Integrally-formed inductor

Abstract

The utility model provides an integrally-formed inductor which comprises a magnetic core and at least two coils. The magnetic core is formed by pressing a first forming part and a second forming part; the first forming part and the second forming part are both formed by pre-pressing magnetic powder; the coil arrangement direction is perpendicular to the axis direction of the coils; the second forming part is provided with at least two accommodating grooves; each accommodating groove is configured to accommodate at least one coil; the first forming part comprises an upper pendulum and a middle column for filling a middle gap of the coil; the upper pendulum basically covers the containing groove. The first forming part and the second forming part are pre-pressed and formed by the magnetic powder, then the first forming part and the second forming part are pressed into the magnetic core, and compared with a magnetic core structure which is directly pressed and formed by the magnetic powder, the technical scheme of the utility model can reduce gaps among powder materials and improve the density of the magnetic core, so that the direct-current resistance value of the inductor is reduced; the inductance characteristic is improved.

Description

Technical Field

[0001] The utility model relates to an inductor, in particular to an integrally formed inductor. Background Art

[0002] The inductor is one of the three major passive electronic components, and has the characteristic of "passing DC but blocking AC". With the demand for miniaturization and thinness of electronic products, electronic components also tend to be miniaturized and modularized. Existing multi-coil one-piece molded inductors are mostly formed by cold pressing of soft magnetic powder. After molding, the coplanarity of the electrodes of multiple coils is low, and the average height difference is greater than 0.1mm, which is not conducive to the welding of the inductor and the circuit board. On the other hand, the powder filling process has a low compaction density, resulting in a low core density and a large DC resistance of the inductor. Utility Model Content

[0003] The utility model provides an integrally formed inductor, wherein a magnetic core is formed by pressing a pre-pressed first forming part and a second forming part, thereby increasing the density of the magnetic core and reducing the DC resistance value of the inductor.

[0004] The utility model provides an integrally formed inductor, comprising a magnetic core and at least two coils; the arrangement direction of at least two of the coils is perpendicular to the axial direction of the coils; the magnetic core comprises a first forming part and a second forming part; the first forming part and the second forming part are both made of pre-pressed magnetic powder; the second forming part has at least two accommodating grooves; each of the accommodating grooves is configured to accommodate at least one coil; the first forming part comprises an upper swing and a middle column filling a gap in the middle of the coil; the upper swing basically covers the accommodating groove.

[0005] Furthermore, the first forming part includes an upper swing and a plurality of middle pillars; the plurality of middle pillars are integrally formed with the upper swing.

[0006] Furthermore, the accommodating groove includes an arc-shaped area and a square area; the coil includes a winding portion and a wire outlet portion; and the wire outlet portion is located in the square area.

[0007] Furthermore, two accommodating grooves are arranged in a group along the length direction of the second forming part; the square areas of each group of accommodating grooves are connected; the first forming part also includes a partition wall that prevents adjacent coils from approaching each other; the partition wall is formed by extending from the upper swing in the direction close to the second forming part.

[0008] Furthermore, it also includes electrodes; the electrodes are formed by the wire outlet of the coil extending out of the square area of ​​the accommodating groove; when observed along the direction perpendicular to the axis of the coil, the surfaces of the multiple electrodes are basically flat.

[0009] Furthermore, it also includes a shielding cover bonded to the magnetic core; the shielding cover includes a bottom plate and a side wall; the bottom plate basically covers one surface of the magnetic core; and the side wall is configured to strengthen the connection between the shielding cover and the magnetic core.

[0010] Furthermore, the second molded portion is provided with a matching groove matching with the side wall of the shielding cover.

[0011] Furthermore, the coil is made by horizontally winding a flat wire.

[0012] The beneficial effects of the utility model are as follows: the first forming part and the second forming part in the present application are pre-pressed and formed by magnetic powder, and then the first forming part and the second forming part are pressed into a magnetic core. Compared with the magnetic core structure directly pressed and formed by magnetic powder, the technical solution of the present application can reduce the gap between the powder materials and increase the density of the magnetic core, thereby reducing the DC resistance value of the inductor and improving the inductance characteristics. In addition, the electrode in the present application is formed by the outlet of the coil, and a plating layer is formed on the surface of the electrode. The height difference of the surfaces of multiple electrodes is reduced through the electroplating process, and the coplanarity of multiple electrodes is improved to ensure the stability of the welding between the inductor and the circuit board. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 This is a schematic diagram of the integrated inductor for this application;

[0014] Figure 2 Schematic diagram of an exploded view of an integrated inductor structure of a certain embodiment

[0015] Figure 3 for Figure 2 A schematic diagram of the structure of the first forming part;

[0016] Figure 4 for Figure 2 A schematic diagram of a receiving groove of the second forming part;

[0017] Figure 5 It is a schematic diagram of an exploded structure of an integrally formed inductor in another embodiment;

[0018] Figure 6 This is a schematic structural diagram of the first forming portion in another embodiment;

[0019] Figure 7 A schematic diagram of a receiving groove of a second forming portion in another embodiment;

[0020] Marked in the figure are: 100, magnetic core; 101, electrode; 110, first molded part; 111, upper swing; 112, middle column; 113, partition wall; 120, second molded part; 121, receiving groove; 122, matching groove; 200, coil; 300, shielding cover; 310, bottom plate; 320, side wall. DETAILED DESCRIPTION

[0021] In order to deepen the understanding of the present utility model, exemplary embodiments will be described in detail here, and examples thereof are shown in the accompanying drawings. When the following description refers to the accompanying drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with the present application.

[0022] The terms used in this application are only for the purpose of describing specific embodiments and are not intended to limit this application. Unless otherwise defined, the technical terms or scientific terms used in this application should be understood by people with ordinary skills in the field to which this utility model belongs. The words "first", "second" and similar words used in this application do not indicate any order, quantity or importance, but are only used to distinguish different components. Similarly, words such as "one" or "one" do not indicate quantity restrictions, but indicate that there is at least one. "Multiple" or "several" means two and more than two. Unless otherwise specified, words such as "front", "rear", "lower" and / or "upper" are only for the convenience of explanation and are not limited to one position or one spatial orientation. Words such as "include" or "include" mean that the elements or objects appearing in front of "include" or "include" include the elements or objects listed after "include" or "include" and their equivalents, and do not exclude other elements or objects. Words such as "connect" or "connected" are not limited to physical or mechanical connections, and can include electrical connections, whether direct or indirect. The singular forms "a", "said" and "the" used in this specification and the appended claims are also intended to include plural forms, unless the context clearly indicates otherwise. It should also be understood that the term "and / or" used herein refers to and encompasses any or all possible combinations of one or more of the associated listed items.

[0023] Embodiment 1

[0024] Please refer to Figures 1 to 4The present application provides an integrally formed inductor, comprising a magnetic core 100 and two coils 200; the two coils 200 of the present application are arranged "flat", and the arrangement direction is perpendicular to the axial direction of the coils 200; the magnetic core 100 comprises a first forming portion 110 and a second forming portion 120; the first forming portion 110 comprises an upper swing 111 and a middle column 112 filling the middle gap of the coils 200; the second forming portion 120 has at least two accommodating grooves 121; each of the accommodating grooves 121 is configured to accommodate at least one coil 200; the accommodating grooves 121 comprise an arc-shaped area and a square area, and the square areas of the two accommodating grooves 121 are located at both ends of the second forming portion 120; the coil 200 comprises a winding portion and a wire outlet portion; the wire outlet portion is located in the square area. The electrode 101 of the inductor in the present application is formed by the outlet portion of the coil 200 extending out of the square area of ​​the receiving groove 121. The electrode 101 and the coil 200 are an integral structure with good conductivity. However, since the coil 200 is subjected to cold pressing and / or hot pressing, the electrode surface height difference is large and the coplanarity is poor. In this embodiment, an electroplating layer is formed on the electrode surface to make the electrode surface height difference less than 0.1 mm, and the coplanarity is good, which can ensure that the welding point is stable and reliable when the inductor is subsequently welded to the circuit board; the upper swing 111 covers the receiving groove 121 and is provided with an opening to avoid the outlet portion of the coil 200, which can basically completely cover the receiving groove 121.

[0025] In other embodiments, the number of coils 200 and accommodating grooves 120 may be three, four or more, and the plurality of coils 200 and accommodating grooves 121 may be arranged along the length direction and width direction of the second forming portion 120; and every two accommodating grooves 121 along the length direction of the second forming portion 120 form a group.

[0026] The magnetic core 100 in this embodiment includes a first forming part 110 and a second forming part 120. In actual production, a flat wire is firstly wound horizontally to form a coil 200. Then, magnetic powder is put into a mold for cold pressing and / or hot pressing to obtain the first forming part 10 and the second forming part 120. Finally, the coil 200 is placed in the receiving groove 121 of the second forming part 120, and the first forming part 110 is covered and then hot pressed to obtain a semi-finished inductor. During the hot pressing process, the first forming part 110 and the second forming part 120 are deformed under the action of pressure and gradually become a shape that completely wraps the coil 200, eliminating the internal gap and forming a dense magnetic core 100.

[0027] On the basis of the above, if Figure 2As shown, the inductor of the present application further includes a shielding cover 300 bonded to the magnetic core 100; the shielding cover 300 includes a bottom plate 310 and a side wall 320; the bottom plate 310 basically covers one surface of the magnetic core 100. The second molded portion 120 is provided with a matching groove 122 that matches the side wall 320 of the shielding cover 300. The side wall 320 of the shielding cover 300 is bent and buckled into the matching groove 122, further strengthening the connection between the shielding cover 300 and the magnetic core 100. The side wall 320 avoids the electrode 101 and is lower in height than the electrode 101.

[0028] Embodiment 2

[0029] Please refer to Figure 5 As shown, the difference between this embodiment and the first embodiment is that the first forming portion 110 includes an upper swing 111 and two middle pillars 112; the two middle pillars 112 are integrally formed with the upper swing 111 and are evenly distributed on the upper swing 111. In other embodiments, the number of the middle pillars 112 can be three, four or more, and the middle pillars 112 correspond to the receiving slots 120 and the coils 200 one by one.

[0030] Embodiment 3

[0031] Please refer to Figure 6 and Figure 7 The difference between this embodiment and the first embodiment is that the square area of ​​the accommodating groove 121 is close to the center of the second forming part 120 and is interconnected; the wire outlets of the two coils 200 extend from the middle of the magnetic core 100; in order to prevent the two coils 200 from approaching each other and causing a short circuit, the first forming part 110 also includes a partition wall 113 to prevent adjacent coils 200 from approaching each other; the partition wall 113 is formed by extending the upper swing 111 in a direction close to the second forming part 120.

[0032] The above is only a preferred embodiment of the present application and does not constitute any form of limitation on the present application. Although the present application has been disclosed as a preferred embodiment as above, it is not intended to limit the present application. Any technician familiar with the profession can make some changes or modify the technical contents disclosed above into equivalent embodiments without departing from the scope of the technical solution of the present application. However, any simple modification, equivalent change and modification made to the above embodiments based on the technical essence of the present application without departing from the content of the technical solution of the present application still falls within the scope of the technical solution of the present application.

Claims

1. An integrated molded inductor, characterized in that: It comprises a magnetic core and at least two coils; the arrangement direction of at least two coils is perpendicular to the axial direction of the coils; the magnetic core comprises a first forming part and a second forming part; the first forming part and the second forming part are both made of pre-pressed magnetic powder; the second forming part has at least two accommodating grooves; each of the accommodating grooves is configured to accommodate at least one coil; the first forming part comprises an upper swing and a middle column filling the gap in the middle of the coil; the upper swing basically covers the accommodating grooves.

2. The one-piece molded inductor according to claim 1, characterized in that: The first forming part includes an upper swing and a plurality of middle pillars; the plurality of middle pillars are integrally formed with the upper swing.

3. The one-piece molded inductor according to claim 1, characterized in that: The accommodating groove includes an arc-shaped area and a square area; the coil includes a winding portion and a wire outlet portion; the wire outlet portion is located in the square area.

4. The one-piece molded inductor according to claim 3, characterized in that: The accommodating grooves along the length direction of the second forming part form a group of two each; the square areas of each group of the accommodating grooves are connected; the first forming part also includes a partition wall that prevents adjacent coils from approaching each other; the partition wall is formed by extending from the upper swing in the direction close to the second forming part.

5. The one-piece molded inductor according to claim 3, characterized in that: It also includes an electrode; the electrode is formed by the wire outlet of the coil extending out of the square area of ​​the receiving groove; When viewed in a direction perpendicular to the axis of the coil, the surfaces of the plurality of electrodes are substantially flush.

6. The one-piece molded inductor according to claim 1, characterized in that: It also includes a shielding cover bonded to the magnetic core; the shielding cover includes a bottom plate and a side wall; the bottom plate basically covers one surface of the magnetic core; and the side wall is configured to strengthen the connection between the shielding cover and the magnetic core.

7. The one-piece molded inductor according to claim 6, characterized in that: The second molding portion is provided with a matching groove matching with the side wall of the shielding cover.

8. The one-piece molded inductor according to claim 1, characterized in that: The coil is made by horizontally winding a flat wire.

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