filter

Abstract

A filter includes: a body defining a first surface; and at least one coil assembly defining a second surface, the coil assembly being disposed inside the body, the second surface being parallel to the first surface. The coil assembly includes a first coil and a second coil stacked on top of each other. The first coil has a first lead extending from each end of its first coil, and the second coil has a second lead extending from each end of its second coil. An insulator is provided between the first coil and the second coil. This allows the coil assembly to be disposed flat inside the body, and the stacked first and second coils reduce the overall height to meet thinness requirements.

Description

Technical Field

[0001] This invention relates to a filter, and more particularly to a thinner filter. Prior Technology

[0002] Referring to Figures 7 and 7a, the conventional filter includes a body 3 and a coil assembly 4. The coil assembly 4 is located inside the body 3. The body 3 defines a first surface 30, and the coil assembly 4 defines a second surface 40, which is perpendicular to the first surface 30. The coil assembly 4 includes a first coil 41 and a second coil 42 that are stacked together. Referring to Figure 7b, because the coil assembly 4 of the conventional filter is vertically mounted on the body 3, the conventional filter has a relatively high height H1 when mounted on the circuit board 50. However, the relatively high height of the conventional filter causes the following problem:

[0003] 1. Poor stability: Since the coil group 4 of the conventional filter is vertically mounted on the body 3, the center of gravity is relatively high, making it easier to shake or fall off under mechanical vibration or impact.

[0004] Second, it occupies a relatively large area on a printed circuit board (PCB). Although conventional filters have a small footprint on a printed circuit board (PCB), they are relatively tall, which may affect the overall design of the product, especially in space-constrained applications.

[0005] Third, production automation is difficult: conventional filters usually require manual soldering or special insertion machines, which affects production efficiency and increases manufacturing costs.

[0006] Therefore, how to eliminate the above-mentioned deficiencies is the technical difficulty that the inventors of this case want to solve. Summary of the Invention

[0007] In view of the conventional application, the present invention aims to solve and improve the problems and deficiencies existing in the conventional application.

[0008] To achieve the above objectives, the present invention provides a filter comprising: a body defining a first surface; and at least one coil group defining a second surface, the at least one coil group being disposed on the body, the second surface being parallel to the first surface, the at least one coil group comprising a first coil and a second coil superimposed on each other, the two ends of the first coil being bent to extend into a first lead, the two ends of the second coil being bent to extend into a second lead, and the first lead and the second lead extending in the same direction, and an insulator being disposed between the first coil and the second coil.

[0009] The first coil and the second coil are flat coils.

[0010] The exterior of the main body is provided with at least one heat sink.

[0011] When there are two or more coil groups, the coil groups are arranged at the same spacing.

[0012] The main body comprises a body and a cover.

[0013] In this way, the at least one coil group can be arranged in parallel on the body, and the at least one coil group includes a first coil and a second coil that are superimposed on each other, so as to reduce the overall height and meet the requirements of thinness. Simple Explanation of the Diagram

[0014]

[0015] [Figure 1] is a schematic diagram of the filter in this embodiment.

[0016] [Figure 2] is an exploded view of the filter in this embodiment.

[0017] [Figure 3] is a schematic diagram of the coil assembly and insulator in this embodiment.

[0018] [Figure 4] is a schematic diagram of the three coil groups in this embodiment.

[0019] [Figure 5] is a schematic diagram of the heat sink provided on the outside of the main body in this embodiment.

[0020] [Figure 5A] is a front view of the body with heat sinks on the outside in this embodiment.

[0021] [Figure 6] is a side view of the filter in this embodiment.

[0022] [Figure 6A] is a schematic diagram of the filter being mounted on the circuit board in this embodiment.

[0023] [Figure 7] is a front view of a conventional filter.

[0024] [Figure 7A] is a side view of a conventional filter.

[0025] [Figure 7B] is a schematic diagram of a conventional filter installed on a circuit board.

[0026] [Figure 8] is a graph comparing the conventional filter and the filter of this embodiment. Implementation

[0027] To facilitate a concise understanding for your examiner of the other features, advantages, and effects of this invention, the invention is described in detail below with reference to the accompanying drawings:

[0028] Please refer to Figures 1, 2, and 3. This invention provides a filter comprising:

[0029] A body 1 is defined, which has a first surface 10 (shown in Figure 6). The body 1 can be assembled or formed into a single piece by hot-pressing or cold-pressing iron powder, depending on design requirements and application scenarios. When the body 1 is assembled, it can be disassembled into a base 11 and a cover 12. The base 11 serves as a support, carrying and securing other components. The cover 12 is mounted on the base 11 to enclose the filter, providing electromagnetic shielding and mechanical protection, protecting internal components from physical damage and environmental factors. The body 1 can also be designed with heat dissipation capabilities to improve the filter's heat dissipation performance. Specifically, the exterior of the body 1 can be equipped with at least one heat sink 13 (shown in Figures 5 and 5A). This heat sink 13 enhances heat dissipation efficiency, ensuring the filter remains stable during high-power or high-frequency operation and preventing overheating from affecting performance or lifespan. The advantages of modular design are convenient maintenance and replacement; damaged parts can be replaced individually without replacing the entire unit, and different covers 12 can be used to adjust electromagnetic shielding or heat dissipation as needed. Integrated design means the main body 1 cannot be disassembled. The advantages of integrated design are compact structure, reduced mechanical loosening or environmental impact, and improved reliability.

[0030] The at least one coil group 2 defines a second surface 20, is disposed on the body 1, and the second surface 20 is parallel to the first surface 10. The at least one coil group 2 includes a first coil 21 and a second coil 22 that are superimposed on each other. The two ends of the first coil 21 are bent to extend into a first joint 211, and the two ends of the second coil 22 are bent to extend into a second joint 221. The first joint 211 and the second joint 221 extend in the same direction. An insulator 23 is provided between the first coil 21 and the second coil 22. The first coil 21 and the second coil 22 can be flat coils. When there are two or more coil groups 2, they are arranged at the same spacing. The number of at least one coil group 2 can be two as shown in FIG1, including two first coils 21 and two second coils 22, or three as shown in FIG4, including three first coils 21 and three second coils 22, but is not limited thereto.

[0031] When two flat coils are stacked, the insulator 23 between the two flat coils is commonly chosen from the following materials: plastic materials, such as polyvinyl chloride (PVC) or polyethylene (PE), or rubber, or ceramic or glass.

[0032] In the specific implementation of this case, the body 1 is manufactured by pressing magnetic materials, such as ferrite or metal alloys (such as Fe-Si alloys, Fe-Ni alloys, etc.). If ferrite is used for the body 1, high-temperature sintering is required to improve magnetic properties and mechanical strength. If metal alloy is used for the body 1, low-temperature sintering or resin bonding molding may be used, and metal electrodes may be fabricated on the body 1.

[0033] The fabrication of at least one coil group 2: Precision stamping or laser cutting techniques can be used to cut flat copper wires according to the design dimensions to form the first coil 21 and the second coil 22. The surface of the second coil 22 can be coated with an insulator 23 (such as a PI film or electroplated insulating layer). The first coil 21 is stacked on top of the second coil 22, with the two ends of the first coil 21 bent to extend into first leads 211, and the two ends of the second coil 22 bent to extend into second leads 221. The first coil 21 and the second coil 22 are placed inside the body 1, and the first leads 211 of the first coil 21 and the second leads 221 of the second coil 22 are soldered to the metal electrodes of the body 1 to ensure a stable conductive connection.

[0034] Please refer to Figure 6A. Because the coil group 2 of the filter in this embodiment is arranged parallel to the body 1, the height H2 of the filter on the circuit board 5 is relatively low. Please refer to Figures 7A and 7B. Conversely, because the coil group 4 of a conventional filter is arranged vertically on the body 3, the height H1 of a conventional filter on the circuit board 50 is relatively high. In comparison, the filter in this embodiment has at least one coil group 2 arranged parallel to the body 1, and this at least one coil group 2 includes a first coil 21 and a second coil 22 that overlap each other, achieving the goal of reducing the overall height and meeting the requirements for thinness.

[0035] Table 1

[0036] Please refer to Table 1. The first sample is a conventional filter, and the second sample is the filter of this embodiment. Table 1 compares the performance of the two filters at the same size. The results show that the first sample has a higher saturation current, indicating that it has a higher load capacity and can handle larger loads, thereby improving the reliability of the filter. The higher saturation current helps prevent overheating or damage caused by excessive current, making the filter more stable and reliable, and enabling it to operate for extended periods under more extreme conditions without performance degradation.

[0037] Table 2

[0038] Please refer to Table 2, which contains test data for a conventional filter. The higher the bias voltage, the more unstable the average inductance value becomes.

[0039] Table 3

[0040] Please refer to Table 3, which contains the test data for the filter in this embodiment. The higher the bias voltage, the more stable the average inductance value remains, without degradation.

[0041] Please refer to Figure 8. Curve A1 represents a conventional filter. The higher the bias voltage, the more unstable the average inductance value becomes. Curve A2 represents the filter in this embodiment. The higher the bias voltage, the more stable the average inductance value becomes, without degradation.

[0042] The above discussion is merely a preferred embodiment of the present invention and is not intended to limit the scope of the present invention. Therefore, any equivalent modifications, combinations, substitutions, or modifications made without departing from the spirit and scope of the present invention should be covered within the scope of the patent application of the present invention.

[0043] Learned Technology

[0044] 3: Ontology

[0045] 30: First Page

[0046] 4: Coil assembly

[0047] 41: First coil

[0048] 42: Second coil

[0049] 40: Second page

[0050] 50: Circuit board

[0051] H1: Height

[0052] This invention

[0053] 1: Ontology

[0054] 10: First Page

[0055] 11: base body

[0056] 12: Cover

[0057] 13: Heatsink

[0058] 2: Coil assembly

[0059] 20: Second page

[0060] 21: First coil

[0061] 211: First foot

[0062] 22: Second coil

[0063] 221: Second foot

[0064] 23: Insulator

[0065] 5: Circuit board

[0066] H2: Height

[0067] A1: Known Filter

[0068] A2: Filter

Claims

1. A filter comprising: a body defining a first surface; and at least one coil assembly defining a second surface, the at least one coil assembly being disposed inside the body and the second surface being parallel to the first surface, the at least one coil assembly comprising a first coil and a second coil stacked together, the two ends of the first coil being bent to extend into a first lead, the two ends of the second coil being bent to extend into a second lead, and the first lead and the second lead extending in the same direction, an insulator being disposed between the first coil and the second coil; wherein, The body is provided with at least one heat sink on its exterior, and the body includes a base and a cover. The at least one coil group is disposed on the base, and the cover is disposed on the base and covers the at least one coil group. When there are two or more coil groups, the coil groups are arranged at the same spacing.

2. The filter as described in claim 1, wherein the first coil and the second coil are flat coils.

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