A coil structure with high stability

Abstract

The utility model discloses a coil structure that high stability, it includes the shell, the shell includes cylinder portion and is located the top cap portion of cylinder portion top, and the cylinder portion other end is the open design, coil assembly is installed in the shell, and its top surface is provided with a plurality of convex ribs, bottom cover is installed in the shell opening place and is packed in the shell with the coil assembly, and the bottom cover axial compression coil assembly makes the convex rib butt joint top cap portion lower surface, the utility model can avoid coil and shell to take place displacement, and sway, and utilize secondary injection molding process, and the reliability of coil is greatly strengthened.

Description

Technical Field

[0001] This utility model relates to the field of coil manufacturing technology, and in particular to a coil structure with high stability. Background Technology

[0002] As a fundamental inductive element, a coil utilizes a spiral structure formed by winding wire to achieve the mutual conversion of electrical energy and magnetic energy. This characteristic makes coils play an indispensable role in modern electronic and electrical technology, and they are widely used in transformers, inductors, motors, electromagnets, wireless charging transmitter / receiver modules, and various sensors (such as current sensors and position sensors) in many other fields.

[0003] Existing patent CN216957622U discloses an electromagnetic coil manufactured by secondary injection molding. In this design, the conductor end and connector are injection molded in one step, and then the conductor is injection molded to the encapsulation body on the electromagnetic coil body in a second step. This improves the connection strength between the conductor and the electromagnetic coil body, making the connection less prone to breakage.

[0004] In the above solution, although a secondary injection molding process is used to form the encapsulated body and connector structure, it is essentially a basic covering layer for the coil body, rather than a reinforced protective layer for complex external environments. Without an outer shell, its resistance to physical impact, water and dust resistance decreases, further exacerbating the reliability risks of the coil. If an additional outer shell is added to compensate for the above-mentioned protective defects, the existing technology faces new technical challenges: because the surface morphology and dimensional accuracy of the encapsulated body formed by secondary injection molding are greatly affected by fluctuations in the injection molding process, if the outer shell design is too loose, assembly gaps can easily occur, causing shaking and failing to provide effective protection.

[0005] Therefore, it is necessary to design a new utility model to solve the above-mentioned technical problems. Utility Model Content

[0006] The main purpose of this invention is to provide a coil structure with high stability, which can prevent the coil from shifting or shaking with the outer shell, and the reliability of the coil is greatly enhanced by using a secondary injection molding process.

[0007] This utility model achieves the above objective through the following technical solution: a coil structure with high stability, comprising: The outer casing includes a cylindrical portion and a top cover portion located at the top of the cylindrical portion, and the other end of the cylindrical portion is designed to be open; A coil assembly is installed inside the housing, and its top surface is provided with several raised ribs. A bottom cover is installed at the opening of the housing to encapsulate the coil assembly inside the housing; the bottom cover axially presses the coil assembly so that the rib abuts against the lower surface of the top cover.

[0008] Furthermore, the coil assembly includes a frame assembly, a coil wound around the periphery of the frame assembly, and a plastic part that covers the outer ring of the frame assembly and is injection molded into a single structure.

[0009] Furthermore, the skeleton assembly includes a skeleton body and a metal terminal embedded in the bottom end of the skeleton body.

[0010] Furthermore, the main body of the skeleton includes a column portion, a first limiting disk portion located at the top of the column portion, and a second limiting disk portion located at the bottom of the column portion. The column portion, the first limiting disk portion, and the second limiting disk portion together form a coil winding groove, and the coil is wound in the coil winding groove and wound around the outer periphery of the column portion.

[0011] Furthermore, a first positioning block is provided on the upper surface of the first limiting disc portion, and a positioning hole is provided on the top cover portion to cooperate with the first positioning block to achieve angular positioning of the two.

[0012] Furthermore, a second positioning block is provided on the lower surface of the second limiting disc, and a positioning groove is provided on the bottom cover to cooperate with the second positioning block to achieve angular positioning of the two.

[0013] Furthermore, the upper surface of the second limiting disc portion is provided with a first wiring groove extending from the column portion; the circumferential surface of the second limiting disc portion is provided with a second wiring groove communicating with the first wiring groove; the lead wire of the coil passes through the first wiring groove and the second wiring groove in sequence and then winds around the metal terminal.

[0014] Furthermore, the rib is provided on the upper surface of the first limiting disc portion.

[0015] Furthermore, the metal terminal is provided with a first fixing block for fixing one of the wire ends of the coil and a second fixing block for fixing the other wire end of the coil.

[0016] Furthermore, the first fixing block and the second fixing block are in an open state when the coil leads are wound, and in a closed and flattened state after the winding is completed and welded.

[0017] Compared with the prior art, the advantages of this invention's highly stable coil structure are as follows: (1) High structural stability: By setting ribs on the upper end of the skeleton and forming an interference fit with the inner wall of the shell, the axial and circumferential movement of the skeleton in the shell is effectively restricted, avoiding loosening, wear or abnormal noise caused by relative displacement of components, and ensuring long-term stable operation of the product in a vibration environment.

[0018] (2) High reliability: The enameled coil is completely covered in the coil part by using a secondary injection molding process, which completely isolates the coil from the external environment, significantly enhances the insulation strength and withstand voltage performance, and effectively prevents the risk of short circuit or leakage caused by foreign objects such as dust and moisture. Attached Figure Description

[0019] Figure 1 This is a three-dimensional structural diagram of this embodiment; Figure 2 This is a schematic diagram of the exploded structure of this embodiment; Figure 3 This is a cross-sectional structural diagram of this embodiment; Figure 4 This is a schematic diagram of the exploded structure of the coil assembly in this embodiment; Figure 5 This is a three-dimensional structural diagram of the skeleton component in this embodiment; Figure 6 This is a bottom-view structural diagram of this embodiment; Figure 7 This is a partial cross-sectional structural diagram of this embodiment.

[0020] The diagram is marked as follows: 100 - Highly stable coil structure; 1-Coil assembly, 11-Frame assembly, 111-Frame body, 1111-Column part, 1112-First limiting disk, 11121-First positioning block, 11122-Protruding rib, 1113-Second limiting disk, 11131-Second positioning block, 11132-First wiring groove, 11133-Second wiring groove, 1114-Coil winding groove, 112-Metal terminal, 1121-First fixing block, 1122-Second fixing block, 12-Coil, 13-Plastic part; 2-Outer shell, 21-Cylindrical part, 22-Top cover part, 221-Positioning hole; 3-Bottom cover, 31-Positioning groove. Detailed Implementation

[0021] The present invention will be further described in detail below with reference to specific embodiments.

[0022] Example: Please refer to Figures 1 to 4 This embodiment provides a highly stable coil structure 100, which includes a coil assembly 1, a shell 2 sleeved on the coil assembly 1, and a bottom cover 3 that seals one open end of the shell 2. The coil assembly 1 includes a skeleton assembly 11, a coil 12 wound around the outer periphery of the skeleton assembly 11, and a plastic part 13 covering the outer ring of the skeleton assembly 11.

[0023] The coil used in this embodiment is made of copper wire. In other embodiments, the coil may also be made of other metal materials besides copper, and is not limited to a single material; in addition, the coil may also be made of multiple strands of wire, and its winding method can be flexibly adjusted.

[0024] The outer shell 2 is an integral structure and includes a cylindrical part 21 sleeved on the coil assembly 1 and a top cover part 22 located at the top of the cylindrical part 21. The bottom end of the cylindrical part 21 is designed to be open, and the bottom cover 3 is installed at the opening of the outer shell 2.

[0025] The skeleton assembly 11 includes a skeleton body 111 and a metal terminal 112 embedded in the bottom end of the skeleton body 111.

[0026] The main body 111 includes a column portion 1111, a first limiting disk portion 1112 located at the top of the column portion 1111, and a second limiting disk portion 1113 located at the bottom of the column portion 1111. The column portion 1111, the first limiting disk portion 1112, and the second limiting disk portion 1113 together form a coil winding groove 1114. The coil 12 is wound in the coil winding groove 1114 and is wound around the outer periphery of the column portion 1111.

[0027] The upper surface of the first limiting disc portion 1112 is provided with a first positioning block 11121, and the top cover portion 22 of the outer shell 2 is provided with a positioning hole 221 that cooperates with the first positioning block 11121 to achieve angular positioning of the two.

[0028] The lower surface of the second limiting disc 1113 is provided with a second positioning block 11131, and the bottom cover 3 is provided with a positioning groove 31 that cooperates with the second positioning block 11131 to achieve angular positioning of the two.

[0029] The upper surface of the second limiting disc portion 1113 is also provided with a first wiring groove 11132 extending from the column portion 1111; the circumferential surface of the second limiting disc portion 1113 is provided with a second wiring groove 11133 communicating with the first wiring groove 11132.

[0030] When assembling the coil assembly 1 into the housing 2, in order to prevent the coil assembly 1 and the housing 2 from being displaced relative to each other during subsequent use, it is necessary to ensure that the coil assembly 1 remains fixed. Therefore, a number of protruding ribs 11122 are also provided on the first limiting disc portion 1112 of the skeleton body 111.

[0031] The metal terminal 112 is provided with a first fixing block 1121 for fixing the wire end and a second fixing block 1122 for fixing the wire tail. The first fixing block 1121 and the second fixing block 1122 are in an open state when the coil 12 is wound. After the winding is completed and welded, the two are in a closed and flattened state.

[0032] The winding method of coil 12 is as follows: its wire end is wound at the first fixing block 1121 and pressed by it, and then passes through the second wire routing groove 11133 and the first wire routing groove 11132 in sequence; coil 12 is wound in the coil winding groove 1114 and wound around the outer periphery of the column part 1111; finally, the wire end passes through the first wire routing groove 11132 and the second wire routing groove 11133 in sequence, and is wound at the second fixing block 1122 and pressed by it; after the winding is completed, the first fixing block 1121 and the second fixing block 1122 are welded so that the wire end and the wire end are completely fixed.

[0033] During assembly, the positioning hole 21 on the outer shell 2 is first engaged with the first positioning block 11121 on the coil assembly 1, and the bottom cover 3 is installed at the open end of the outer shell 2, so that the positioning groove 31 on the bottom cover 3 engages with the second positioning block 11131 on the coil assembly 1, thereby achieving preliminary axial positioning of the coil assembly 1, the outer shell 2, and the bottom cover 3. Subsequently, the bottom cover 3 is pressed into the outer shell 2 to form a reliable riveted fit with the outer shell 2. At the same time, the protruding rib 11122 on the coil assembly 1 abuts against the lower surface of the top cover 22 inside the outer shell 2, and the two adopt an interference fit to form a tight fit, thereby eliminating assembly gaps and suppressing shaking. This structure can effectively limit the shaking of the coil assembly 1 inside the outer shell 2 after assembly, avoid positional displacement caused by vibration or external stress, and improve the long-term stability and reliability of the overall structure.

[0034] Without the ribs 11122, the coil assembly 1 and the lower surface of the top cover 22 of the outer shell 2 form a surface contact, which has the following drawbacks: First, in order to ensure the reliability of the surface contact, the flatness and parallelism requirements of the upper surface of the coil assembly 1 and the lower surface of the top cover 22 are extremely high, which greatly increases the difficulty of processing the parts; Second, when subjected to vibration or impact, the frictional force between the large-area contact surfaces is unevenly distributed, which can easily produce small relative displacements, which may lead to loosening between the coil assembly 1 and the outer shell 2 in the long term, affecting the stability and reliability of the equipment in long-term operation.

[0035] In this embodiment, by setting a number of protruding ribs 11122, the coil assembly 1 and the lower surface of the top cover 22 of the outer shell 2 form point contact, which has the following advantages: First, point contact can reduce the machining accuracy requirements of the part mating surface (i.e., the lower surface of the top cover 22), reducing manufacturing difficulty and cost; Second, point contact can provide a clear and stable support point, suppressing displacement trends in all directions in a vibration environment, so its positioning reliability is better than that of surface contact; Third, after the protruding ribs 11122 abut against the lower surface of the top cover 22, an interference fit is formed, which cancels out the shaking gap and better ensures the stability of the coil assembly 1.

[0036] The plastic part 13 is formed by a two-stage injection molding process, which aims to encapsulate the first, second and third positions on the coil assembly 1 by injection molding, so as to select injection molding materials with different physical properties for local molding according to the performance requirements of different functional areas.

[0037] The first position is the cylindrical portion 1111 after the coil 12 is wound. Since there is no direct insulating structure between the cylindrical portion 1111 after the coil 12 and the inner wall of the outer shell 2, if small external impurities enter this gap, it can easily lead to a decrease in the insulation performance between the coil assembly 1 and the outer shell 2, and in severe cases, may cause a short circuit. Therefore, the first position needs to be injection molded. Furthermore, the injection molding material at the first position has certain elasticity and damping characteristics, which can effectively isolate the influence of external electromagnetic interference on the coil assembly 1 and suppress the transmission of vibrations generated during the operation of the coil assembly 1 to the outer shell 2, thereby reducing the overall operating noise and achieving a good noise reduction effect.

[0038] The second location is the weld joint between coil 12 and metal terminal 112. Since coil 12 and metal terminal 112 form an electrical connection through welding, the mechanical strength and electrical stability of the weld joint area directly affect the overall reliability of the product. Therefore, the weld joint area between coil 12 and metal terminal 112 is fully encapsulated and sealed by a secondary injection molding process. This effectively resists the impact and vibration of external mechanical stress on the weld joint, as well as the intrusion of foreign objects such as dust and moisture, preventing oxidation or loosening of the weld joint, thereby significantly improving the stability of the connection area and the overall electrical reliability of the product.

[0039] The third location is at the junction of the first wiring groove 11132 and the second wiring groove 11133. Since the coil 12 needs to pass through the first wiring groove 11132 and the second wiring groove 11133 after winding, this location also needs to be injection molded to avoid short circuits between the coil ends and the inner wall of the outer casing 2 due to the lack of insulation.

[0040] During the secondary injection molding process, different materials can be used for the first, second, and third positions according to their functional requirements. For example, the second position can use engineering plastics with excellent impact resistance to enhance the protection of the solder joints, while the first and third positions can use modified plastics with outstanding insulation properties to improve the insulation withstand voltage level. Although the materials can be selected differently, the continuity of the secondary injection molding process ensures a seamless, continuous integral structure without any seams. This takes into account the performance requirements of different areas while ensuring the structural integrity and high reliability of the coil assembly 1, further guaranteeing the overall performance stability and reliability of this invention.

[0041] The above descriptions are merely some embodiments of this utility model. For those skilled in the art, various modifications and improvements can be made without departing from the concept of this utility model, and all such modifications and improvements fall within the protection scope of this utility model.

Claims

1. A coil structure with high stability, characterized in that, It includes: The outer casing includes a cylindrical portion and a top cover portion located at the top of the cylindrical portion, and the other end of the cylindrical portion is designed to be open; A coil assembly is installed inside the housing, and its top surface is provided with several raised ribs. A bottom cover is installed at the opening of the housing to encapsulate the coil assembly inside the housing; the bottom cover axially presses the coil assembly so that the rib abuts against the lower surface of the top cover.

2. The high-stability coil structure as described in claim 1, characterized in that: The coil assembly includes a frame assembly, a coil wound around the periphery of the frame assembly, and a plastic part that covers the outer ring of the frame assembly and is injection molded into a single structure.

3. The high-stability coil structure as described in claim 2, characterized in that: The skeleton assembly includes a skeleton body and metal terminals embedded in the bottom end of the skeleton body.

4. The high-stability coil structure as described in claim 3, characterized in that: The main body of the skeleton includes a column part, a first limiting disk part located at the top of the column part, and a second limiting disk part located at the bottom of the column part. The column part, the first limiting disk part, and the second limiting disk part together form a coil winding groove. The coil is wound in the coil winding groove and is wound around the outer periphery of the column part.

5. The high-stability coil structure as described in claim 4, characterized in that: The upper surface of the first limiting disc is provided with a first positioning block, and the top cover is provided with a positioning hole that cooperates with the first positioning block to achieve angular positioning of the two.

6. The high-stability coil structure as described in claim 4, characterized in that: The lower surface of the second limiting disc is provided with a second positioning block, and the bottom cover is provided with a positioning groove that cooperates with the second positioning block to achieve angular positioning of the two.

7. The high-stability coil structure as described in claim 4, characterized in that: The upper surface of the second limiting disc portion is provided with a first wiring groove extending from the column portion; the circumferential surface of the second limiting disc portion is provided with a second wiring groove communicating with the first wiring groove; the lead wire of the coil passes through the first wiring groove and the second wiring groove in sequence and then winds around the metal terminal.

8. The high-stability coil structure as described in claim 4, characterized in that: The rib is provided on the upper surface of the first limiting disc portion.

9. The high-stability coil structure as described in claim 3, characterized in that: The metal terminal is provided with a first fixing block for fixing one of the wire ends of the coil and a second fixing block for fixing the other wire end of the coil.

10. The high-stability coil structure as described in claim 9, characterized in that: The first fixing block and the second fixing block are in the open state when the coil lead is wound, and in the closed and flattened state after the winding is completed and welded.

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