A corrugated spring-like inductor

Abstract

A kind of corrugated spring-like inductance, including electrode and outer wrapping material, outer wrapping material is covered to form inductance except the outer surface at the two ends of electrode, and the exposed part of electrode as pin;Inductance is wound into corrugated shape, and is bent into rectangle, inductance includes corrugated part, folding part and electrode part, corrugated part and folding part all have multiple, corrugated part includes multiple upper corrugation and multiple lower corrugation, and upper corrugation and lower corrugation are all axisymmetric figure, the corrugation of upper corrugation arches towards top, and the corrugation of lower corrugation arches towards bottom, multiple upper corrugation and multiple lower corrugation are alternately connected to form corrugated part, the surface of two ends of folding part is perpendicular to each other to connect two corrugated parts, and electrode part is the part of electrode on two ends not covered, the utility model discloses inductance presents the structure of air core coil, and the upper and lower two layers of corrugation are formed with many hollow holes due to reverse phase, which is very beneficial to heat dissipation, and heat dissipation is faster under the action of fan, and temperature rise will not become the restriction of inductance working current.

Description

Technical Field

[0001] This utility model relates to the field of inductors, and in particular to a corrugated spring-shaped inductor. Background Technology

[0002] Copper-iron co-fired inductors are mainly used in power supply modules for chips that operate under high current for extended periods. Because they operate under high current for extended periods, the inductors in the power supply modules need to have high saturation current and high temperature rise current.

[0003] When a regular inductor operates under high current for an extended period, its temperature will rise rapidly. If heat dissipation is insufficient, the operating temperature often reaches the upper limit of operation (usually 40°C above room temperature) before the product reaches magnetic saturation. For conventionally designed inductors, the saturation cutoff current (the current when the magnetic permeability decreases by 20% or 30%) is higher than the temperature rise cutoff current (the current when the temperature rises by 40°C above room temperature), which limits the use of the inductor. Utility Model Content

[0004] The technical problem to be solved by this utility model is to overcome the defect of the existing technology that the temperature rise cutoff current limits the use of inductors, and to provide a corrugated spring-shaped inductor.

[0005] The technical solution adopted by this utility model to solve its technical problem is a corrugated spring-shaped inductor, including electrodes and an outer covering material. The outer covering material covers the outer surface except for the two ends of the electrodes to form an inductor, and the exposed parts at both ends of the electrodes serve as leads. The inductor is wound into a corrugated shape and bent into a rectangle with a hollow center. The inductor includes a corrugated part, a folded part, and an electrode part. There are multiple corrugated parts and multiple folded parts. The corrugated part includes multiple upper corrugations and multiple lower corrugations, and the upper corrugations and lower corrugations are axially symmetrical. The corrugations of the upper corrugations arch upwards, and the corrugations of the lower corrugations arch upwards. Multiple upper corrugations and multiple lower corrugations are sequentially staggered to form a corrugated part. The two end surfaces of the folded part are perpendicular to each other to connect two corrugated parts. The electrode part is the part of the electrode whose two ends are not covered.

[0006] Furthermore, the inductor is hollow at the center after being wound and bent.

[0007] Furthermore, the inductor is bent into a multi-layered spiral rectangle, and the corrugated portion and the folded portion are stacked one on top of the other. The horizontal center lines of the two end surfaces of the folded portion are not on the same horizontal plane, so that multiple corrugated portions and folded portions have a height difference to form a stack.

[0008] Furthermore, the corrugated portions located on the same side at different heights are arranged such that the upper corrugation of the upper layer aligns with the lower corrugation of the lower layer, and the lower corrugation of the upper layer aligns with the upper corrugation of the lower layer, to form multiple hollow through holes.

[0009] Furthermore, the two electrode portions of the inductor are located at the upper and lower ends of the multi-layered spiral rectangle, and the folded portion of the electrode portion closest to the bottom extends from the bottom and folds towards the plane where the top electrode portion is located.

[0010] Furthermore, the outer coating material is a magnetic material, and the electrode material is copper.

[0011] This utility model has the following beneficial technical effects:

[0012] The inductor has an air-core coil structure. Due to the opposite phase of the upper and lower corrugations, there are many hollow holes, which is very beneficial for heat dissipation. With the help of a fan, the heat dissipation is faster, and the temperature rise will not become a limitation of the inductor's operating current. The temperature rise cutoff current of the inductor with this design is usually much higher than the saturation cutoff current. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the overall structure of Embodiment 1 of the Corrugated Spring-shaped Inductor of this utility model;

[0014] Figure 2 This is a cross-sectional view of Embodiment 1 of the Corrugated Spring-shaped Inductor of this utility model;

[0015] Figure 3 This is a schematic diagram of the overall structure of Embodiment 2 of the Corrugated Spring-shaped Inductor of this utility model.

[0016] Explanation of reference numerals in the attached figures:

[0017] 1. Electrode; 2. Outer wrapping material; 3. Inductor; 31. Corrugated section; 311. Upper corrugation; 312. Lower corrugation; 32. Folded section; 33. Electrode section. Detailed Implementation

[0018] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments.

[0019] Reference Figure 1 This embodiment includes an electrode 1 and an outer wrapping material 2, wherein the outer wrapping material 2 wraps around the electrode 1, but the two ends of the electrode 1 are peeled out of the outer wrapping material 2 to expose them to the air and be used as leads. Specifically, the outer wrapping material 2 is a magnetic material, while the electrode 1 is made of copper.

[0020] After electrode 1 is wrapped by outer material 2, it forms inductor 3. Inductor 3 is wound into a corrugated shape and then bent into an approximately rectangular shape. At this time, inductor 3 includes corrugated part 31, folded part 32 and electrode part 33. Corrugated part 31 is the part of inductor 3 with a corrugated shape, and corrugated part 31 specifically includes upper corrugation 311 and lower corrugation 312. One corrugated part 31 has multiple upper corrugations 311 and lower corrugations 312. Both the upper corrugation 311 and the lower corrugation 312 are axially symmetrical shapes. The corrugations of the upper corrugation 311 arch upwards, and the corrugations of the lower corrugation 312 arch downwards. Meanwhile, the corrugated portion 31 consists of the upper corrugation 311 and multiple lower corrugations 312 connected in an alternating manner. The folded portion 32 is the corner of a rectangle, and the two end surfaces of the folded portion 32 are perpendicular to each other to connect the two corrugated portions 31. The approximate shape of the folded portion 32 is a quarter-circular fan shape. The electrode portion 33 is the part on the electrode 1 that serves as a pin.

[0021] Example 1

[0022] Reference Figure 1 and Figure 2 The inductor 3 is bent into a multi-layered spiral rectangle. That is, starting from the first fold 32, the height of the inductor 3 gradually increases. However, even with the increase in height, each layer is still rectangular as a whole, and the spiral shape is not circular but rectangular. At the same time, because it is bent into a multi-layered spiral rectangle, multiple corrugated parts 31 or multiple folded parts 32 are stacked vertically. The main purpose is to achieve this by the fact that the horizontal center lines of the two ends of the folded part 32 are not on the same horizontal plane, so that the height increases layer by layer during the bending process. Since the height difference changes at the two ends of the folded part 32, and the corrugated part 31 is set horizontally, although the heights of the corrugated parts 31 connected to the two ends of the folded part 32 are different, each corrugated part 31 in each layer is still set horizontally.

[0023] Furthermore, on the entire inductor 3, the corrugated portions 31 at different heights on the same side are not completely aligned. The upper corrugation 311 of the upper corrugated portion 31 is aligned with the lower corrugation 312 of the lower corrugated portion 31, and the lower corrugation 312 of the upper corrugated portion 31 is aligned with the upper corrugation 311 of the lower corrugated portion 31. That is, the corrugations of the upper and lower corrugated portions 31 are out of phase. Therefore, multiple hollow through holes are formed between the two corrugated portions 31, which is conducive to heat dissipation.

[0024] Since the inductor 3 is a multi-layered spiral rectangle, the two electrode portions 33 are located at the top and bottom layers respectively. Both electrode portions 33 are connected folded portions 32. The electrode portion 33 located at the top layer is arranged along the length direction of the corrugated portion 31, while the folded portion 32 connected to the bottom electrode portion 33 extends from the bottom and extends to the top layer, while folding towards the plane where the top electrode portion 33 is located. The folding direction is also arranged along the length direction of the corrugated portion 31. Both electrode portions 33 are ultimately located at the top layer.

[0025] Example 2

[0026] Reference Figure 3 There are two inductors 3, and each inductor 3 is bent into a "U" shape with an opening on one side. However, the composition is still the same: a corrugated part 31, a folded part 32, and an electrode part 33. The electrode part 33 is located on one side of the opening, and the orientation of the electrode part 33 is the same as that of the opening. The two inductors 3 are stacked vertically, but the two "U" shaped openings face opposite directions. The electrode part 33 of the lower inductor 3 extends upward and folds to the surface, while the electrode part 33 of the upper inductor 3 folds in the opposite direction to the opening. Finally, they all fold over the upper inductor 3.

[0027] The method for manufacturing inductor 3 is as follows:

[0028] 1. Insulated flake powder is mixed with epoxy resin, PVB (polyvinyl butyral), and organic solvent to form a casting slurry. The epoxy resin and PVB content in the casting slurry is 10 wt% of the magnetic powder mass. 2. The casting slurry is used to prepare a 0.5 mm thick film with a copper wire cross-section of 0.5 × 4 mm. 3. The thick film is cut into strips and applied to the surface of the flat copper wire to fully wrap it. 4. The wrapped copper wire is pressed into a corrugated shape with a corrugation period of 6 mm, and then... Figure 1 5. The wire ends are stripped to expose the copper electrode 1, which is then flattened as the lead-out end and baked at high temperature to set the shape. 6. Tin is electroplated onto the lead-out copper wire.

[0029] Test characteristics: 4.7μH, saturation cutoff current 50A, temperature rise cutoff current 70A. Temperature rise will not be a bottleneck in use. Meanwhile, a flat copper wire integrally molded inductor with the same external dimensions and inductance value has a temperature rise current of 40A.

[0030] The above are all preferred embodiments of this utility model, and are not intended to limit the scope of protection of this utility model. Identical components are represented by the same reference numerals. It should be noted that the terms "front," "rear," "left," "right," "up," and "down" used in the following description refer to directions in the accompanying drawings, while the terms "inner" and "outer" refer to directions toward or away from the geometric center of a specific component. Therefore, all equivalent changes made to the structure, shape, and principle of this utility model should be included within the scope of protection of this utility model.

Claims

1. A corrugated spring-shaped inductor, characterized in that, The inductor includes electrodes (1) and an outer covering material (2). The outer covering material (2) covers the outer surface of the electrodes (1) except for the two ends to form an inductor (3), and the exposed portions of the electrodes (1) at both ends serve as leads. The inductor (3) is wound into a corrugated shape and bent into a rectangle with a hollow center. The inductor (3) includes a corrugated portion (31), a folded portion (32), and an electrode portion (33). The corrugated portion (31) and the folded portion (32) each have multiple portions. The corrugated portion (31) includes multiple upper corrugations (31). 1) and multiple lower corrugations (312), and the upper corrugations (311) and lower corrugations (312) are both axisymmetric graphics. The corrugations of the upper corrugations (311) arch upwards towards the top, and the corrugations of the lower corrugations (312) arch downwards towards the bottom. Multiple upper corrugations (311) and multiple lower corrugations (312) are sequentially staggered to form corrugated parts (31). The two end surfaces of the folded part (32) are perpendicular to each other to connect the two corrugated parts (31). The electrode part (33) is the part of the electrode (1) whose two ends are not covered.

2. The corrugated spring-shaped inductor according to claim 1, characterized in that, The inductor (3) is hollow in the center after being wound and bent.

3. The corrugated spring-shaped inductor according to claim 1, characterized in that, The inductor (3) is bent into a multi-layered spiral rectangle, and the corrugated part (31) and the folded part (32) are stacked one on top of the other. The horizontal center lines of the two ends of the folded part (32) are not on the same horizontal plane, so that multiple corrugated parts (31) and folded parts (32) have a height difference to form a stack.

4. A corrugated spring-shaped inductor according to claim 3, characterized in that, The corrugated portions (31) located on the same side at different heights have the upper corrugation (311) of the upper layer aligned with the lower corrugation (312) of the lower layer, and the lower corrugation (312) of the upper layer aligned with the upper corrugation (311) of the lower layer, to form multiple hollow through holes.

5. A corrugated spring-shaped inductor according to claim 3, characterized in that, The two electrode portions (33) of the inductor (3) are located at the upper and lower ends of the multi-layer spiral rectangle. The folded portion (32) of the electrode portion (33) closest to the bottom extends from the bottom and folds towards the plane where the electrode portion (33) at the top is located.

6. A corrugated spring-shaped inductor according to claim 1, characterized in that, The outer packaging material (2) is a magnetic material, and the electrode (1) is made of copper.

Images