TW202425019A - Method for forming magnetic element winding does not affect power density of magnetic element - Google Patents

Abstract

A method for forming a magnetic element winding is provided, comprising steps of firstly providing a winding frame, and then winding a wire on the winding frame to form a plurality of windings of basic coils. The length of a wire segment from each of two ends of the wire to the portion that is wound to form the basic coils is greater than the length of the wire for winding the plurality of windings of coils. Afterward, two line segments of the wire that are connected to two ends of the basic coils are used to continue winding the plurality of windings of coils to complete a magnetic element winding. The magnetic element winding has two line outlet tails, and the two line outlet tails are formed by extending the outermost ones of the plurality of coils..

Description

Method for forming magnetic element winding

The present invention relates to a forming method of a magnetic element winding, and more particularly to a forming method in which two outgoing wire ends of the magnetic element winding are both formed by extending the outermost wires of a plurality of coils.

The winding is one of the important components of the magnetic element. Apart from the current solution implemented with integrated circuits, there are two main implementation solutions for the winding. One is to directly wind it on a winding frame, and the other is to have a component (coil cake) form to participate in the structure of the magnetic element. In either of the above two implementation solutions, the winding of the winding is to wind a winding frame with a portion of a wire close to one end, and then just wind it continuously in the same direction. When the number of winding turns (i.e., the number of winding turns) reaches the setting, the winding is stopped, and after cutting off part of the wire, the two ends of the wire are used as the two outlet ends.

However, the current winding method causes one of the two wire ends to be the inner wire of the winding (as shown in 50 in FIG. 1 ), which causes the winding to have an overlap due to the adjustment of the position of the inner wire portion. The height of the overlapping portion is at least the wire diameter, thereby affecting the power density of the magnetic component, which is inconsistent with the current research and development trend.

The main purpose of the present invention is to solve the subsequent implementation problems derived from the existing magnetic element winding forming method.

To achieve the above-mentioned purpose, the present invention provides a method for forming a magnetic element winding, comprising the following steps: Step 1: providing a winding frame; Step 2: using a wire rod to wind a plurality of turns of basic coils on the winding frame, the length of each wire segment at both ends of the wire rod that winds the basic coils is greater than the length of the wire rod for winding the plurality of turns of coils; and Step 3: using two wire segments on the wire rod that connect the two ends of the basic coil to continue winding the plurality of turns of coils, respectively, to complete a magnetic element winding, the magnetic element winding having two outgoing wire ends, the two outgoing wire ends are both formed by extending from the outermost of the plurality of coils.

In one embodiment, in the step three, one of the two wire segments is first used to wind a plurality of turns of coils to form a first portion, and then the other of the two wire segments is used to wind the remaining plurality of turns of coils based on the first portion to form a second portion overlapping the first portion, and the two outgoing wire ends are respectively extended from the outermost of the first portion and the second portion.

In one embodiment, in the second step, a portion of the wire that is not the end is used as a winding point, and two portions of the wire adjacent to the winding point are used to continue winding the basic coils, and the coils formed by the two portions have different numbers of turns.

In one embodiment, the method includes a fourth step of performing a shaping operation on the magnetic element winding and removing the winding frame.

In one embodiment, the wire comprises a metal inner core and a heat-fusible outer skin covering the metal inner core.

In one embodiment, the shaping operation is performed by dispensing glue.

In one embodiment, the shaping operation is performed by wrapping with adhesive tape.

Through the above implementation of the present invention, compared with the conventional method, the following characteristics are achieved: the basic coils initially generated by the winding method of the present invention help the subsequent winding of the coils, making the overall winding steps simple. Through the above method, the magnetic element winding of the present invention no longer overlaps the coils due to the position adjustment of the inner coil outlet part, and no longer affects the power density of a magnetic element using the magnetic element winding.

The detailed description and technical contents of the present invention are as follows with reference to the accompanying drawings:

Please refer to FIG. 2 . The present invention provides a magnetic element winding 20. The magnetic element winding 20 is characterized in that: the two outgoing wire ends 21 of the magnetic element winding 20 are formed by extending from the outermost of the plurality of coils 22 included in the magnetic element winding 20. The magnetic element winding 20 of the present invention does not have a portion of the outgoing wire from the inner coil of the magnetic element winding 20, so that the magnetic element winding 20 no longer overlaps the coils 22 due to the position adjustment of the inner coil outgoing wire portion, and no longer affects the power density of a magnetic element using the magnetic element winding 20. On the other hand, the magnetic element winding 20 of the present invention can be an independent component (as shown in FIG. 1 , known as a coil in the industry) used to constitute the magnetic element, or the magnetic element winding 20 can be a winding generated during the winding process of a transformer.

Please refer to Figures 2, 3 and 4. In order to make the magnetic element winding 20 mentioned above, the present invention also provides a forming method 30 of the magnetic element winding, comprising the following steps: Step 1 31, providing a winding frame 40; Step 2 32: using a wire 41 to wind a plurality of turns of the basic coil 23 on the winding frame 40, the length of each of the two ends of the wire 41 to wind the parts of the basic coils 23 is greater than the length of the wire 41 to wind the plurality of turns of the coil 22; and Step three 33: Use the two wire segments 42 on the wire 41 connected to the two ends of the basic coils 23 to respectively continue winding the multiple turns of coils 22 to complete the magnetic element winding 20. The magnetic element winding 20 has the two outgoing wire ends 21, and the two outgoing wire ends 21 are formed by extending from the outermost of the multiple turns of coils 22.

To further explain, the winding frame 40 can be in a suitable form according to the implementation requirements. The winding frame 40 can be implemented as a transformer winding frame, or can be separated after the magnetic element winding 20 is manufactured. On the other hand, the wire 41 can be an enameled wire, a multi-layer insulated wire, etc.

Please refer to FIG. 3 and FIG. 4 again. In step 2 32, the wire 41 uses a portion other than the end as the winding starting point. Specifically, the length of the wire segment retained after the winding of the wire 41 is not only used as one of the two outgoing wire ends 21, but can still be wound with a certain number of turns. In one embodiment, during the implementation of step 2 32, the basic coils 23 are wound with two portions of the wire 41 adjacent to the winding starting point. The coils wound with the two portions have different numbers of turns. For example, one of the two portions is wound with one turn, and the other of the two portions is wound with two turns. Furthermore, the two parts referred to in this article are inseparable from the wire 41. After the two parts are wound, the remaining line segments will continue to implement the step three 33. That is to say, after the wire 41 completes the winding of the basic wires 23, the length of the line segments of each of the two ends of the wire 41 that are wound around the basic coils 23 will be greater than the length of the wire 41 that is wound around the multiple turns of coils 22. The aforementioned parts of each of the two ends of the wire 41 that are wound around the basic coils 23 are equivalent to the remaining line segments after the two parts are wound. In addition, during the process of winding the basic coils 23 by the two parts, at least one of the basic coils 23 wound by one of the two parts will be overlapped on at least one of the basic coils 23 wound by the other of the two parts along the winding frame 40.

Please refer to FIG. 3, FIG. 5 and FIG. 6 again. After the step 2 32 is completed, the step 3 33 is continued. The two wire segments 42 on the wire 41 connected to the two ends of the basic coils 23 (i.e., the remaining wire segments after the two parts are wound) are used to wind the plurality of turns of the coils 22. During the winding process, the two wire segments 42 are wound starting from one of the connected basic coils 23. The winding direction is not along the winding frame 40, but is wound in a circle-by-circle manner. After the predetermined number of turns is completed, the magnetic element winding 20 is completed. The magnetic element winding 20 is formed by extending the two outgoing wire ends 21 of the plurality of turns of the coil 22 located at the outermost side through the method of the present invention, thereby solving the various problems derived from the inner coil outgoing wire. Furthermore, the predetermined number of turns mentioned in this article does not refer to the total number of turns of the magnetic element winding 20. The total number of turns of the magnetic element winding 20 is the number of turns of the basic coils 23 plus the number of turns of the coils 22. In one embodiment, in the step three 33, one of the two wire segments 42 is first used to wind the plurality of turns of the coil 22 and form a first portion 241, and then the other of the two wire segments 42 is used to wind the remaining plurality of turns of the coil 22 based on the first portion 241 and form a second portion 242 overlapping the first portion 241. The two wire ends 21 are respectively formed by extending from the outermost ones of the first portion 241 and the second portion 242.

Please refer to FIG. 7 , in one embodiment, the forming method 30 of the magnetic element winding further includes a fourth step 34: performing a shaping operation on the magnetic element winding 20 and removing the winding frame 40. After the fourth step 34 of this embodiment is completed, the magnetic element winding 20 can participate in the subsequent magnetic element structure in the form of a component. Please refer to FIG. 8 , in one embodiment, the wire 41 includes a metal inner core 411 and a heat-meltable outer skin 412 covering the metal inner core 411. The shaping operation is performed by heating the semi-finished product of the magnetic element winding 20 to melt the heat-meltable outer skin 412, and then cooling it to complete the shaping. In addition to the above, the shaping operation can also be implemented by glue spotting or tape wrapping. The glue spotting location can be selected according to the implementation requirements. The glue spotting can be as shown in Figure 9, where the number 60 in Figure 9 is the glue spotting location, and the tape wrapping solution can be as shown in Figure 10, where the number 61 in Figure 10 is the tape.

20: Magnetic winding 21: Wire end 22: Coil 23: Basic coil 241: Part I 242: Part II 30: Method 31: Step 1 32: Step 2 33: Step 3 34: Step 4 40: Winding rack 41: Wire 411: Metal core 412: Heat-fusible outer skin 42: Wire segment 50: Overlapping part 60: Glue point 61: Tape

Figure 1, a schematic diagram of the structure of a conventional magnetic element winding. Figure 2, a schematic diagram of the structure of a magnetic element winding according to an embodiment of the present invention. Figure 3, a schematic diagram of the steps of a forming method of a magnetic element winding according to an embodiment of the present invention. Figure 4, a schematic diagram of the implementation of a forming method of a magnetic element winding according to an embodiment of the present invention (I). Figure 5, a schematic diagram of the implementation of a forming method of a magnetic element winding according to an embodiment of the present invention (II). Figure 6, a schematic diagram of the implementation of a forming method of a magnetic element winding according to an embodiment of the present invention (III). Figure 7, a schematic diagram of the steps of a forming method of a magnetic element winding according to another embodiment of the present invention. Figure 8, a schematic diagram of the cross-sectional structure of a wire used in a magnetic element winding according to an embodiment of the present invention. Figure 9, a schematic diagram of the structure of a magnetic element winding according to another embodiment of the present invention. Figure 10 is a schematic diagram of the structure of a magnetic element winding in another embodiment of the present invention.

30: Methods

31: Step 1

32: Step 2

33: Step 3

Claims (8)

A method for forming a magnetic element winding comprises the following steps: Step 1: providing a winding frame; Step 2: using a wire to wind a plurality of turns of basic coils on the winding frame, wherein the length of each wire segment at both ends of the wire that winds the basic coils is greater than the length of the wire for winding the plurality of turns of coils; and Step 3: using two wire segments on the wire that connect the two ends of the basic coils to continue winding the plurality of turns of coils respectively, so as to complete a magnetic element winding, wherein the magnetic element winding has two outgoing wire ends, and the two outgoing wire ends are both formed by extending from the outermost of the plurality of coils. A method for forming a magnetic element winding as described in claim 1, wherein in step three, one of the two wire segments is first used to wind a plurality of turns of coils to form a first portion, and then the other of the two wire segments is used to wind the remaining plurality of turns of coils based on the first portion to form a second portion overlapping the first portion, and the two wire ends are formed by extending from the outermost of the first portion and the second portion, respectively. A method for forming a magnetic element winding as described in claim 2, wherein in step 2, a portion of the wire that is not the end is used as a winding point, and two portions of the wire adjacent to the winding starting point are used to continue winding the basic coils, and the number of turns of the coils formed by the two portions is different. A method for forming a magnetic element winding as described in claim 1, wherein in step 2, a portion of the wire that is not the end is used as a winding point, and two portions of the wire adjacent to the winding starting point are used to continue winding the basic coils, and the number of turns of the coils formed by the two portions is different. The method for forming a magnetic element winding as described in any one of claims 1 to 4 further includes a fourth step: performing a shaping operation on the magnetic element winding and removing the winding frame. A method for forming a magnetic element winding as described in claim 5, wherein the wire comprises a metal inner core and a heat-meltable outer skin covering the metal inner core. A method for forming a magnetic element winding as described in claim 5, wherein the shaping operation is performed by dispensing glue. A method for forming a magnetic element winding as described in claim 5, wherein the shaping operation is carried out by wrapping with adhesive tape.

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