preferred embodiment of this utility model and is only used to illustrate the technical solution of this utility model, not to limit it. Although this utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the various embodiments of this utility model.
Claims
1. A winding die for a flat wire inductor, characterized in that, The device includes a base, which has a horizontal straight inlet groove arranged along the wire conveying direction and a mounting hole communicating with the end of the horizontal straight inlet groove. A winding insert for carrying a workpiece is embedded in the mounting hole. An inclined straight inlet groove and an inclined arc inlet groove are formed between the winding insert and the base. The beginning of the inclined straight inlet groove communicates with the end of the horizontal straight inlet groove, and the end of the inclined straight inlet groove communicates with the beginning of the inclined arc inlet groove. The winding insert has a limiting groove for inserting an external workpiece, and the end of the inclined arc inlet groove communicates with the limiting groove. The bottom of both the inclined straight inlet slot and the inclined circular arc inlet slot are set obliquely downward relative to the horizontal plane.
2. The winding mold for a flat wire inductor according to claim 1, characterized in that, The angle between the bottom of the inclined straight inlet slot and the inclined circular arc inlet slot and the horizontal plane is 5° to 15°.
3. A winding mold for a flat wire inductor according to claim 2, characterized in that, The width of the horizontal straight inlet slot is equal to the width of the inclined straight inlet slot.
4. A winding mold for a flat wire inductor according to claim 1, characterized in that, The limiting groove of the winding insert is a rectangular groove or a circular groove.
5. A winding mold for a flat wire inductor according to claim 1, characterized in that, It also includes a cover plate that can slide laterally relative to the base, the cover plate having a horizontal covering portion and an inclined covering portion fixedly connected in sequence.
6. A winding die for a flat wire inductor according to claim 5, characterized in that, The inclined covering part includes a straight covering part that is inclined downward and an arc covering part that is fixed to the straight covering part and is inclined downward; In the mold-closed state, the horizontal cover portion covers the horizontal straight inlet groove to form a horizontal straight inlet channel, the straight cover portion covers the inclined straight inlet groove to form an inclined straight inlet channel, and the arc cover portion covers the inclined arc inlet groove to form an inclined arc inlet channel.
7. A winding die for a flat wire inductor according to claim 5, characterized in that, The top surface of the winding insert extends upward to form a limiting protrusion for restricting the sliding position of the cover plate.
8. A winding die for a flat wire inductor according to claim 5, characterized in that, The top of the base has a sliding groove arranged in a transverse direction, the cover plate is inserted into the sliding groove, the cover plate has an elongated hole, and the top of the base has a threaded hole aligned axially with the elongated hole. The winding mold also includes a locking screw. The outer periphery of the locking screw is fitted with a locking nut, a spring and a pressing block arranged sequentially from top to bottom. The top end of the spring abuts against the locking nut, the bottom end of the spring abuts against the pressing block, the bottom surface of the pressing block abuts against the cover plate, and the pressing block has a through hole for the locking screw to pass through.
9. A winding die for a flat wire inductor according to claim 1, characterized in that, The bottom of the limiting groove has a first channel arranged vertically and located on the side of the end outlet of the inclined arc inlet groove.
10. A winding die for a flat wire inductor according to claim 1 or 9, characterized in that, The bottom of the limiting groove has a second channel arranged vertically and located at the intersection of the inclined straight inlet groove and the inclined circular arc inlet groove.