CN210668039U - Inductor - Google Patents

Abstract

The utility model provides an inductor, this inductor includes: the annular magnetic core comprises a first magnetic core and a second magnetic core which are oppositely combined, wherein the first magnetic core is provided with a first winding area, and the second magnetic core is provided with a second winding area; and the coil is formed by winding a conducting wire which is continuously wound in the first winding area and the second winding area. The utility model discloses an inductor parasitic loss is little, small, can obtain through automated production, and production efficiency is high.

Description

Inductor

Technical Field

The utility model mainly relates to the inductor field especially relates to an adopt inductor to box-like concatenation.

Background

With the development of power electronic technology, inductors capable of converting electric energy into magnetic energy and storing the magnetic energy are widely applied. Particularly, as the frequency of the power switching frequency is increased, the inductance element tends to have a small inductance, a high frequency, and a low power consumption at a large ripple. To achieve these characteristics, higher demands are placed on the winding of the inductor. At present, manual winding or semi-automatic winding is still adopted for winding of the inductance coil, and particularly for the annular inductor, manual winding is still required, so that the production efficiency is low and the manufacturing cost is high. In addition, the inductor adopting the manual or semi-automatic winding method has the problem of uneven coil arrangement, thereby causing larger size and higher parasitic loss of the inductor.

SUMMERY OF THE UTILITY MODEL

The to-be-solved technical problem of the utility model is to provide an adopt toroidal inductor to box-like concatenation, can use the machine to carry out automated production in the coil coiling step.

In order to solve the above technical problem, the utility model provides an inductor, its characterized in that includes: the annular magnetic core comprises a first magnetic core and a second magnetic core which are oppositely combined, wherein the first magnetic core is provided with a first winding area, and the second magnetic core is provided with a second winding area; and a coil wound by a wire continuously wound in the first winding region and the second winding region. In an embodiment of the present invention, the first winding area and the second winding area are coated with an insulating material.

In an embodiment of the present invention, the first magnetic core has a first involution area, the second magnetic core has a second involution area, and the first magnetic core and the second magnetic core are involuted through the first involution area and the second involution area.

In an embodiment of the present invention, the first magnetic core and the second magnetic core are U-shaped magnetic cores.

In an embodiment of the present invention, the coil includes a plurality of layers of wires wound on the first winding region and the second winding region.

In an embodiment of the present invention, the number of layers of the multi-layer conductive wire is 2 or 3.

The utility model discloses an adopt the magnetic core of box-like concatenation for can adopt automatic spiral to simplify production technology and improve the arrangement regularity of solenoid in the spiral step of magnetic core, the inductor that obtains has that parasitic parameter loss is little, small advantage, can also obtain through automatic generation, increases substantially production efficiency, reduces manufacturing cost.

Drawings

In order to make the aforementioned objects, features and advantages of the present invention more comprehensible, embodiments of the present invention are described in detail below with reference to the accompanying drawings, wherein:

fig. 1 is one of schematic perspective views of an inductor according to an embodiment of the present invention;

fig. 2 is a second schematic perspective view of an inductor according to an embodiment of the present invention;

fig. 3 is a third schematic perspective view of an inductor according to an embodiment of the present invention;

fig. 4 is a schematic perspective view of a magnetic core coated with an insulating material according to an embodiment of the present invention;

fig. 5 is an exemplary flow chart of a method of fabricating an inductor according to an embodiment of the present invention;

fig. 6A-6F are schematic diagrams illustrating a process of manufacturing an inductor according to an embodiment of the present invention.

Detailed Description

In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in detail below.

In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention, but the present invention may be practiced in other ways than those specifically described herein, and thus the present invention is not limited by the specific embodiments disclosed below.

As used in this application and the appended claims, the terms "a," "an," "the," and/or "the" are not intended to be inclusive in the singular, but rather are intended to be inclusive in the plural unless the context clearly dictates otherwise. In general, the terms "comprises" and "comprising" merely indicate that steps and elements are included which are explicitly identified, that the steps and elements do not form an exclusive list, and that a method or apparatus may include other steps or elements.

Flow charts are used in this application to illustrate operations performed by manufacturing methods according to embodiments of the present invention. It should be understood that the preceding operations are not necessarily performed in the exact order in which they are performed. Rather, various steps may be processed in reverse order or simultaneously. Meanwhile, other operations are added to or removed from these processes.

Fig. 1 is a schematic perspective view of an inductor according to an embodiment of the present invention. As shown in fig. 1, the inductor 100 of the present embodiment includes a toroidal core 110 and a coil 120. The annular magnetic core 110 is formed by splicing a first magnetic core 111 and a second magnetic core 112. Fig. 1 shows an inductor 100 in which a first core 111 and a second core 112 have been spliced together and can be put into use. The first core 111 has a first winding area 121, and the second core 112 has a second winding area 122. The first winding area 121 is located in the middle of the first core 111, and the second winding area 122 is located in the middle of the second core 112. The coil 120 is formed by winding a wire continuously wound in a first winding region 121 and a second winding region 122. As shown in fig. 1, the wire is a generally round wire, typically a copper wire coated with an insulating material. The insulating material may be an insulating varnish. The present invention is not limited to the shape and material of the wire, and other wires such as flat wire may be used in other embodiments.

In the embodiment shown in fig. 1, the annular magnetic core 110 formed by the first magnetic core 111 and the second magnetic core 112 by matching is exemplified by a "square" structure, and four corners of the annular magnetic core are arc-shaped. It is understood that the toroidal core 110 may also have other toroidal configurations, such as rectangular, circular, irregular toroidal, and the like. It is understood that the illustration in fig. 1 is merely illustrative and not intended to limit the physical size and shape of the inductor of the present invention.

In the embodiment shown in fig. 1, the cross-section of first core 111 and second core 112 along line AA' is approximately rectangular. In other embodiments, the cross-section of first and second magnetic cores 111, 112 along line AA' may be circular, elliptical, etc.

Fig. 1 shows a preferred embodiment of the present invention, in which the shape structures of the first magnetic core 111 and the second magnetic core 112 are symmetrical to each other. It is understood that in other embodiments, the first magnetic core 111 and the second magnetic core 112 may also have non-symmetrical shapes.

Referring to fig. 1, the inductor 100 further includes two terminals 141, 142. The two terminals 141 and 142 are connected to both ends of a wire for winding the coil 120. After the inductor 100 completes winding the coil 120, the two ends of the wire are connected to the terminals 141, 142, respectively. The inductor 100 is connected to other electronic components or circuits through the two terminals 141 and 142. It is understood that there may be a portion of the terminals 141, 142 where the wires are covered by the insulating material, such as the portion connected to the wires; yet another portion of the area is conductive material, such as the end portions.

Referring to fig. 1, in some embodiments, inductor 100 further includes a skeleton 130. The two bobbins 130 are respectively located at both ends of the coil 120, and serve to isolate the coil 120 from the magnetic core 110. The frame 130 is typically made of an insulating material.

As shown in fig. 1, the coil 120 may be divided into a first coil 120a wound on the first core 111 and a second coil 120b wound on the second core 112. In some embodiments, the first coil 120a and the second coil 120b are not in contact with each other with a gap of about 1-2mm therebetween. It will be appreciated that in order to obtain such an inductor, the shape and dimensions of the first and second magnetic cores 111, 112 need to be adapted accordingly.

Fig. 2 is a second schematic perspective view of an inductor according to an embodiment of the present invention. Referring to fig. 2, the bobbin 130 is not yet mounted to the inductor 100. The bobbin 130 is fork-shaped and can be inserted into a corresponding portion of the inductor 100 in parallel along the illustrated first direction D1. One of the bobbins 131 is located at one end of the coil 120, and the other bobbin 132 is located at the other end of the coil 120. The fork structure of the bobbin 130 is designed to fit closely with the first and second magnetic cores 111 and 112 of the inductor 100. After the bobbins 130 are mounted, the coil 120 may be just positioned between the two bobbins 130, so that the coil 120 may be isolated from portions of both ends of the first and second magnetic cores 111 and 112.

Fig. 3 is a third schematic perspective view of an inductor according to an embodiment of the present invention. Referring to fig. 3, the first and second cores 111 and 112 of the inductor are not yet aligned. As shown in fig. 3, there is a short transition wire between the first winding area 121 and the second winding area 122, referred to as transition 123. The transition section 123 further indicates that the coil 120 is formed by continuously winding a wire around the first winding region 121 and the second winding region 122.

Referring to fig. 3, the first magnetic core 111 may have a first aligning region 113, the second magnetic core 112 may have a second aligning region 114, and the first magnetic core 111 and the second magnetic core 112 may be aligned by the first aligning region 113 and the second aligning region 114. As shown in fig. 3, two first alignment regions 113 having a planar shape are provided at the portions protruding from both ends of the first magnetic core 111, and two second alignment regions 112 having a planar shape are provided at the portions protruding from both ends of the second magnetic core 112. The positions of the first involution area 113 and the second involution area 114 correspond to each other, and the two first involution areas 113 on the first magnetic core 111 can just involute with the two second involution areas 114 on the second magnetic core 112, so that the first magnetic core 111 and the second magnetic core 112 form the annular magnetic core 110. Preferably, the first apposition area 113 and the second apposition area 114 are both equal in area and shape. In order to firmly connect the first magnetic core 111 and the second magnetic core 112 together through the first apposition area 113 and the second apposition area 114, in one example, an adhesive may be coated on the first apposition area 113 and the second apposition area 114 for adhering the first apposition area 113 and the second apposition area 114. The glue may be an insulating glue.

In one embodiment, the coil 120 may include a plurality of layers of wires wound on the first and second winding areas 121 and 122.

In one embodiment, the number of layers of the multilayer wire may be 2 or 3. As shown in fig. 1 to 3, the wires wound on the first winding area 121 and the second winding area 122 are 2 layers.

Fig. 4 is a schematic perspective view of a magnetic core coated with an insulating material according to an embodiment of the present invention. Referring to fig. 4, the core 410 corresponds to the first and second cores 111 and 112 shown in fig. 1 to 3. In the preferred embodiment, the shape and structure of first core 111 and second core 112 are the same, and both can be described with reference to core 410 in fig. 4. In the embodiment shown in fig. 4, core 410 is a U-shaped core. The corner of the U-shaped magnetic core is approximately right-angled and has a certain radian. The U-shaped core is mainly composed of three parts, a long straight part 411 for winding the coil and two end parts 412, 413 not used for winding the coil. Since fig. 4 shows the magnetic core 410 coated with the insulating material 420, the long straight portion 411 of the magnetic core 410 is almost completely coated with the insulating material 420. Both ends 412, 413 of the U-shaped core are perpendicularly connected to the long straight portion 411 and form both vertical sides of the U-shape. The length d1 of the long straight portion 411 is greater than the length d2 of the ends 412, 413. The width w of the long straight portion 411 and the width w of the end portions 412, 413 are equal. The first winding area 121 of the first magnetic core 111 and the second winding area 122 of the second magnetic core 112 mainly include the long straight portion 411 of the U-shaped magnetic core.

In some embodiments, core 410 is an integrally formed U-shaped core. In other embodiments, core 410 is a U-shaped core formed from multiple pieces, such as a split, long straight section 411, and ends 412, 413 spliced together.

Referring to fig. 4, the core 410 is coated with an insulating material 420. the insulating material 420 is uniformly coated on the straight portion 411 of the U-shaped core, and functions to insulate the core body and the wires wound thereon. Accordingly, the first winding area 121 of the first magnetic core 111 and the second winding area 122 of the second magnetic core 112 of the inductor 100 shown in fig. 1-3 may be coated with an insulating material 420. In an example, the insulating material 420 may be NOMEX insulating paper, insulating tape, insulating varnish, or the like, which is not limited in this embodiment.

Although the first core 111 and the second core 112 are illustrated as U-shaped cores in the above-described embodiment, it is understood that the first core 111 and the second core 112 may be other U-shaped cores, such as circular arcs, arbitrary arcs, and the like, and the shape of the U-shaped cores may be such that the first core 111 and the second core 112 may be spliced together and form a ring structure.

The utility model discloses the annular magnetic core of inductor is obtained by the mode that two magnetic cores involutory concatenations, consequently when carrying out the coiling of coil, can adopt automatic coiler to carry out the continuous coiling of coil to two magnetic cores, and machine or manual work will be around two magnetic cores of good coil to involutory concatenations. The utility model discloses an inductor is compared with the manual or semi-automatic wire-wound inductor of traditional utilization, and the spiral speed can improve by a wide margin, has avoided the shortcoming of inefficiency, the uniformity difference of manual coiling, can accomplish high-efficiently and carry out the coiling steadily, is fit for mass production.

In addition, under high frequency conditions, such as frequencies of 1kHz to 500kHz, most electronic components have certain parasitic parameters that slow the operating speed of the circuit, change the frequency response, and produce energy losses known as parasitic losses. Compare with traditional manual or semi-automatic wire-wound inductor, the utility model discloses an inductor can adopt the machine to carry out automatic spiral, makes the coil arrangement of inductor closely even, neatness height to can reduce the parasitic parameter of solenoid, make the parasitic loss of inductor diminish. Meanwhile, the coil arrangement regularity is high, and the coil winding space can be saved, so that the size of the inductor is reduced.

The utility model also provides a method of preparation inductor. The inductor as described above can be manufactured according to the method of manufacturing an inductor. Therefore, the description of the inductor and the accompanying drawings in the foregoing description can also be used to explain the method for manufacturing the inductor of the present invention.

Fig. 5 is an exemplary flow chart of a method of fabricating an inductor according to an embodiment of the present invention. Referring to fig. 5, the method for manufacturing the inductor of the present embodiment includes the following steps:

step 510, providing a first magnetic core and a second magnetic core which are separated, wherein the first magnetic core is provided with a first winding area, and the second magnetic core is provided with a second winding area.

Step 520, a first coil is wound around the first winding area with a conductive wire.

In step 530, a second coil is wound on the second winding area with the conducting wire.

And 540, combining the first magnetic core and the second magnetic core.

Fig. 6A-6F are schematic diagrams illustrating a process of manufacturing an inductor according to an embodiment of the present invention. The steps of the method for manufacturing the inductor according to the present embodiment will be described in detail with reference to fig. 5 and fig. 6A to 6F.

The separated first and second magnetic cores 111 and 112 provided in step 510 are shown as magnetic core 610 in fig. 6A. According to the preferred embodiment of the present invention, the shape and structure of the first and second magnetic cores 111 and 112 are the same, and thus, fig. 6A shows only one magnetic core 610 for explaining the first and second magnetic cores 111 and 112. Comparing fig. 4 and fig. 6A, it can be seen that the magnetic core 610 of this embodiment is also a U-shaped magnetic core. The corner of the U-shaped magnetic core is approximately right-angled and has a certain radian. The U-shaped core is mainly composed of three parts, a long straight part 611 for winding the coil and two ends 612, 613 not for winding the coil. Both ends 612, 613 are perpendicularly connected to the long straight portion 611 and form the two vertical sides of the U-shape. The length d1 of the long straight portion 611 is greater than the length d2 of the ends 612, 613. The width w of the long straight portion 611 and the width w of the ends 612, 613 are equal. For the first and second magnetic cores 111 and 112, the long straight portion 611 of the magnetic core 610 constitutes the first winding area 121 of the first magnetic core 111 and the second winding area 122 of the second magnetic core 112.

In some embodiments, in the method for manufacturing an inductor of the present invention, the first winding area 121 and the second winding area 122 are coated with an insulating material. As shown in fig. 6A and 6B in combination, in contrast to fig. 6A, the magnetic core 610 in fig. 6B is coated with an insulating material 620 at its long straight portion 611. The insulating material 620 is uniformly coated on the straight portion 611 of the U-shaped core to isolate the core body and the wire wound thereon. In an example, the insulating material 420 may be NOMEX insulating paper, insulating tape, insulating varnish, or the like, which is not limited in this embodiment.

Step 510 may also include placing the first and second cores 111 and 121 on an automatic winding machine in preparation for starting winding. The utility model discloses an in the embodiment, when automatic coil winding machine has a station, then put first magnetic core 111 earlier and carry out the wire winding on the station, take off first magnetic core 111 after the wire winding is ended, carry out the wire winding with second magnetic core 121 side on this station again, analogize in proper order. When the automatic winding machine is provided with a plurality of stations, the plurality of magnetic cores can be placed on the corresponding stations firstly, and then the plurality of magnetic cores are wound one by one. Taking an example that the automatic winding machine has two stations, the first magnetic core 111 and the second magnetic core 121 can be respectively placed on the two stations, and then the first magnetic core 111 is wound by using a conducting wire, and then the second magnetic core is wound, so as to form a continuous winding process.

In step 520, a first coil is wound with a wire in a first winding area. Fig. 6C shows an initial step of winding a first coil in the first winding area 121. Referring to FIG. 6C, the conductive line 630 starts from one end of the first routing area 121, which is called the start end. And then wound in a counterclockwise direction around the first winding area 121 in a certain starting direction, for example, a second direction D2 shown in fig. 6C. Note that, during winding, a length is reserved at the end of the wire 630 for connecting with the terminal 141 or 142 of the inductor 100 shown in fig. 1.

According to the utility model discloses a U type magnetic core because its first wire winding region 121 and the regional 122 of second wire winding all are long straight structure, consequently can conveniently fix it on automatic coil winding machine, utilizes automatic coil winding machine to realize quick inseparable wire winding again. For the U-shaped magnetic core with a certain radian in the winding area, automatic winding can be realized by correspondingly setting the automatic winding machine.

In step 530, the second winding continues with the wire in the second winding area. Referring to fig. 6D, step 520 is completed, i.e., the winding process for the first winding area 121 is completed, and the winding process for the second winding area 122 is started. Since this embodiment winds two layers of wires around the first winding area 121, the first wire pack 631 includes two layers of wires. In some embodiments, the first wire wrap 631 may include multiple layers of conductive wire. In some embodiments, the number of layers of the multilayer wire is 2 or 3. It will be appreciated that for a package having multiple layers of wire, the inner layer of wire may be wound immediately adjacent the core and the outer layer of wire may be wound sequentially outwardly.

Since the first wire package 631 includes two layers of wires, after the winding of the first winding area 121 is finished, the end of the wire 630 returns to the beginning of the winding of the wire 630. For an automatic winding machine having two stations, the winding of the second package with the wire 630 may continue at the second winding region 122 of the second core 112. The section of the wire 630 that transitions from the first winding area 121 to the second winding area 122 is referred to as the transition section 123.

It is understood that the positions of the terminals of the wire 630 may be different when the first winding region 121 winds the single-layer and double-layer wires. As shown in fig. 6D, the first winding region 121 winds a double-layer (2-layer) wire, and after the first coil 631 is wound, the end of the wire 630 is close to the left end of the first magnetic core 111. The second core 112 is placed to the left of the first core 111 to continue the wire winding. If the first winding area 121 winds a single layer (e.g., 1 layer) of wire, the end of the wire 630 should be close to the right end of the first magnetic core 111 after the first coil 631 is wound. Accordingly, the continuous winding of the wire can be realized by placing the second magnetic core 112 at the right side of the first magnetic core 111.

Referring to fig. 6E, the step 530 is completed, i.e., the winding step for the second winding area 122 is completed, and the second coil 632 is formed. This embodiment winds two layers of wire around the second winding area 122 and thus the second package 632 includes two layers of wire. In some embodiments, the second wire package 632 may include multiple layers of wires. In some embodiments, the number of layers of the multilayer wire is 2 or 3.

The inductor can be formed by winding the first magnetic core 111 of the first coil 631 and winding the second magnetic core 112 of the second coil 632.

In step 540, first core 111 and second core 112 are aligned.

Referring to fig. 6F, in one embodiment, the first magnetic core 111 has a first aligning region 113, the second magnetic core 112 has a second aligning region 114, and the first magnetic core 111 and the second magnetic core 112 are aligned by the first aligning region 113 and the second aligning region 114.

As shown in fig. 6A and 6F, the first core 111 has two planar first mating regions 113 at its two ends 612a and 613a, and the second core 112 also has two planar second mating regions 114 at its two ends 612b and 613 b. The positions of the first involution area 113 and the second involution area 114 correspond to each other, and the two first involution areas 113 on the first magnetic core 111 can just involute with the two second involution areas 114 on the second magnetic core 112, so that the first magnetic core 111 and the second magnetic core 112 form the annular magnetic core 110. Preferably, the first apposition area 113 and the second apposition area 114 are both equal in area and shape. In order to firmly connect the first magnetic core 111 and the second magnetic core 112 together through the first apposition area 113 and the second apposition area 114, in one example, an adhesive may be coated on the first apposition area 113 and the second apposition area 114 for adhering the first apposition area 113 and the second apposition area 114. The glue may be an insulating glue.

According to the process of manufacturing the inductor shown in fig. 6A-6F, the two terminals 141, 142 of the finally obtained inductor are located at the same end of the inductor. This embodiment is not intended to limit the specific location of the terminals 141, 142. In other embodiments, the two terminals 141, 142 may be located at two ends of the inductor respectively, or may be located at any position on the coil of the inductor.

It is understood that after the step shown in fig. 6E completes the winding of the magnetic cores, the first magnetic core 111 and the second magnetic core 112 may be removed from the automatic winding machine separately or together, and the first aligning region 113 of the first magnetic core 111 and the second aligning region 114 of the second magnetic core 112 are aligned, so that the first magnetic core 111 and the second magnetic core 112 are aligned and spliced into a ring-shaped magnetic core. The involution step may also be performed by a machine, thereby achieving an integrated automated operation of winding and involution.

In the preferred embodiment of the present invention, the first magnetic core 111 and the second magnetic core 112 are U-shaped magnetic cores. In other embodiments, the first and second magnetic cores 111 and 112 are not limited to the shapes shown in the drawings of the present invention, and may have other shapes, such that the first and second magnetic cores 111 and 112 may be combined to form a ring structure.

The method for manufacturing the inductor of the utility model respectively carries out the solenoid winding on the two magnetic cores forming the inductor, and can adopt the automatic winding in the winding step, thereby simplifying the production process, greatly improving the production efficiency and reducing the manufacturing cost; increasing the regularity of the arrangement of the coils makes the arrangement of the coils more compact, thereby reducing the parasitic parameter losses of the coils and reducing the size of the inductor.

The utility model discloses the manufacturing method of inductor carries out continuous solenoid coiling to two magnetic cores of constituteing the inductor to will wind two magnetic cores of good coil and to closing the concatenation in order to form required toroidal inductor. The utility model discloses a manufacturing method of inductor can adopt automatic coiler to simplify production technology and improve the arrangement regularity of solenoid, compares with traditional manual or semi-automatic coiling method, and the coiling speed can improve by a wide margin, has avoided the shortcoming of inefficiency, the uniformity difference of manual coiling, can accomplish high-efficient and carry out the coiling steadily, is fit for mass production.

In addition, at high frequencies, many electronic components have parasitic parameters that slow the operating speed of the circuit, change the frequency response, and create energy losses known as parasitic losses. Compare with traditional manual or semi-automatic coiling method, the utility model discloses a manufacturing method of inductor adopts the machine to realize the automation of whole flow, and the inductor of producing still has the coil and arranges closely even, advantage that the regularity is high to can further reduce the parasitic parameter of solenoid, make the parasitic loss of inductor diminish. Meanwhile, the coil winding space can be saved due to the high arrangement regularity of the coils, so that the size of the inductor is reduced.

Although the present invention has been described with reference to the present specific embodiments, it will be understood by those skilled in the art that the above embodiments are merely illustrative of the present invention, and various equivalent changes and substitutions may be made without departing from the spirit of the present invention, and therefore, changes and modifications to the above embodiments within the spirit of the present invention will fall within the scope of the claims of the present application.

Claims (6)

1. An inductor, comprising:

the annular magnetic core comprises a first magnetic core and a second magnetic core which are oppositely combined, wherein the first magnetic core is provided with a first winding area, and the second magnetic core is provided with a second winding area; and

and the coil is formed by winding a conducting wire which is continuously wound in the first winding area and the second winding area.

2. The inductor of claim 1, wherein the first winding area and the second winding area are coated with an insulating material.

3. The inductor of claim 1, wherein the first magnetic core has a first mating zone and the second magnetic core has a second mating zone, the first and second magnetic cores being mated by the first and second mating zones.

4. The inductor of claim 1, wherein the first and second magnetic cores are U-shaped magnetic cores.

5. The inductor of claim 1, wherein the coil comprises a plurality of layers of wire wound around the first winding area and the second winding area.

6. The inductor of claim 5, wherein the number of layers of the multilayer wire is 2 or 3.

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