CN103680861A - Flat coil inductor, flat coil and manufacture method of flat coil - Google Patents
Flat coil inductor, flat coil and manufacture method of flat coil Download PDFInfo
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- CN103680861A CN103680861A CN201310609092.9A CN201310609092A CN103680861A CN 103680861 A CN103680861 A CN 103680861A CN 201310609092 A CN201310609092 A CN 201310609092A CN 103680861 A CN103680861 A CN 103680861A
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Abstract
The invention discloses a flat coil inductor, a flat coil and a manufacture method of the flat coil. The flat coil inductor comprises a magnetic core, a magnetic cover covering the magnetic core and the flat coil coiled on the magnetic core, wherein the magnetic core is provided with, at least, a first groove and a second groove. The flat coil comprises, at least, the top end base portion and two side edge flattening portions, wherein the base portion is larger than the side edge flattening portions in thickness, the side edge flattening portions are larger than the base portion in width, the base portion is embedded into the first groove, and the side edge flattening portions are embedded into the second groove. The side edge flattening portions are formed by locally flattening the flat coil of the inductor, so that different thicknesses are obtained, the side edge flattening portions are larger than the base portion in width but are smaller than the base portion in thickness, and a magnetic core accommodating space defined by the flat coil is increased. The magnetic core can be matched and assembled with a large corresponding magnetic core, so that the direct-current resistance of the inductor in a limited size range is decreased, the saturation current is increased, and the inductor can obtain the best electrical characteristics.
Description
Technical field
The present invention relates to inductor art, refer in particular to the manufacture method of a kind of flatwise coil inductor, flatwise coil and flatwise coil.
Background technology
Current inductor generally comprises magnetic core and coil, and coil winding, on magnetic core, when electric current flows through, wherein can be full of magnetic energy, and when electric current diminishes, the magnetic energy in coil can produce one strength, stops curent change.It has wide range of applications, and comprises server, work station, power supply unit, monitor, switch, motherboard, scanner, telephone set, modulator-demodulator etc.
Ye You producer substitutes original coil turning to wire with flatwise coil on the market now.When producing flatwise coil, choose the thin flat sheet of metal that electric conductivity is good, be wound on magnetic core and form.Due to the size restrictions of inductor, the width of flatwise coil cannot be done widely, makes the space of accommodating magnetic core in flatwise coil less, cannot reach the electrical characteristic of low D.C. resistance, high saturation current.
Summary of the invention
In view of this, the present invention is directed to the disappearance of prior art existence, its main purpose is to provide a kind of flatwise coil inductor, can in limited size range, make inductor reach the characteristic of low D.C. resistance and high saturation current.
For achieving the above object, the present invention adopts following technical scheme:
A kind of flatwise coil of inductor, this flatwise coil at least comprises that a top base portion and dual-side flatten portion, the thickness of this base portion is greater than the thickness that side is flattened portion, and the width that side is flattened portion is greater than the width of base portion, by this base portion, the dual-side portion of flattening, encloses the space that forms accommodating magnetic core.
Preferably, the lower ora terminalis that described dual-side is flattened portion inwardly turnover extends to form base and flattens portion, and it is identical or thinner that the thickness that the thickness of portion flattens portion with dual-side is flattened on this base, and the width that portion is flattened on base is less than the width that dual-side is flattened portion.
A kind of flatwise coil inductor, include magnetic core, be covered on the magnetic lid of magnetic core top and be wound on the flatwise coil on magnetic core, this magnetic core is at least provided with the first groove and in both sides, is provided with the second groove at top, this flatwise coil at least comprises top base portion, dual-side is flattened portion, the thickness of this base portion is greater than the thickness that side is flattened portion, the width that side is flattened portion is greater than the width of base portion, base portion is embedded in the first groove between magnetic core and magnetic lid, the dual-side portion of flattening is embedded in the second groove of magnetic core both sides, by base portion and the dual-side portion of flattening, enclose the space that forms accommodating magnetic core.
Preferably, the lower ora terminalis that the dual-side of described flatwise coil is flattened portion inwardly turnover extends to form base and flattens portion, the thickness that portion is flattened on this base and dual-side flatten that the thickness of portion is identical or than dual-side, to flatten the thickness of portion thinner, the width that portion is flattened on base is less than the width that side is flattened portion, the magnetic core two bottom sides of correspondence the 3rd groove of stepping down out, this base portion of flattening is accommodated in the 3rd groove.
Preferably, the width that portion is flattened on the base of described flatwise coil is greater than the width of base portion.
Preferably, the end face of described base portion flushes with magnetic core end face or is lower than magnetic core end face, and dual-side flattens the lateral surface of portion and two relative lateral surfaces of magnetic core flush, and the bottom surface of portion is flattened on base and the bottom surface of magnetic core flushes or higher than the bottom surface of magnetic core.
A manufacture method for the flatwise coil of inductor, comprises the following steps
(1) select a thin flat sheet of metal, on sheet metal, at least define base portion and flatten portion's two parts with pre-side;
(2) at the pre-side of thin flat sheet of metal both sides, flatten portion's upper end blank to certain depth, make the side at two ends flatten portion's attenuation, then in the position of blank mouth, turn down downwards;
(3) the pre-side portion of flattening is flattened and form side and flatten portion, the width that reprocessing side is flattened portion is less than the thickness of base portion to the thickness that is more than or equal to base widths and side and flattens portion.
Preferably, in step (3), the dual-side of described flatwise coil is flattened portion needs corner location to carry out grinding process after flattening.
Preferably, in step (1), the pre-side of described thin flat sheet of metal is flattened portion's end and is further defined pre-base and flatten portion, when completing, the side portion of flattening flattens after processing, the first blank of upper surface of portion is flattened to certain depth in this pre-base, more inwardly turns down to such an extent that to base, flatten portion in the position of blank mouth.
Preferably, the described base portion of flattening further flattens, and it is identical or flatten width thinner, that portion is flattened on base and be less than side and flatten the width that the width of portion and width that portion is flattened on base are greater than base portion that the thickness that portion is flattened on base and side are flattened the thickness of portion.
The present invention compared with prior art has obvious advantage and beneficial effect, particularly, as shown from the above technical solution, in the situation that not changing original inductor size size, formation side is flattened in the flatwise coil part of inductor and flatten portion, to obtain different thickness, the width that makes side flatten portion is greater than the width of base portion, thickness is less than the thickness of base portion, thereby the space that is enclosed accommodating magnetic core by flatwise coil becomes large, coordinate assembling with corresponding larger magnetic core, make to diminish at the D.C. resistance of limited size range internal inductance device, it is large that saturation current becomes, therefore make inductor obtain best electrical characteristic.
And in producing the method for flatwise coil, before the side portion of flattening turns down, first pre-side is flattened to portion's blank to process, make pre-side flatten portion's attenuation, convenient turnover processing; In like manner, before the base portion of flattening turnover, also first the pre-base portion of flattening is carried out to blank, can more convenient turnover processing, making flatwise coil after turnover, whole the lines flow smoothly, without interference problem.In addition, when the side portion of flattening, flatten/flatten after processing, further corner location is carried out to grinding process, can make the side portion of flattening become upright, and size is identical with the second groove.
For more clearly setting forth architectural feature of the present invention and effect, below in conjunction with accompanying drawing and specific embodiment, the present invention is described in detail.
Accompanying drawing explanation
Fig. 1 is the exploded view of the first embodiment of the present invention, and the flatwise coil in figure is not yet affixed in the second groove;
Fig. 2 is the assembled state figure of Fig. 1;
Fig. 3 is the assembling finished figure of the first embodiment of the present invention, and the flatwise coil in figure has been affixed in the second groove;
Fig. 4 is the bottom schematic view of Fig. 3;
Fig. 5 is the exploded view of Fig. 3;
Fig. 6 is flatwise coil the first production stage schematic diagram of the first embodiment of the present invention;
Fig. 7 is flatwise coil the second production stage schematic diagram of the first embodiment of the present invention;
Fig. 8 is flatwise coil the 3rd production stage schematic diagram of the first embodiment of the present invention;
Fig. 9 is flatwise coil the 4th production stage schematic diagram of the first embodiment of the present invention;
Figure 10 is the flatwise coil finished product front view of the first embodiment of the present invention;
Figure 11 is the flatwise coil finished product stereogram of the first embodiment of the present invention;
Figure 12 is the assembling finished figure of the second embodiment of the present invention;
Figure 13 is the exploded view of Figure 12;
Figure 14 is the assembling finished figure of the present invention's the 3rd embodiment;
Figure 15 is the exploded view of Figure 14.
Accompanying drawing identifier declaration:
10, magnetic core 11, the first groove
12, the second groove 13, the 3rd groove
20, Ci Gai
30, flatwise coil 31, base portion
32, side flatten portion 32 ', pre-side flattens portion
321 ', blank 322 ', polishing
33, base flatten portion 33 ', pre-base flattens portion.
Embodiment
Please refer to shown in Fig. 1 to Fig. 5, it has demonstrated the concrete structure of the first embodiment of the present invention, and this flatwise coil inductor includes magnetic core 10, magnetic lid 20 and flatwise coil 30.
Wherein, this magnetic core 10 is provided with the first groove 11, is provided with the second groove 12 in both sides, in bottom, is provided with the 3rd groove 13 at top.This magnetic lid 20 is covered on magnetic core 10 tops.
This flatwise coil 30 selects pure copper material to make, it is wound on magnetic core 10, this flatwise coil 30 comprises that top base portion 31, dual-side are flattened portion 32 and portion 33 is flattened on beneath base, this base flatten portion 33 be by dual-side, flatten portion 32 lower ora terminalis inwardly turnover extend to form or flatten for the second time thinner.This base portion 31 is embedded in the first groove 11 between magnetic core 10 and magnetic lid 20, dual-side is flattened in the second groove 12 that portion 32 is embedded in magnetic core 10 both sides, this base is flattened portion 33 and is accommodated in the 3rd groove 13, the end face of described base portion 31 is flushed or more lower slightly than magnetic core 10 end faces with magnetic core 10 end faces, dual-side flattens the lateral surface of portion 32 and the relative lateral surface of magnetic core 10 flushes, and base is flattened that the bottom surface of portion 33 and the bottom surface of magnetic core 10 flush or be slightly higher than the bottom surface of magnetic core 10.
The thickness D1 of this base portion 31 is greater than the thickness D2 that side is flattened portion 32, the thickness D3 that portion 33 is flattened on this base and side flatten that the thickness D2 of portion 32 is identical or than side, to flatten the thickness D2 of portion 32 thinner, and dual-side flattens the width W 2 of portion 32 and be greater than base and flatten the width W 3 of portion 33 and the width W 1 of base portion 31, and the base width W 3 of flattening portion 33 is greater than the width W 1 of base portion 31.In the situation that keeping original inductor overall dimension constant, this width that dual-side is flattened to portion 32 broadens, make area become large, the area change that one side side is flattened portion 32 makes greatly D.C. resistance diminish, the space that makes on the other hand flatwise coil 30 enclose the accommodating magnetic core 10 of formation becomes large, thereby can hold larger magnetic core 10, make saturation current become large, so inductor obtain best electrical characteristic.
As shown in Fig. 6-11, it has shown the manufacture method of above-mentioned flatwise coil 30, and moulding flatwise coil 30 comprises the following steps:
One, as shown in Figure 6, first select a thin flat sheet of metal, on sheet metal, define base portion 31, pre-side flatten portion 32 ' and pre-base flatten portion's 33 ' tri-parts;
Two, as shown in Figure 7, then the pre-side of thin flat sheet of metal both sides flatten portion 32 ' and pre-base flatten portion's 33 ' upper end blank 321 ' to certain depth, make the side at two ends flatten portion's 32 attenuation, thereby the thickness D1 of base portion 31 is greater than the thickness D2 ' at two ends;
Three, as shown in Figure 8, then at the position downward bending of blank 321 ' mouth; Finally pre-side is flattened to portion 32 ' flatten and formed side and flatten portion 32, the width W 2 that makes side flatten portion 32 is greater than base portion 31 width W 1 and side and flattens the thickness D1 that the thickness D2 of portion 32 is less than base portion 31.It is pointed out that pre-side flatten portion 32 ' thickness D2 ' (be blank 321 ' after thickness D2 ') be greater than the thickness D2 that side is flattened portion 32, after flattening processing, obtains side and flatten portion 32, and the width W after flattening 2 is greater than W1.In addition, the dual-side of described flatwise coil 30 is flattened portion 32 after flattening, and need to polish 322 to corner location ' process, and make side flatten portion 32 and become upright, and size is identical with the second groove 12.
Four, as Figure 8-9, because needs are flattened portion 33 ' further turn down to pre-base, therefore portion 33 ' need before turnover blank 321 ' to certain depth is flattened on this pre-base, in the position of blank 321 ' mouth, inwardly turn down again, to form base, flatten portion 33, can be accommodated in the 3rd groove 13 of magnetic core 10 bottoms.
Five, portion 33 is flattened in base and further flatten, make thickness that base flattens portion 33 and side flatten the thickness of portion 32 identical or flatten width thinner, that portion 33 is flattened on base and be less than side and flatten the width that the width of portion 32 and width that portion 33 is flattened on base are greater than base portion 31.
In addition, while manufacturing a finished product, also need punching press sinter molding to go out magnetic core 10 and magnetic lid 20, the base portion of flatwise coil 30 31 is installed in first groove 11 at magnetic core 10 tops, the side of both sides is flattened in the second groove 12 that portion 32 is flush-mounted in magnetic core 10 both sides, finally magnetic lid 20 is covered on to magnetic core 10 tops, just obtains finished product.
As shown in Figure 12,13, it has demonstrated the concrete structure of the second embodiment of the present invention, flatwise coil inductor structure, method and the first embodiment of this second embodiment are basic identical, difference is to save the structure that portion 33 is flattened on base, therefore, at corresponding the 3rd groove 13 that omits in the bottom of magnetic core 10, and when producing flatwise coil 30, omit the making step that portion 33 is flattened on base.In the present embodiment, even if save the structure that portion 33 is flattened on base, but base portion 31 and dual-side by flatwise coil 30 are flattened the space that portion 32 is enough to enclose the inner accommodating magnetic core 10 of shaping, also the area that the design of flattening portion 32 by dual-side also can reach the space that makes accommodating magnetic core 10 becomes large effect, thereby can accommodating larger magnetic core 10, realize D.C. resistance and diminish, saturation current becomes large object.
As shown in Figure 14,15, it has demonstrated the concrete structure of the present invention's the 3rd embodiment, flatwise coil inductor structure, method and the first embodiment of this 3rd embodiment are basic identical, difference is, in machining flat coil 30 processes, opposite side flattens portion 32 and polishes 322 ' while processing, side may be flattened to all polishings 322 of portion's 32 both sides widened sections ' fall, the width that makes side flatten portion 32 equates with the width of base portion 31, and the width that portion 33 is flattened on base also equates with the width of base portion 31.
In sum, design focal point of the present invention is, formation side is flattened in the flatwise coil of inductor 30 parts and flatten portion 32, to obtain different thickness, the width that makes side flatten portion 32 is greater than the width of base portion, thickness is less than the thickness of base portion 31, like this, side is flattened portion 32 and is obtained larger area, thereby the space that is enclosed accommodating magnetic core 10 by flatwise coil 30 becomes large, coordinate assembling with corresponding larger magnetic core 10, make to diminish at the D.C. resistance of limited size range internal inductance device, it is large that saturation current becomes, therefore make inductor obtain best electrical characteristic.
And in producing the method for flatwise coil 30, when turnover side, flatten before portion 32, first pre-side is flattened to portion's 32 carry out ' blanks 321 ' processing, make pre-side flatten portion's 32 ' attenuation, convenient turnover processing; In like manner, on turnover base, flatten before portion 33, also first to pre-base flatten portion 33 ' carry out blank 321 ', can more convenient turnover processing, making flatwise coil 30 after turnover, whole the lines flow smoothly, without interference problem.In addition, when side, flatten portion 32 and flatten/flatten after processing, further to corner location polish 322 ' process, can make side flatten portion 32 and become upright, and size is identical with the second groove 12.
The above, it is only preferred embodiment of the present invention, not technical scope of the present invention is imposed any restrictions, therefore any trickle modification, equivalent variations and modification that every foundation technical spirit of the present invention is done above embodiment all still belong in the scope of technical solution of the present invention.
Claims (10)
1. the flatwise coil of an inductor, it is characterized in that: this flatwise coil at least comprises that a top base portion and dual-side flatten portion, the thickness of this base portion is greater than the thickness that side is flattened portion, the width that side is flattened portion is greater than the width of base portion, by this base portion, the dual-side portion of flattening, encloses the space that forms accommodating magnetic core.
2. the flatwise coil of inductor according to claim 1, it is characterized in that: the lower ora terminalis that described dual-side is flattened portion inwardly turnover extends to form base and flattens portion, the thickness that portion is flattened on this base and dual-side flatten that the thickness of portion is identical or than dual-side, to flatten the thickness of portion thinner, and the width that portion is flattened on base is less than the width that dual-side is flattened portion.
3. a flatwise coil inductor, include magnetic core, be covered on the magnetic lid of magnetic core top and be wound on the flatwise coil on magnetic core, this magnetic core is at least provided with the first groove and in both sides, is provided with the second groove at top, it is characterized in that: this flatwise coil at least comprises top base portion, dual-side is flattened portion, the thickness of this base portion is greater than the thickness that side is flattened portion, the width that side is flattened portion is greater than the width of base portion, base portion is embedded in the first groove between magnetic core and magnetic lid, the dual-side portion of flattening is embedded in the second groove of magnetic core both sides, by base portion and the dual-side portion of flattening, enclose the space that forms accommodating magnetic core.
4. flatwise coil inductor according to claim 3, it is characterized in that: the lower ora terminalis that the dual-side of described flatwise coil is flattened portion inwardly turnover extends to form base and flattens portion, the thickness that portion is flattened on this base and dual-side flatten that the thickness of portion is identical or than dual-side, to flatten the thickness of portion thinner, the width that portion is flattened on base is less than the width that side is flattened portion, the magnetic core two bottom sides of correspondence the 3rd groove of stepping down out, this base portion of flattening is accommodated in the 3rd groove.
5. flatwise coil inductor according to claim 4, is characterized in that: the width that portion is flattened on the base of described flatwise coil is greater than the width of base portion.
6. flatwise coil inductor according to claim 4, it is characterized in that: the end face of described base portion flushes with magnetic core end face or be lower than magnetic core end face, dual-side flattens the lateral surface of portion and two relative lateral surfaces of magnetic core flush, and the bottom surface of portion is flattened on base and the bottom surface of magnetic core flushes or higher than the bottom surface of magnetic core.
7. a manufacture method for the flatwise coil of inductor, is characterized in that: comprise the following steps
(1) select a thin flat sheet of metal, on sheet metal, at least define base portion and flatten portion's two parts with pre-side;
(2) at the pre-side of thin flat sheet of metal both sides, flatten portion's upper end blank to certain depth, make the side at two ends flatten portion's attenuation, then in the position of blank mouth, turn down downwards;
(3) the pre-side portion of flattening is flattened and form side and flatten portion, the width that reprocessing side is flattened portion is less than the thickness of base portion to the thickness that is more than or equal to base widths and side and flattens portion.
8. the manufacture method of flatwise coil inductor according to claim 7, is characterized in that: in step (3), the dual-side of described flatwise coil is flattened portion needs corner location to carry out grinding process after flattening.
9. the manufacture method of flatwise coil inductor according to claim 7, it is characterized in that: in step (1), the pre-side of described thin flat sheet of metal is flattened portion's end and is further defined pre-base and flatten portion, when completing, the side portion of flattening flattens after processing, the first blank of upper surface of portion is flattened to certain depth in this pre-base, more inwardly turns down to such an extent that to base, flatten portion in the position of blank mouth.
10. the manufacture method of flatwise coil inductor according to claim 9, it is characterized in that: the described base portion of flattening further flattens, it is identical or flatten width thinner, that portion is flattened on base and be less than side and flatten the width that the width of portion and width that portion is flattened on base are greater than base portion that the thickness that portion is flattened on base and side are flattened the thickness of portion.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201310609092.9A CN103680861B (en) | 2013-11-27 | The manufacture method of flatwise coil inducer, flatwise coil and flatwise coil |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201310609092.9A CN103680861B (en) | 2013-11-27 | The manufacture method of flatwise coil inducer, flatwise coil and flatwise coil |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN103680861A true CN103680861A (en) | 2014-03-26 |
| CN103680861B CN103680861B (en) | 2016-11-30 |
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| CN106340374A (en) * | 2015-07-10 | 2017-01-18 | 脉冲电子股份有限公司 | Step gap inductor apparatus and methods |
| CN107068331A (en) * | 2015-12-21 | 2017-08-18 | 英飞凌科技奥地利有限公司 | For the surface mounting inductor being placed on the power stage of power converter |
| CN107546000A (en) * | 2017-09-08 | 2018-01-05 | 遂宁普思电子有限公司 | Inductor |
| US10333407B2 (en) | 2015-05-06 | 2019-06-25 | Infineon Technologies Austria Ag | Power stage packages of a multi-phase DC-DC converter under a coupled inductor |
| CN113053636A (en) * | 2021-03-15 | 2021-06-29 | 墨尚电子技术(上海)有限公司 | Large-current surface-mounted power inductor and manufacturing method thereof |
| US11049638B2 (en) | 2016-08-31 | 2021-06-29 | Vishay Dale Electronics, Llc | Inductor having high current coil with low direct current resistance |
| US11283356B2 (en) | 2015-05-29 | 2022-03-22 | Infineon Technologies North America Corp. | Method of assembling a DC-DC converter |
| US11948724B2 (en) | 2021-06-18 | 2024-04-02 | Vishay Dale Electronics, Llc | Method for making a multi-thickness electro-magnetic device |
| USD1034462S1 (en) | 2021-03-01 | 2024-07-09 | Vishay Dale Electronics, Llc | Inductor package |
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Cited By (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US10333407B2 (en) | 2015-05-06 | 2019-06-25 | Infineon Technologies Austria Ag | Power stage packages of a multi-phase DC-DC converter under a coupled inductor |
| US11283356B2 (en) | 2015-05-29 | 2022-03-22 | Infineon Technologies North America Corp. | Method of assembling a DC-DC converter |
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| US11049638B2 (en) | 2016-08-31 | 2021-06-29 | Vishay Dale Electronics, Llc | Inductor having high current coil with low direct current resistance |
| US11875926B2 (en) | 2016-08-31 | 2024-01-16 | Vishay Dale Electronics, Llc | Inductor having high current coil with low direct current resistance |
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| USD1034462S1 (en) | 2021-03-01 | 2024-07-09 | Vishay Dale Electronics, Llc | Inductor package |
| CN113053636A (en) * | 2021-03-15 | 2021-06-29 | 墨尚电子技术(上海)有限公司 | Large-current surface-mounted power inductor and manufacturing method thereof |
| US11948724B2 (en) | 2021-06-18 | 2024-04-02 | Vishay Dale Electronics, Llc | Method for making a multi-thickness electro-magnetic device |
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