A copper sheet inductor structure

Abstract

The utility model belongs to the inductance technical field discloses a copper sheet inductance structure, including copper sheet main part, lower magnetic core and upper magnetic core, lower magnetic core is equipped with locating groove and recess, recess is set up in the both sides of lower magnetic core along the width direction of lower magnetic core, the copper sheet main part is overlapped in lower magnetic core and the both sides of copper sheet main part are respectively limited in locating groove, is equipped with positioning part in recess, upper magnetic core and lower magnetic core are integrally formed spare, upper magnetic core is covered in copper sheet main part and fills up recess. Through setting recess in the both sides of lower magnetic core, remove the powder of lower magnetic core easy to crack in the side wall of copper sheet main part, fill up this part through upper magnetic core when subsequent secondary processing, under the premise of guaranteeing the overall height size unchangeable, avoid the problem of cracking, ensure the characteristics unchangeable simultaneously, effectively prolong the service life of copper sheet inductance structure.

Description

Technical Field

[0001] This utility model relates to the field of inductor technology, and in particular to a copper sheet inductor structure. Background Technology

[0002] Copper sheet inductors, also known as co-fired copper-iron inductors, are a new type of inductor made by encapsulating copper sheets inside magnetic powder using powder metallurgy. The copper sheet inside the inductor is U-shaped, with its two ends serving as electrodes. To meet the requirements of copper loss and high current handling in copper sheet inductors, the direct current resistance (DCR) of the copper sheet needs to be kept low. This results in a larger cross-sectional area of ​​the copper sheet, i.e., increased sheet thickness. Consequently, the stress required during the pressing and molding of the magnetic powder also increases. During the secondary filling and pressing of the magnetic powder, the magnetic powder density at the horizontal sidewalls of the copper sheet is relatively low, making it prone to cracking. This leads to a reduced service life or even renders the inductor unusable, resulting in its scrapping. Utility Model Content

[0003] The purpose of this invention is to provide a copper sheet inductor structure that avoids the problem of magnetic powder cracking on the side of the copper sheet, extends service life, and ensures a high yield rate.

[0004] To achieve this objective, the present invention adopts the following technical solution: a copper sheet inductor structure, comprising a copper sheet body, a lower magnetic core, and an upper magnetic core, wherein the copper sheet body is U-shaped; the lower magnetic core is provided with a positioning groove and a recess, the positioning groove being symmetrically arranged on both sides of the lower magnetic core along the length direction of the lower magnetic core, and the recess being symmetrically arranged on both sides of the lower magnetic core along the width direction of the lower magnetic core; the copper sheet body overlaps the lower magnetic core, and both sides of the copper sheet body are respectively confined within the positioning groove; the bottom surface of the copper sheet body is flush with the bottom surface of the lower magnetic core; the recess is provided with a positioning part extending away from the lower magnetic core along the width direction of the lower magnetic core, the length of the positioning part in the width direction of the lower magnetic core being greater than the length of the recess; the upper magnetic core and the lower magnetic core are integrally formed, and the upper magnetic core covers the copper sheet body and fills the recess.

[0005] Preferably, the positioning part is located in the middle section of the groove.

[0006] Preferably, along the length direction of the lower magnetic core, the width of the positioning portion is less than or equal to one-third of the length of the groove.

[0007] Preferably, the positioning part is rectangular in shape.

[0008] Preferably, the sidewall of the positioning part and the bottom wall of the groove are transitioned by a rounded corner.

[0009] Preferably, the bottom of the lower magnetic core is provided with a hollow portion, which is located below the groove and extends from one side of the lower magnetic core to the other side along the width direction of the lower magnetic core.

[0010] Preferably, the upper magnetic core covers the sidewall of the lower magnetic core and the sidewall of the upper magnetic core is flush with the sidewall of the positioning part.

[0011] Preferably, the two adjacent sidewalls of the lower magnetic core are transitioned by a rounded corner.

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

[0013] The beneficial effects of this invention are as follows: During the production of the copper sheet inductor structure, the lower magnetic core needs to be fabricated by pressure-limited bonding of magnetic powder. After the copper sheet body and the lower magnetic core are fixedly connected, the upper magnetic core is then processed in a secondary manner, so that the upper and lower magnetic cores enclose the copper sheet body to form the required copper sheet inductor structure. By setting grooves on both sides of the lower magnetic core, the powder material that easily cracks on the sidewalls of the copper sheet body is removed. During subsequent secondary processing, this part is filled with the upper magnetic core. This avoids cracking while ensuring that the overall height remains unchanged, and also ensures that the characteristics remain unchanged, effectively extending the service life of the copper sheet inductor structure. By setting a positioning part, the lower magnetic core can be positioned during secondary processing, preventing it from shifting in the mold, thus improving production efficiency and yield. Attached Figure Description

[0014] Figure 1 This is a perspective view of the copper sheet inductor structure according to an embodiment of the present invention;

[0015] Figure 2 This is a schematic diagram of the structure of the lower magnetic core and copper sheet body according to an embodiment of the present invention;

[0016] Figure 3 This is a cross-sectional view of the copper sheet inductor structure according to an embodiment of the present invention.

[0017] In the diagram: 100, copper sheet body; 200, lower magnetic core; 210, positioning groove; 220, groove; 221, positioning part; 230, hollow part; 300, upper magnetic core. Detailed Implementation

[0018] 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.

[0019] 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.

[0020] 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.

[0021] 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.

[0022] If the thickness of the copper sheet body 100 is relatively thick (usually greater than or equal to 1mm), during the secondary filling and pressing of magnetic powder, the magnetic powder at the side wall of the copper sheet body 100 is formed by the splicing of the upper and lower magnetic cores. The magnetic powder at this point is relatively loose and has a low density. Under the extrusion of processing pressure, it is very easy to crack, resulting in a reduced service life or even failure to leave the factory and direct scrapping.

[0023] Reference Figures 1 to 3 As shown, a copper sheet inductor structure provided according to an embodiment of this application includes a copper sheet body 100, a lower magnetic core 200 and an upper magnetic core 300. The copper sheet body 100 has a U-shaped shape, and the two ends of the U-shaped copper sheet body 100 are the electrodes of the copper sheet inductor structure.

[0024] The lower magnetic core 200 is provided with a positioning groove 210 and a recess 220. The positioning groove 210 is symmetrically arranged on both sides of the lower magnetic core 200 along the length direction, and the recess 220 is symmetrically arranged on both sides of the lower magnetic core 200 along the width direction. Specifically, the two ends of the U-shaped copper sheet body 100 are matched in shape, and the length of the recess 220 is equal to the length of the horizontal part of the U-shaped copper sheet body 100. The copper sheet body 100 overlaps with the lower magnetic core 200, and both sides of the copper sheet body 100 are respectively confined within the positioning groove 210. The bottom surface of the copper sheet body 100 is flush with the bottom surface of the lower magnetic core 200. At the same time, the inner sidewall of the copper sheet body 100 abuts against the bottom wall of the positioning groove 210 and the top wall of the lower magnetic core 200, respectively, and the two sidewalls of the copper sheet body 100 are flush with the two sidewalls of the lower magnetic core 200. The groove 220 is provided with a positioning part 221 extending away from the lower magnetic core 200 along the width direction of the lower magnetic core 200. The length of the positioning part 221 in the width direction of the lower magnetic core 200 is greater than the length of the groove 220. The upper magnetic core 300 and the lower magnetic core 200 are integrally formed parts, and the upper magnetic core 300 covers the copper sheet body 100 and fills the groove 220.

[0025] Understandably, during the production of copper sheet inductor structures, it is necessary to first press magnetic powder to process the lower magnetic core 200, fix the copper sheet body 100 and the lower magnetic core 200 together, and then process the upper magnetic core 300 a second time so that the upper magnetic core 300 and the lower magnetic core 200 wrap around the copper sheet body 100 to form the required copper sheet inductor structure.

[0026] By setting grooves 220 on both sides of the lower magnetic core 200, the powder material that is prone to cracking in the lower magnetic core 200 on the side wall of the copper sheet body 100 is removed. In subsequent secondary processing, the upper magnetic core 300 fills this part. While ensuring that the overall height and size remain unchanged, cracking problems are avoided, and the characteristics remain unchanged, effectively extending the service life of the copper sheet inductor structure.

[0027] During the secondary processing of the copper sheet inductor structure, the lower magnetic core 200 and the copper sheet body 100 need to be moved into the secondary processing mold. To facilitate the placement and demolding of the lower magnetic core 200, the cavity of the secondary processing mold is usually slightly larger than the lower magnetic core 200. By setting a positioning part 221, which protrudes from the side wall of the lower magnetic core 200, the positioning part 221 can position the lower magnetic core 200 during secondary processing (i.e., when the lower magnetic core 200 is transferred to the secondary processing mold), preventing the lower magnetic core 200 from shifting in the mold and improving production efficiency and yield.

[0028] Furthermore, the thickness of the copper sheet body 100 is greater than or equal to 1 mm.

[0029] If the copper sheet body 100 is too thin, the pressure applied to it during processing may not be sufficient to directly break up the powder, and it may even be impossible to form a compact magnetic core structure in the groove 220. Limiting the thickness of the copper sheet body 100 to more than 1 mm ensures that the powder in the groove 220 is compacted, forming a tight and stable magnetic core structure, thereby further improving the yield of the copper sheet inductor structure.

[0030] Reference Figure 2 As shown, it can be understood that the positioning part 221 is located in the middle section of the groove 220, that is, along the length direction of the lower magnetic core 200, the distance between the two sides of the positioning part 221 and the side wall of the opposite groove 220 is equal, that is, the positioning part 221 divides the groove 220 into two groove structures with the same shape and the same size.

[0031] The positioning part 221 is set at the center of the groove 220 to ensure that the powder filling force on both sides of the positioning part 221 is consistent during the secondary processing of the lower magnetic core 200. This avoids the problem of uneven force on the positioning part 221 and the problem of skewness caused by more powder filling and greater pressure on one side of the positioning part 221 and less powder filling and less pressure on the other side, thereby improving the structural stability of the positioning part 221.

[0032] Furthermore, along the length direction of the lower magnetic core 200, the width of the positioning part 221 is less than or equal to one-third of the length of the groove 220. In other words, along the length direction of the lower magnetic core 200, the length of the grooves 220 on both sides of the positioning part 221 is greater than the width of the positioning part 221.

[0033] The width of the positioning part 221 is limited to less than one-third of the length of the groove 220 to avoid the positioning part 221 being too wide, which would increase the volume of the positioning part 221 and cause cracking at the position of the positioning part 221 after secondary processing.

[0034] The positioning part 221 has a rectangular shape.

[0035] Setting the positioning part 221 into a cuboid shape, both the cross-section and longitudinal section of the positioning part 221 are rectangular, which facilitates the design and manufacturing of the one-time processing mold, simplifies the structure of the lower magnetic core 200, reduces the production cost of the lower magnetic core 200, and facilitates subsequent pressing and molding with the upper magnetic core 300.

[0036] Continue to refer to Figure 2 As shown, it can be understood that the side wall of the positioning part 221 and the bottom wall of the groove 220 are transitioned by a rounded corner.

[0037] The base of the positioning part 221 and the bottom of the groove 220 are connected by a rounded corner, which can avoid stress concentration at the connection between the positioning part 221 and the lower magnetic core 200 during secondary processing, optimize stress distribution, and ensure that the powder of the upper magnetic core 300 in the groove 220 is compact and stable.

[0038] Further, the overall shape of the lower magnetic core 200 is approximately Wang-shaped, and the adjacent side walls of the lower magnetic core 200 are transitioned by rounded corners.

[0039] The side walls of the lower magnetic core 200 are also transitioned by rounded corners, which, while improving the structural consistency of the lower magnetic core 200, avoids stress concentration at the corners of the lower magnetic core 200 and improves the structural stability of the lower magnetic core 200.

[0040] Refer to Figure 3 As shown, it can be understood that a hollow portion 230 is provided at the bottom of the lower magnetic core 200. The hollow portion 230 is located below the groove 220 and extends from one side of the lower magnetic core 200 to the other side along the width direction of the lower magnetic core 200. At this time, the total height of the positioning portion 221 and the hollow portion 230 is the height of the lower magnetic core 200.

[0041] By providing the hollow portion 230, on the one hand, the hollow portion 230 can form a concave-convex structure on the bottom surface of the copper sheet inductor structure, which is convenient for the positioning of the copper sheet inductor structure during subsequent use; on the other hand, the hollow portion 230 is formed on the bottom surface of the lower magnetic core 200, which can limit the lower magnetic core 200 along the length direction of the lower magnetic core 200 during secondary processing and improve the production efficiency of the copper sheet inductor structure.

[0042] Further, the upper magnetic core 300 covers the side walls of the lower magnetic core 200 and the side walls of the upper magnetic core 300 are flush with the side walls of the positioning portion 221, that is, the upper magnetic core 300 covers not only the top wall and side walls of the copper sheet main body 100, but also the top wall and side walls of the lower magnetic core 200.

[0043] Through the above arrangement, the outer wall of the copper sheet inductor structure can be ensured to be flat, the connection tightness between the upper magnetic core 300 and the lower magnetic core 200 can be improved, and the service life of the copper sheet inductor structure can be further extended.

[0044] Obviously, the above-mentioned embodiments of the present invention are merely examples for clearly explaining the present invention, rather than limitations on the implementation manners of the present invention. For those of ordinary skill in the art, various obvious changes, re-adjustments and substitutions can be made without departing from the protection scope of the present invention. It is not necessary and impossible to enumerate all the implementation manners here. Any modifications, equivalent substitutions and improvements made within the spirit and principle of the present invention shall be included within the protection scope of the claims of the present invention.

Claims

1. A copper sheet inductor structure, characterized in that, include: The copper sheet body (100) has a U-shaped shape. The lower magnetic core (200) is provided with a positioning groove (210) and a groove (220). The positioning groove (210) is symmetrically arranged on both sides of the lower magnetic core (200) along the length direction of the lower magnetic core (200). The groove (220) is symmetrically arranged on both sides of the lower magnetic core (200) along the width direction of the lower magnetic core (200). The copper sheet body (100) overlaps the lower magnetic core (200) and both sides of the copper sheet body (100) are respectively confined within the positioning groove (210). The bottom surface of the copper sheet body (100) is flush with the bottom surface of the lower magnetic core (200). The groove (220) is provided with a positioning part (221) extending away from the lower magnetic core (200) along the width direction of the lower magnetic core (200). The length of the positioning part (221) in the width direction of the lower magnetic core (200) is greater than the length of the groove (220). The upper magnetic core (300) and the lower magnetic core (200) are integrally formed parts, and the upper magnetic core (300) covers the copper sheet body (100) and fills the groove (220).

2. The copper sheet inductor structure according to claim 1, characterized in that, The positioning part (221) is located in the middle section of the groove (220).

3. The copper sheet inductor structure according to claim 2, characterized in that, Along the length direction of the lower magnetic core (200), the width of the positioning part (221) is less than or equal to one-third of the length of the groove (220).

4. The copper sheet inductor structure according to claim 2, characterized in that, The positioning part (221) is rectangular in shape.

5. The copper sheet inductor structure according to claim 2, characterized in that, The side wall of the positioning part (221) and the bottom wall of the groove (220) are connected by a rounded corner.

6. The copper sheet inductor structure according to claim 1, characterized in that, The bottom of the lower magnetic core (200) is provided with a hollow part (230), which is located below the groove (220) and extends from one side of the lower magnetic core (200) to the other side along the width direction of the lower magnetic core (200).

7. The copper sheet inductor structure according to claim 1 or 6, characterized in that, The upper magnetic core (300) covers the sidewall of the lower magnetic core (200), and the sidewall of the upper magnetic core (300) is flush with the sidewall of the positioning part (221).

8. The copper sheet inductor structure according to claim 1, characterized in that, The adjacent two sidewalls of the lower magnetic core (200) are transitioned by rounded corners.

9. The copper sheet inductor structure according to claim 1, characterized in that, The thickness of the copper sheet body (100) is greater than or equal to 1 mm.

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