CN110660559A

CN110660559A - Inductor element shell, inductor element and manufacturing method thereof

Info

Publication number: CN110660559A
Application number: CN201910918325.0A
Authority: CN
Inventors: 屈相平; 龚帮辉; 刘金南
Original assignee: Shenzhen Sunlord Electronics Co Ltd
Current assignee: Shenzhen shunluo Automotive Electronics Co., Ltd
Priority date: 2019-09-26
Filing date: 2019-09-26
Publication date: 2020-01-07

Abstract

An inductor element shell comprises a shell body and Pin needles, wherein the Pin needles comprise a plurality of bottom Pin needles and a plurality of side Pin needles, the bottom Pin needles are arranged at the bottom of the shell body, the side Pin needles are arranged on the side faces of the shell body, the bottom Pin needles are used for mounting, and the side Pin needles are used for winding and welding magnetic ring leads. The inductor element shell adopts a side edge winding welding mode to replace the traditional bottom winding welding mode, thereby effectively reducing the processing operation difficulty, solving the problems of thermal damage of a wire insulating layer, tin bead explosion and splashing into the product and the flatness of a patch Pin needle in the processing process, ensuring the voltage resistance characteristic of the product, improving the process yield and reducing the production cost.

Description

Inductor element shell, inductor element and manufacturing method thereof

Technical Field

The invention relates to an inductor element housing, an inductor element and a manufacturing method thereof.

Background

The inductor element has the function of passing direct current and blocking alternating current, the structure is diversified, and the inductor element can be formed by forming a loop by using conductive materials such as coils. The coil of the inductor element has one winding and also has a plurality of windings. In a broad sense, a structure having a plurality of windings such as a common mode choke, a low power isolation transformer, or the like may also be referred to as an inductor element.

The network transformer is a relatively typical inductor element, which is also called data mercury, and is mainly used in various ethernet devices, such as high-performance digital switches, routers, servers and other digital devices. The network transformer mainly has the functions of signal transmission, impedance matching, waveform restoration, signal clutter suppression, high voltage isolation and the like.

The network transformer module is an indispensable part in a network card circuit, the basic composition unit of the network transformer module mainly comprises a pulse transformer, a common mode filter, a middle tap capacitor and an autotransformer, one Side of the network transformer connected with an IC end is called a Physical Side (Physical Side), and one end of the network transformer contacted with an external data line is called a Cable Side (Cable Side). The network transformer in the ethernet device has the following functions: firstly, transmitting data, namely transmitting a signal transmitted from a data line end to an equipment IC end in a coupling mode; secondly, high-voltage isolation is carried out, so that the IC end of the equipment is isolated from the outside, the equipment IC is prevented from being damaged by surge or thunder, and the anti-interference capability is enhanced; voltage matching, namely, the levels transmitted from the data line ends are different, and the levels are isolated by using a network transformer without influencing equipment ICs (integrated circuits); and fourthly, signal clutter is suppressed, and a common mode filter in the network transformer can filter clutter common mode signals and improve signal quality.

The traditional network transformer shell is also divided into a shell and Pin needles, wherein the Pin needles are divided into a bottom Pin needle and a side Pin needle, a groove is formed in a cylinder of the bottom Pin needle, an enameled wire is wound on the groove and then welded and fixed, and the side Pin needle is bent into a gull wing shape and used for customer mounting. However, the shell is complex in production process and fine in operation. The head of the lead of the magnetic ring needs high-temperature tin immersion to remove the insulating layer on the surface of the copper wire, the requirement of the removal position is kept consistent, and the tin immersion of a plurality of leads needs to avoid mutual tin connection. The length from a depainting point of a lead of the magnetic ring to a Pin foot at the bottom needs to be reasonably controlled, the lead is difficult to arrange and the DCR is increased due to overlong lead accumulation, and the magnetic ring is pulled up and suspended due to overlong lead accumulation, so that the disconnection is easily caused. And (3) clamping the lead wire by adopting a tool with a smooth surface for winding, wherein the lead wire wound on the Pin needle needs to be tightly bound, otherwise the lead wire is easy to scatter. Because of the tin soldering at the bottom, the soldering flux explodes and cracks to cause tin balls to enter the product, and the enameled wire insulating film is easy to be damaged by heat radiation in the soldering process. The gull-wing type Pin needle is long in whole, is difficult to avoid touch stress in the production process, and is easy to cause poor coplanarity. In a word, the traditional network transformer shell is adopted for production, time and labor are wasted, the processing cost is high, and poor electrical performance is easy to occur.

Therefore, how to improve the structure and the production process flow of the inductor element and improve the production efficiency and the product quality of the inductor element is a problem to be solved urgently in the industry.

The above background disclosure is only for the purpose of assisting understanding of the concept and technical solution of the present invention, and is not prior art to the present patent application, and should not be used for evaluating the novelty and inventive step of the present application in the case that there is no clear evidence that the above content is disclosed at the filing date of the present patent application.

Disclosure of Invention

The invention mainly aims to provide an inductor element shell, an inductor element and a manufacturing method thereof, and aims to solve the series of technical problems of complex process flow, low production efficiency and product consistency and the like in the prior art.

In order to achieve the purpose, the invention adopts the following technical scheme:

an inductor element shell comprises a shell body and Pin needles, wherein the Pin needles comprise a plurality of bottom Pin needles and a plurality of side Pin needles, the bottom Pin needles are arranged at the bottom of the shell body, the side Pin needles are arranged on the side faces of the shell body, the bottom Pin needles are used for mounting, and the side Pin needles are used for winding and welding magnetic ring leads.

Further:

the side surface Pin needles are opposite to the bottom surface Pin needles in the vertical direction one by one.

The side surface Pin needle and the bottom surface Pin needle are staggered from each other in the vertical direction.

The Pin needles on the side surfaces are all positioned on the same horizontal plane.

The side Pin needles are not all in the same horizontal plane.

The side surface Pin needles and the bottom surface Pin needles are communicated in the shell in a one-to-one correspondence mode.

The bottom of the shell is provided with wire passing grooves, the number and the positions of the wire passing grooves correspond to the Pin needles on the side faces, and arc chamfers are arranged on the inner side and the outer side of each wire passing groove and used for protecting an insulating paint film of a lead from being damaged when the lead of the magnetic ring is hung.

The side Pin needle is provided with a groove for guiding and limiting when the enameled wire is wound, and the groove is preferably an arc-shaped groove.

An inductor component is provided with the inductor component shell.

A method of manufacturing an inductor element, comprising the steps of:

winding on the magnetic material to form a coil as required to form a magnetic ring, and pre-soaking in insulating paint or silica gel;

arranging the magnetic ring in the inductor element shell, branching, and winding a lead of the magnetic ring onto a corresponding side Pin needle through a wire slot;

conducting soldering tin conduction on the lead wound on the Pin needle on the side face, and preferably cutting off redundant parts of the lead before conducting soldering tin conduction;

preferably, insulating paint or silica gel is also dispensed for magnetic ring fixation.

The invention has the following beneficial effects:

the invention provides an inductor element shell and a manufacturing method thereof, wherein the inductor element shell comprises a shell body and Pin needles, the Pin needles are respectively arranged at the bottom and the side surfaces of the shell body, the bottom Pin needle is used for mounting, and the side surface Pin needle is used for lead wire winding welding. The inductor element shell provided by the invention adopts a side winding welding mode to replace the traditional bottom winding welding mode, so that the processing operation difficulty is effectively reduced, the problems that a wire insulating layer is easily subjected to thermal damage, tin beads are cracked and splashed into a product and the flatness of a patch Pin needle is easily caused in the processing process are solved, the voltage-resistant characteristic of the product is ensured, the processing yield is improved, and the production cost is reduced.

Drawings

Fig. 1 is a front view of an inductor element assembly bobbin in example 1.

Fig. 2 is a left side view of an inductor element assembling cord semi-finished product in embodiment 1.

Fig. 3 is a bottom view of a semi-finished inductor element assembling bobbin in example 1.

Fig. 4 is a perspective view of an inductor element case in embodiment 1.

Fig. 5 is a front view of an inductor element assembly bobbin in example 2.

Fig. 6 is a bottom view of an inductor element assembly bobbin in example 2.

Reference numerals:

1-shell, 2-bottom Pin needle, 3-side Pin needle, 4-wire groove and 5-groove.

Detailed Description

The embodiments of the present invention will be described in detail below. It should be emphasized that the following description is merely exemplary in nature and is not intended to limit the scope of the invention or its application.

Non-limiting and non-exclusive embodiments will be described with reference to the following figures 1-6, in which like reference numerals refer to like parts, unless otherwise specified.

Referring to fig. 1 to 6, in an embodiment of the present invention, an inductor element housing includes a housing 1 and Pin pins, the Pin pins include a plurality of bottom Pin pins 2 and a plurality of side Pin pins 3, the bottom Pin pins 2 are disposed at the bottom of the housing 1, the side Pin pins 3 are disposed at the sides of the housing 1, wherein the bottom Pin pins 2 are configured for mounting, and the side Pin pins 3 are configured for winding and welding magnetic ring leads.

In different embodiments, the position of the side Pin 3 may be opposite to the bottom Pin 2 (as shown in fig. 6), and the side Pin 3 may be shifted from the bottom Pin 2 to the left or right (as shown in fig. 2-3); the side pins 3 may be in the same horizontal plane (as shown in fig. 5), and some of the side pins 3 may be in an up-and-down staggered position (as shown in fig. 1-2 and 4).

In some embodiments, the side Pin pins 3 and the bottom Pin pins 2 are communicated with each other in a one-to-one correspondence manner inside the housing 1.

In a preferred embodiment, the bottom of the housing 1 is provided with wire passing grooves 4, and the number and positions of the wire passing grooves 4 correspond to the lateral pins 3. The wire passing groove 4 is used for protecting the enameled copper wire from damaging the insulating paint film when the enameled copper wire is hung. Advantageously, the inner side and the outer side of the wire passing groove 4 are both arc-shaped chamfers.

In the preferred embodiment, the Pin 3 on the side is provided with a groove 5, and the groove 5 plays a role in guiding and limiting when used for winding enameled wires. Groove shapes include, but are not limited to, arcs.

In various embodiments, the material of the housing 1 includes, but is not limited to, plastics, such as: bakelite, LCP, and the like; the Pin needle is made of copper material, such as phosphor bronze, red copper, etc.

In another embodiment of the invention, an inductor element has the inductor element housing of any of the previous embodiments.

Embodiments of the present invention also provide methods of manufacturing inductor elements using the inductor element housings of the previous embodiments. In some embodiments, the method may comprise the steps of:

the first step is as follows: winding on the magnetic material to form a coil as required to form a magnetic ring (coil), and pre-soaking insulating paint or silica gel;

the second step is that: the magnetic ring is arranged in a shell 1 of the inductor element shell for branching, and a lead is wound to a Pin needle 3 on the corresponding side surface through a wire slot 4;

the third step: after the coils on the Pin needles 3 on the side surfaces are arranged, redundant parts of the leads are cut off, and then soldering tin conduction is carried out;

the fourth step: and (5) again pointing insulating paint or silica gel for magnetic ring fixation, and finishing the manufacture of the inductor element after the complete solidification and the qualified appearance electrical property inspection.

By adopting the method for manufacturing the inductor element by using the inductor element shell, the production process is simple, the product yield is improved, and the production cost is reduced.

Firstly, the position of a magnetic ring is processed, and then the length of a control lead is wound, so that the lead is ensured to be proper and the position of the magnetic ring is reasonable. And secondly, due to the fact that the Pin needles on part of the side surfaces are staggered up and down, the Pin needles are far away in distance and easy to wind, and the enameled wire in the shell cavity is not scratched by the side winding mode. Thirdly, the Pin needles on the side surfaces are enough in length, the number of winding turns is effectively guaranteed, the sharp cutter is used for cutting off the redundant Pin needles on the side surfaces and the coils, the wire ends are guaranteed not to be scattered, and soldering tin is firm and stable in electrical property. And fourthly, winding the wires on the side for soldering, covering the bottom by using a jig, wherein at the moment of soldering, soldering flux is exploded but tin beads cannot splash into the product, and the insulated film of the enameled wire is not damaged by heat radiation in the soldering process. Fifthly, the bottom patch Pin is short and high in strength, and the clearance is avoided in the machining process, so that the coplanarity consistency of all Pin pins can be well guaranteed. In a word, the inductor element produced by adopting the inductor element shell of the invention can effectively ensure the voltage-resistant characteristic of products, improve the process yield and reduce the production cost.

The first embodiment is as follows:

an inductor component casing as shown in fig. 1 and 4 comprises a shell 1 and Pin needles, wherein the Pin needles are integrally C-shaped and comprise a bottom Pin needle 2 and side Pin needles 3, the bottom Pin needle 2 is arranged at the bottom of the shell 1, the side Pin needles 3 are arranged at the sides of the shell 1, the bottom Pin needle 2 is used for customer mounting, and the side Pin needles 3 are used for winding threads.

As shown in fig. 2, the mounting position of the Pin needle 3 on the side surface is staggered from the position of the Pin needle 2 on the bottom surface, so that the AOI judgment after the customer patches is convenient; and the Pin pins 3 on the side surface move upwards, the taps Pin move upwards, and the rest Pin pins are positioned on the same horizontal plane and used for increasing the distance between the Pin pins and avoiding tin connection during soldering. The bottom of the shell 1 is provided with a wire passing groove 4, the number and the position of the wire passing groove correspond to those of the Pin needles 3 on the side face, and the inner side and the outer side of the wire passing groove 4 are both arc chamfers and used for protecting an insulated paint film from being damaged when an enameled copper wire is hung.

As shown in fig. 3, the side Pin 3 of the inductor element housing 1 is provided with a groove 5, preferably in the shape of an arc, for guiding and limiting the enameled wire. The length of the Pin needle 3 on the side surface is flexible, the Pin needle is adjusted according to needs, the Pin needle is wound for enough circles, after the lead is tightly bound, the redundant lead and the Pin needle are cut off, tin is soldered, and the Pin needle 3 does not exceed the edge of the Pin needle 2 on the bottom after tin soldering.

When the inductor element shell is used for assembling, a magnetic ring which is pre-dipped with insulating paint or silica gel is arranged in a shell 1, the bottom of a strong magnet adsorbs or a soft colloid presses down to fix the magnetic ring, then a head wire and a tail wire of the magnetic ring are threaded from a corresponding thread passing groove 4 and are wound on a Pin needle 3 on the side surface, the coil position on the Pin needle is arranged, redundant Pin needles 3 and coils are cut off, and then a semi-finished inductor element is dipped with tin and soldered to complete the assembling of the inductor element. As such, the structure constitutes a typical network transformer product.

Example two:

as shown in fig. 5 to 6, the inductor element casing includes a casing 1 and Pin needles 2, the Pin needles 2 are C-shaped as a whole, and include bottom Pin needles 2 and side Pin needles 3, the bottom Pin needles 2 are disposed at the bottom of the casing 1, the side Pin needles 3 are disposed at the sides of the casing 1, the bottom Pin needles 2 are used for customer mounting, and the side Pin needles 3 are used for thread winding. The side surface Pin needle 3 is arranged at a position right opposite to the bottom surface Pin needle 2; the Pin needles 3 are arranged on the side surface and are positioned on the same horizontal plane. The bottom of the shell 1 is provided with a wire passing groove 4, the number and the position of the wire passing groove correspond to those of the Pin needles 3 on the side face, and the inner side and the outer side of the wire passing groove 4 are both arc chamfers and used for protecting an insulated paint film from being damaged when an enameled copper wire is hung. The inductor element housing 1 and the side Pin 3 are provided with grooves 5, including but not limited to arcs, for guiding and limiting the enameled wire. The length of the side Pin 3 of the inductor element shell 1 is flexible, the inductor element shell is adjusted according to needs, enough turns are wound firstly, after the lead is tightly bound, redundant lead and the Pin are cut off, tin is soldered, and the Pin 3 does not exceed the edge of the Pin 2 at the bottom after tin soldering.

When the inductor element shell is used for assembling, a magnetic ring which is pre-dipped with insulating paint or silica gel is arranged in a shell 1, the bottom of a strong magnet adsorbs or a soft colloid presses down to fix the magnetic ring, then a head wire and a tail wire of the magnetic ring are threaded from a corresponding thread passing groove 4 and are wound on a Pin needle 3 on the side surface, the coil position on the Pin needle is arranged, redundant Pin needles 3 and coils are cut off, and then a semi-finished inductor element is dipped with tin and soldered to complete the assembling of the inductor element. In this manner, the structure constitutes a typical common mode product.

The foregoing is a more detailed description of the invention in connection with specific/preferred embodiments and is not intended to limit the practice of the invention to those descriptions. It will be apparent to those skilled in the art that various substitutions and modifications can be made to the described embodiments without departing from the spirit of the invention, and these substitutions and modifications should be considered to fall within the scope of the invention.

Claims

1. An inductor element shell comprises a shell body and Pin needles, and is characterized in that the Pin needles comprise a plurality of bottom Pin needles and a plurality of side Pin needles, the bottom Pin needles are arranged at the bottom of the shell body, the side Pin needles are arranged on the side faces of the shell body, the bottom Pin needles are used for mounting, and the side Pin needles are used for winding and welding magnetic ring leads.

2. An inductor element casing as claimed in claim 1, wherein said side Pin and said bottom Pin are opposed to each other in the vertical direction.

3. An inductor element casing as claimed in claim 1, wherein said side Pin and said bottom Pin are vertically displaced from each other.

4. An inductor component casing as claimed in claim 1, wherein said side Pin pins are all in the same horizontal plane.

5. An inductor component casing as claimed in claim 1, wherein said side Pin pins are not all in the same horizontal plane.

6. An inductor element casing according to any one of claims 1 to 5, wherein the side Pin and the bottom Pin are in one-to-one correspondence conduction inside the case.

7. The inductor element shell according to any one of claims 1 to 6, wherein the bottom of the housing is provided with wire slots, the number and positions of the wire slots correspond to the pins on the side surfaces Pin, and the inner and outer sides of the wire slots are provided with arc chamfers for protecting the magnetic ring lead wires from damaging the insulating paint film of the lead wires when the lead wires are hung.

8. An inductor element casing according to any one of claims 1 to 6, characterized in that the pins of the side pins are provided with grooves for guiding and limiting when winding the enameled wire, preferably arc-shaped grooves.

9. An inductor component having an inductor component housing as claimed in any one of claims 1 to 8.

10. A method of manufacturing an inductor element, comprising the steps of:

arranging the magnetic ring in the inductor element shell as claimed in any one of claims 1 to 8, branching, and winding the lead wires of the magnetic ring onto the corresponding side Pin needles through the wire slots;