CN114639533A - Novel coupling inductor structure design and manufacturing method thereof - Google Patents

Abstract

The invention discloses a novel coupling inductor structure which comprises a coil winding, a hardware material belt and a soft magnetic body, wherein the coil winding comprises a first coil and a second coil, the first coil and the second coil are wound in a parallel winding mode in a double-wire mode, the first coil, the second coil and the hardware material belt are welded, the soft magnetic body is coated on the outer side of the coil winding, and the soft magnetic body is made of a soft magnetic composite material with the magnetic conductivity of 15-120 and is formed by adopting heat transfer molding. In the invention, automation is easy to realize through the manufacturing forms of the coil and the hardware; the magnet adopts a transfer molding process, the molding pressure is less than 20Mpa, the deformation caused by overlarge stress of the coil can be avoided, and the problem of open and short circuit is effectively solved; the magnetic composite material for transfer molding leads the magnetic conductivity to be uniform, and the magnetic conductivity of the formed magnet is uniform and consistent and has small leakage inductance; the whole scheme can realize automatic production, and the product is hot stable, and the quality reliability is high.

Description

A new type of coupled inductor structure design and its manufacturing method

technical field

The invention relates to a novel coupled inductor structure design and a manufacturing method thereof.

Background technique

With the rapid development of the information technology industry, industry, manufacturing industry, and electronics industry, the requirements for inductors in components are getting higher and higher. The failure rate of the corresponding device is raised to the ppm level, and the characteristic stability of the product requires little batch-to-batch variation. At present, the structures of the coupled inductors currently manufactured and sold in large quantities are as follows:

Traditional magnetic surround wire structure:

At present, this type of structure is difficult to automate in winding and hanging. At present, it is basically carried out in a semi-manual way, which is inefficient. At the same time, it requires additional base or case to make SMD devices, which is bulky and takes up more PCB space;

DR magnetic core+sleeve magnetic sleeve+hardware or plastic parts structure:

This structure has poor precision in the control of the assembly gap of the two magnetic cores, and the product has poor characteristic stability. At the same time, because the assembly gap is equivalent to an air gap, the leakage inductance of the product is large and the coupling coefficient is relatively small;

NR core coating structure:

The main problem with this structure is that the relative permeability of the coating layer is low, only 3-5. The leakage inductance of the product is large, and the coupling coefficient is relatively small;

Traditional dry powder integrated pressing structure:

The dry powder molding structure of this type of structure has a large molding pressure, which is easy to cause deformation of the coil and thus cause the problem of open and short circuit.

SUMMARY OF THE INVENTION

To sum up, the above problems are the above problems existing in the existing coupled inductance structure. In order to effectively solve the above problems, the present invention provides a new type of coupled inductance that can be easily automated and has small leakage inductance or magnetic leakage and high quality stability. Structural design and method of manufacture.

In order to achieve the above object, the present invention adopts the following technical solutions:

A novel coupled inductor structure includes a coil winding, a metal strip and a soft magnetic magnet, the coil winding includes a first coil and a second coil, and the first coil and the second coil are double-wound in parallel, and the first coil and the The second coil is welded with the metal material strip, and the soft magnetic magnet is wrapped on the outer side of the coil winding.

As a further description of the above technical solution:

The soft magnetic magnet adopts a soft magnetic composite material with a magnetic permeability of 15-120, and the soft magnetic composite material is mainly a spherical powder of a soft magnetic magnetic material and a thermosetting binder, and the soft magnetic composite material can be subjected to heat transfer molding. forming.

As a further description of the above technical solution:

The stable outer wall of the metal strip is provided with an outer electrode formed by mechanical treatment.

As a further description of the above technical solution:

A method for manufacturing a novel coupled inductor, comprising the following steps:

Step 1: The first coil and the second coil are formed into a coil winding with a high coupling coefficient by means of two-wire parallel winding;

Step 2: Weld the four leads of the first coil and the second coil and the corresponding four welding points on the metal tape to realize electrical connection and mechanical connection;

Step 3: place the coil winding and the metal tape in the middle of the soft magnetic composite material, process the soft magnetic composite material through a heat transfer molding process, and form the required soft magnetic magnet after curing;

Step 4: The metal material tape is angled to form corresponding external electrodes on the outer surface of the soft magnetic magnet.

The present invention at least has the following beneficial effects:

1) It is easy to realize automation through the manufacturing form of coils and hardware;

2) The magnet adopts the transfer molding process, and the molding pressure is less than 20Mpa, which can avoid the deformation of the coil caused by excessive force, and effectively solve the problem of open and short circuit;

3) The magnetic composite material for transfer molding leads to a uniform magnetic permeability, and the magnetic permeability of the magnet after molding is uniform and the leakage inductance is small;

4) The overall solution can realize automatic production, with stable thermal stability and high quality reliability.

Description of drawings

In order to explain the technical solutions of the embodiments of the present invention more clearly, the following briefly introduces the accompanying drawings used in the description of the embodiments. For those of ordinary skill, other drawings can also be obtained from these drawings without any creative effort.

FIG. 1 shows a structure diagram of a coil winding provided according to an embodiment of the present invention;

FIG. 2 shows a connection diagram of a coil and a material strip provided according to an embodiment of the present invention;

FIG. 3 shows a cladding structure diagram of a soft magnetic magnet provided according to an embodiment of the present invention;

Figure 4 shows an isometric view of an inductor provided in accordance with an embodiment of the present invention.

In the figure: 1, coil winding; 101, first coil; 102, second coil; 2, metal material tape; 201, outer electrode; 3, soft magnetic magnet.

Detailed ways

In order to make the objectives, technical solutions and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention, but not to limit the present invention.

Example 1

1-4, a novel coupled inductor structure includes a coil winding 1, a metal strip 2 and a soft magnetic magnet 3, the coil winding 1 includes a first coil 101 and a second coil 102, and the first coil 101 and the second coil The coil 102 is double-wound, and the first coil 101 and the second coil 102 are welded with the metal strip 2. The stable outer wall of the metal strip 2 is provided with an external electrode 201 formed by mechanical processing. Covered on the outside of the coil winding 1, the soft magnetic magnet 3 is made of a soft magnetic composite material with a magnetic permeability of 15-120, and the soft magnetic composite material is mainly a soft magnetic material spherical powder and a thermosetting binder, such as ferromagnetic ferrite Material powder, iron-based soft magnetic metal material powder, and the soft magnetic composite material can be subjected to heat transfer molding;

A method for manufacturing a novel coupled inductor, comprising the following steps:

Step 1: The first coil 101 and the second coil 102 are formed into a coil winding 1 with a high coupling coefficient by winding two wires in parallel;

Step 2: Welding the four leads of the first coil 101 and the second coil 102 and the corresponding four welding points on the metal tape 2 to realize electrical connection and mechanical connection;

Step 3: Place the coil winding 1 and the metal strip 2 in the middle of the soft magnetic composite material, process the soft magnetic composite material through a heat transfer molding process, and form the desired soft magnetic magnet 3 after curing, and use heat transfer molding Manufacturing process, low molding pressure, less damage to coil winding 1 and welding connection points, high reliability, fast production efficiency, and high product quality stability;

Step 4: Corresponding external electrodes 201 are formed on the outer surface of the soft magnetic magnet 3 by the metal material tape 2 through a cornering process.

Working principle: The first coil 101 and the second coil 102 are formed into a coil winding 1 with a high coupling coefficient by double-winding; the four leads of the first coil 101 and the second coil 102 are corresponding The four welding points are welded to realize electrical connection and mechanical connection; the coil winding 1 and the metal strip 2 are placed in the middle of the soft magnetic composite material, and the soft magnetic composite material is processed by a heat transfer molding process and cured. After the required soft magnetic magnet 3 is formed, the heat transfer molding manufacturing process is adopted. The molding pressure is low, and the damage to the coil winding 1 and the welding connection point is small, and the reliability is high, the production efficiency is fast, and the product quality stability is high; Corresponding external electrodes 201 are formed on the outer surface of the soft magnetic magnet 3 by the cornering process.

The foregoing has shown and described the basic principles, main features and advantages of the present invention. It should be understood by those skilled in the art that the present invention is not limited by the above-mentioned embodiments. The above-mentioned embodiments and descriptions describe only the principles of the present invention. Without departing from the spirit and scope of the present invention, there will be various Variations and improvements are intended to fall within the scope of the claimed invention. The scope of protection claimed by the present invention is defined by the appended claims and their equivalents.

Claims (4)

1. A novel coupled inductor structure, characterized in that it comprises a coil winding (1), a metal material tape (2) and a soft magnetic magnet (3), the coil winding (1) comprising a first coil (101) and a first coil (101) and a second coil (101). Two coils (102), and the first coil (101) and the second coil (102) are wound in parallel, and the first coil (101) and the second coil (102) are welded with the metal tape (2), The soft magnetic magnet (3) is wrapped on the outside of the coil winding (1). 2. A novel coupled inductor structure according to claim 1, characterized in that the soft magnetic magnet (3) adopts a soft magnetic composite material with a magnetic permeability of 15-120, and the soft magnetic composite material is mainly soft magnetic Magnetic material spherical powder and thermosetting binder, and the soft magnetic composite material can be subjected to heat transfer molding. 3 . The novel coupled inductor structure according to claim 1 , wherein the stable outer wall of the metal material strip ( 2 ) is provided with an outer electrode ( 201 ) formed by mechanical processing. 4 . 4. a kind of novel coupling inductor manufacturing method according to claim 1, is characterized in that, comprises the steps: Step 1: The first coil (101) and the second coil (102) are formed into a coil winding (1) with a high coupling coefficient by means of two-wire parallel winding; Step 2: Welding the four leads of the first coil (101) and the second coil (102) and the corresponding four welding points on the metal material tape (2) to achieve electrical connection and mechanical connection; Step 3: place the coil winding (1) and the metal material strip (2) in the middle of the soft magnetic composite material, process the soft magnetic composite material through a heat transfer molding process, and form the desired soft magnetic magnet (3) after curing ; Step 4: Corresponding external electrodes (201) are formed on the outer surface of the soft magnetic magnet (3) by the metal material tape (2) through a cornering process.

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