阅读说明：本技术 一种磁封胶电感及其制造方法 (Magnetic sealing glue inductor and manufacturing method thereof ) 是由 梁水金 于 2020-03-26 设计创作，主要内容包括：本发明涉及电感技术领域,尤其涉及一种磁封胶电感,包括磁芯上摆、磁芯柱、磁芯下摆、漆包线线圈和电极材料,所述磁芯柱固定连接在磁芯上摆顶部的中部,所述磁芯下摆固定连接在磁芯柱的顶部,所述漆包线线圈套接在磁芯柱的外表面,所述磁芯下摆两侧的中部均开设有侧面凹槽,所述漆包线线圈的两端分别通过电极材料与侧面凹槽的电极焊接,还包括一种磁封胶电感的制造方法。该发明在绕线步骤中把漆包线线圈固定在磁芯侧面凹槽中,对于同样尺寸的产品绕线空间增大,从而减少阻抗,增加饱和电流,能耗更低,强度更大,产品性能得到改善,使用寿命增加,同时点焊过程不需要使用助焊剂和清洁剂,节约了资源,并且减少对环境的污染。(The invention relates to the technical field of inductance, in particular to a magnetic seal glue inductor which comprises a magnetic core upper pendulum, a magnetic core column, a magnetic core lower pendulum, an enameled wire coil and an electrode material, wherein the magnetic core column is fixedly connected to the middle of the top of the magnetic core upper pendulum, the magnetic core lower pendulum is fixedly connected to the top of the magnetic core column, the enameled wire coil is sleeved on the outer surface of the magnetic core column, side grooves are formed in the middle of two sides of the magnetic core lower pendulum, and two ends of the enameled wire coil are respectively welded with electrodes of the side grooves through the electrode material. According to the invention, the enameled wire coil is fixed in the groove on the side surface of the magnetic core in the winding step, and the winding space of a product with the same size is increased, so that the impedance is reduced, the saturation current is increased, the energy consumption is lower, the strength is higher, the product performance is improved, the service life is prolonged, and meanwhile, the soldering flux and the cleaning agent are not needed in the spot welding process, so that the resource is saved, and the pollution to the environment is reduced.)

1. The utility model provides an inductance is glued to magnetic seal, includes that magnetic core upper hem (1), magnetic core post (2), magnetic core lower hem (3), enameled wire coil (4) and electrode material (6), its characterized in that: the utility model discloses a magnetic core, including magnetic core post (2), magnetic core lower hem (3), enameled wire coil (4), side recess (5) have all been seted up at the middle part of magnetic core post (2), the middle part at magnetic core upper hem (1) top to magnetic core post (2) fixed connection, magnetic core lower hem (3) fixed connection is at the top of magnetic core post (2), enameled wire coil (4) cup joint the surface at magnetic core post (2), the electrode welding of electrode material (6) and side recess (5) is passed through respectively at the both ends of enameled wire coil (4).

2. The magnetic seal inductor of claim 1, wherein: the magnetic core upper hem (1) is an insulating surface, and the magnetic core lower hem (3) is an electrode surface.

3. The magnetic seal inductor of claim 1, wherein: and a glue layer (7) is bonded on the outer surface of the enameled wire coil (4), and the glue layer (7) is filled between the magnetic core upper hem (1) and the magnetic core lower hem (3).

4. A manufacturing method of a magnetic sealing glue inductor is characterized by comprising the following steps:

step one, winding; step two, spot welding the side surface; step three, dispensing; wherein:

in the first step, an enameled wire is wound on the outer surface of the magnetic core column in a designed winding mode to form a coil, and two ends of the enameled wire coil are respectively contacted with side grooves on two sides of the lower hem of the magnetic core by a wire hanging device;

in the second step, a novel welding head is adopted to fix the pins of the enameled wire coil on the side grooves respectively through high temperature, so that the pins are fused with the electrode material;

and in the third step, filling magnetic glue around the enameled wire coil to fix and seal the enameled wire, so as to improve the product characteristics, and fully drying the magnetic glue after filling.

5. The method for manufacturing a magnetic seal inductor according to claim 4, wherein the method comprises the following steps: in the first step, a proper amount of magnetic cores are placed on a feeding vibration disc of the all-in-one machine, and the magnetic cores are arranged in a downward swinging mode and then are sent to a winding position.

6. The method for manufacturing a magnetic seal inductor according to claim 4, wherein the method comprises the following steps: in the step one, the enameled wire is wound on the outer surface of the magnetic core column by a specific number of turns and layers by adjusting the tension of the winding tension device and the winding angle and speed of the winding device, so that the enameled wire is positioned between the magnetic core upper pendulum and the magnetic core lower pendulum.

7. The method for manufacturing a magnetic seal inductor according to claim 4, wherein the method comprises the following steps: in the first step, the wire clamp of the wire hanging device is driven by power to hang the enameled wire from the outer side of the magnetic core column to the side groove connected with the lower hem of the magnetic core.

8. The method for manufacturing a magnetic seal inductor according to claim 4, wherein the method comprises the following steps: in the second step, the spot welding current voltage and time are adjusted according to the welding joint degree, after spot welding is carried out on the side surface, the enameled wire is fused at high temperature, and then the redundant enameled wire is pulled apart by slight pulling force, and the redundant enameled wire is removed.

9. The method for manufacturing a magnetic seal inductor according to claim 4, wherein the method comprises the following steps: in the third step, by controlling the glue discharging amount and the glue dispensing period of the glue dispensing needle head, a proper amount of magnetic glue is filled around the enameled wire coil, and then the inductor passes through a drying oven and is dried to obtain a finished product before packaging.

Technical Field

The invention relates to the technical field of inductors, in particular to a magnetic sealing glue inductor and a manufacturing method thereof.

Background

The magnetic sealing glue inductor is an important component in the electronic industry, in the production process of the traditional magnetic sealing glue inductor, after a magnetic core is wound, an enameled wire is fixed through spot welding, then tin soldering needs to be carried out on a lower hem with an enameled wire pin to ensure the product performance of the inductor, and the tin soldering needs to be carried out through three steps of adding soldering flux, soldering tin on an electrode surface and cleaning. Tin, scaling powder and cleaner use and consume natural resources, and a large amount of electric energy is used for providing high temperature melting scaling powder and tin can cause energy pollution, and the cigarette and the sewage that the cleaning process discharged can cause environmental pollution, and in addition, the magnetic core raw and other materials of traditional production technology have the recess at the lower hem, and the volume and the intensity of raw and other materials magnetism material are little on the one hand, and is very fragile, and the power degree produces the fracture easily a little, and on the other hand wire winding space reduces, and used enameled wire line footpath is less, leads to the impedance great.

In order to overcome a series of problems caused by soldering in the conventional production, the industry has gradually improved the production method, as shown in fig. 4, the conventional production method comprises the steps of coiling, spot welding, soldering, dispensing, typesetting and cleaning, and the stitch is directly fixed on the side surface which is connected with the lower hem but has no groove, however, the enameled wire is easy to fall off due to the fact that the enameled wire is subjected to large tensile force, the reject ratio is high, and the product quality is affected.

Disclosure of Invention

Technical problem to be solved

Aiming at the defects of the prior art, the invention provides the magnetic sealing glue inductor and the manufacturing method thereof, which have the advantages of improving the performance of the inductor product and reducing energy consumption and environmental pollution, and solve the problems that the enameled wire is easy to fall off, the reject ratio is high and the product quality is influenced because the enameled wire is subjected to larger tension in the inductor in the conventional manufacturing method.

(II) technical scheme

In order to achieve the technical problem, the invention provides a magnetic seal glue inductor which comprises a magnetic core upper pendulum, a magnetic core column, a magnetic core lower pendulum, an enameled wire coil and an electrode material, wherein the magnetic core column is fixedly connected to the middle of the top of the magnetic core upper pendulum, the magnetic core lower pendulum is fixedly connected to the top of the magnetic core column, the enameled wire coil is sleeved on the outer surface of the magnetic core column, side grooves are formed in the middle of two sides of the magnetic core lower pendulum, and two ends of the enameled wire coil are respectively welded with the electrodes of the side grooves through the electrode material.

Furthermore, the magnetic core upper hem is an insulating surface, and the magnetic core lower hem is an electrode surface.

Furthermore, a glue layer is bonded on the outer surface of the enameled wire coil, and the glue layer is filled between the upper hem and the lower hem of the magnetic core.

A manufacturing method of a magnetic sealing glue inductor comprises the following steps:

step one, winding; step two, spot welding the side surface; step three, dispensing; wherein:

in the first step, an enameled wire is wound on the outer surface of the magnetic core column in a designed winding mode to form a coil, and two ends of the enameled wire coil are respectively contacted with side grooves on two sides of the lower hem of the magnetic core by a wire hanging device;

in the second step, a novel welding head is adopted to fix the pins of the enameled wire coil on the side grooves respectively through high temperature, so that the pins are fused with the electrode material;

and in the third step, filling magnetic glue around the enameled wire coil to fix and seal the enameled wire, so as to improve the product characteristics, and fully drying the magnetic glue after filling.

Further, in the first step, a proper amount of magnetic cores are placed on a feeding vibration disc of the all-in-one machine, and the magnetic cores are arranged in a downward swinging mode and then are sent to a winding position.

Further, in the step one, the enameled wire is wound on the outer surface of the magnetic core column by a specific number of turns and layers by adjusting the tension of the winding tension device and the winding angle and speed of the winding device, so that the enameled wire is positioned between the magnetic core upper pendulum and the magnetic core lower pendulum.

Further, in the first step, the wire clamp of the wire hanging device is driven by power to hang the enameled wire from the outer side of the magnetic core column to the side groove connected with the lower hem of the magnetic core.

Further, in the second step, the spot welding current voltage and time are adjusted according to the welding joint degree, after spot welding is carried out on the side surface, the enameled wire is fused at high temperature, and then the redundant enameled wire is pulled apart by slight pulling force, and the redundant enameled wire is removed.

Further, in the third step, by controlling the glue discharging amount and the glue dispensing period of the glue dispensing needle head, a proper amount of magnetic glue is filled around the enameled wire coil, and then the inductor passes through a drying oven and is dried to obtain a finished product before packaging.

(III) advantageous effects

The invention provides a magnetic sealing glue inductor and a manufacturing method thereof, which have the following beneficial effects:

1. compared with the traditional structure, the magnetic core lower hem is characterized in that the enameled wire coil is fixed in the groove on the side surface of the magnetic core in the winding step, and the winding space of a product with the same size is increased, so that the impedance is reduced, the saturation current is increased, the energy consumption is lower, the strength is higher, the product performance is improved, and the service life is prolonged.

2. The process adopted by the invention only needs spot welding without using tin for welding, and the improvement of the magnetic core structure mainly comprises the improvement of the side groove and the electrode material, the side groove can ensure that the welding head can be completely flattened and melted by larger pressure to fix the enameled wire, the electrode material is added with copper, so that the melted enameled wire can be better fused with the electrode, the product performance is ensured, scaling powder and a cleaning agent are not needed in the spot welding process, the resource is saved, and the pollution to the environment is reduced.

3. The automatic winding, spot welding and glue dispensing integrated machine greatly simplifies the production process, realizes the functions of automatic winding, automatic spot welding, automatic glue dispensing and the like by using the automatic winding, spot welding and glue dispensing integrated machine, has high automation degree, saves labor, saves the production cost of enterprises, and improves the production efficiency.

Drawings

FIG. 1 is a schematic structural view of the present invention;

FIG. 2 is an exploded view of the structure of the present invention;

FIG. 3 is a production process diagram of the present invention;

fig. 4 is a diagram of a conventional manufacturing process.

In the figure: 1. the magnetic core is swung upwards; 2. a magnetic core column; 3. the magnetic core swings downwards; 4. enameled wire coils; 5. a side groove; 6. an electrode material; 7. and (6) a glue layer.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

Referring to fig. 1-2, a magnetic seal rubber inductor includes a magnetic core upper pendulum 1, a magnetic core column 2, a magnetic core lower pendulum 3, an enameled wire coil 4 and an electrode material 6, wherein the magnetic core column 2 is fixedly connected to the middle of the top of the magnetic core upper pendulum 1, the magnetic core lower pendulum 3 is fixedly connected to the top of the magnetic core column 2, the enameled wire coil 4 is sleeved on the outer surface of the magnetic core column 2, side grooves 5 are respectively formed in the middle of two sides of the magnetic core lower pendulum 3, and two ends of the enameled wire coil 4 are respectively welded to the electrodes of the side grooves 5 through the electrode material 6.

The magnetic core upper hem 1 is an insulating surface, and the magnetic core lower hem 3 is an electrode surface.

And a glue layer 7 is bonded on the outer surface of the enameled wire coil 4, and the glue layer 7 is filled between the magnetic core upper hem 1 and the magnetic core lower hem 3.

Referring to fig. 3, a method for manufacturing a magnetic sealing adhesive inductor includes the following steps:

step one, winding; step two, spot welding the side surface; step three, dispensing; wherein:

in the first step, a proper amount of magnetic cores are placed on a feeding vibration disc of the all-in-one machine, the magnetic cores are arranged in a mode that the lower pendulum faces upwards and then are sent to a winding position, the enameled wires are wound on the outer surface of the magnetic core column by specific turns and layers by adjusting the tension of a winding tension device and the winding angle and speed of the winding device, the enameled wires are located between the upper pendulum of the magnetic core and the lower pendulum of the magnetic core to form a coil, and the enameled wires are hung in a side groove connected with the lower pendulum of the magnetic core from the outer side of the magnetic core column by a wire clamp of a wire hanging device under the driving of power.

In the second step, a novel welding head is adopted to fix the enameled wire coil pins on the side grooves respectively through high temperature, and the spot welding current voltage and time are adjusted according to the welding fitting degree, so that the enameled wire coil pins are fused with the electrode material.

And in the third step, by controlling the glue discharging amount and the glue dispensing period of the glue dispensing needle head, filling magnetic glue around the enameled wire coil to fix and seal the enameled wire, and then drying the inductor in a drying oven to obtain a finished product before packaging.

As shown in fig. 4, the conventional production method comprises coiling, spot welding, dispensing, typesetting and cleaning, in the conventional magnetic core lower hem 3, the side surface of the magnetic core lower hem 3 is not provided with the electrode material 6 and the side surface groove 5, and in the conventional process, after the coil is wound, the enameled wire is cut off, then hanging the enameled wire on the electrode surface to cut off the redundant enameled wire, and after the redundant enameled wire is cut off, because the redundant enameled wire is not fixed, various factors such as wire deviation, wire breakage or multiple wires can possibly occur to the enameled wire, thereby causing poor welding or false welding to affect the yield, and simultaneously, in order to repair the problems, the work of repair personnel is increased, the enameled wire of the new process is hung to the grooves at the two sides after being cut off and is not cut off, the enameled wire is fused at high temperature after spot welding on the side surface, and then the redundant enameled wire is pulled apart by slight tension, so that the problem of poor wire quality is solved.

The traditional process is only to flatten the enameled wire tilted on the electrode surface by a high-temperature welding head so as to enable the enameled wire to be in contact with the electrode surface, the shape of the enameled wire is not changed, and the enameled wire is not fused with an electrode material, because the electrode surface is broken by overlarge spot welding pressure, a new magnetic core is simultaneously acted by two welding heads due to the fact that grooves are arranged on two sides, stress can be balanced, a layer of copper is added to the electrode material of the new magnetic core, the electrode material of the new magnetic core can be well fused with the enameled wire, the traditional process also needs a step of tin soldering, and no further welding is needed after spot welding of the side surface of the new process.

The magnetic sealing glue inductance performance comparison test result is as follows:

the test conditions were 1MHz 1V.

In conclusion, compared with the traditional structure without grooves, the magnetic core lower hem 3 used in the invention fixes the enameled wire coil 4 in the grooves 5 on the side surface of the magnetic core in the winding step, and increases the winding space of the product with the same size, thereby reducing impedance, increasing saturation current, lowering energy consumption, increasing strength, improving product performance and prolonging service life.

The process adopted by the invention only needs spot welding without using tin for welding, and the improvement of the magnetic core structure mainly comprises the improvement of the side groove 5 and the electrode material, the side groove 5 can ensure that a welding head can be completely flattened and melted by larger pressure to fix the enameled wire, the electrode material is added with copper, so that the melted enameled wire can be better fused with the electrode, the product performance is ensured, scaling powder and a cleaning agent are not needed in the spot welding process, the resource is saved, and the pollution to the environment is reduced.

The automatic winding, spot welding and glue dispensing integrated machine greatly simplifies the production process, realizes the functions of automatic winding, automatic spot welding, automatic glue dispensing and the like by using the automatic winding, spot welding and glue dispensing integrated machine, has high automation degree, saves labor, saves the production cost of enterprises, and improves the production efficiency.

It should be noted that, in this document, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.

Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.