Magnetic Component and Its Preparation Method

Abstract

The present invention relates to the technical field of electronic components, and specifically discloses a magnetic component and a preparation method thereof. The magnetic component includes a magnetic core, a wire, and a magnetic body. The magnetic core includes a bottom plate, a first side plate, and a second side plate. The first side plate and the second side plate are disposed on the first surface of the bottom plate, and there is a gap between the first side plate and the second side plate. A first limiting portion is provided on the first surface of the bottom plate, and the first limiting portion is located within the gap; the wire has a coil section and a connection section led out from the end of the coil section, the coil section is disposed within the first limiting portion, and the connection section is limit-connected to the magnetic core; the magnetic body at least covers the magnetic core and the coil section of the wire, and at least a part of the connection section of the wire is exposed outside the magnetic body. The setting of the magnetic core can realize the positioning of the entire wire, and avoid the deformation or dislocation of the coil section during the pressing process. The connection section does not need to be connected to the wire frame, because the coil section can be maximally set, improving the magnetic performance of the magnetic component, and further achieving the effect of optimizing its energy conversion and storage performance.

Description

Technical Field

[0001] The present invention relates to the technical field of electronic components, and particularly to a magnetic component and a preparation method thereof. Background Art

[0002] In the field of electronic technology, magnetic components are the core components for energy conversion and storage, and their performance is related to the efficiency and performance of the entire system. Magnetic components mainly include two categories: inductors and transformers. Taking inductors as an example, an inductor is a component that can convert electrical energy into magnetic energy and store it, also known as a choke, a reactor, or a dynamic reactor.

[0003] In the existing manufacturing process of inductors, usually the inner end and the outer end of the hollow coil are respectively welded to two different connection ends on the lead frame first, then the powdered molding material is injected into the mold in a way that completely surrounds the hollow coil, and then it is pressed into shape by a powder molding machine. Finally, the lead frame is cut off, and the leads are folded to the bottom surface of the inductor. However, the above method is limited by the wire frame, resulting in the hollow coil not being able to be maximized and the magnetic performance not being able to be optimized; and the coil cannot be positioned, and during the pressing process, the coil is prone to damage, deformation, misalignment, etc., thereby affecting the quality of the finished product. Similarly, other magnetic components similar to inductors also have the same above-mentioned defects. Summary of the Invention

[0004] Based on this, it is necessary to provide a magnetic component and a preparation method thereof for the problems that the magnetic performance of the magnetic component cannot be optimized and the coil is prone to deformation.

[0005] A magnetic component includes:

[0006] A magnetic core, including a bottom plate, a first side plate and a second side plate. The bottom plate includes an opposite first surface and a second surface. The first side plate and the second side plate are symmetrically arranged on the first surface of the bottom plate, and there is a gap between the first side plate and the second side plate. A first limiting portion is arranged on the first surface of the bottom plate, and the first limiting portion is located within the gap;

[0007] A wire, having a coil section and a connection section led out from the end of the coil section. The coil section is arranged within the first limiting portion, and the connection section is in limiting connection with the magnetic core;

[0008] A magnetic body, at least covering the magnetic core and the coil section of the wire, and at least a part of the connection section of the wire is exposed outside the magnetic body.

[0009] In one embodiment, the first side plate has a first concave surface, the second side plate has a second concave surface, and the first concave surface and the second concave surface are arranged oppositely.

[0010] In one embodiment, the first limiting portion is a first groove provided on the first surface of the bottom plate.

[0011] In one embodiment, the first groove has a flat bottom surface, the orthographic projection of the coil segment at the bottom of the first groove is located within the bottom surface of the first groove, and the shape of the first groove matches the shape of the coil segment.

[0012] In one embodiment, the first groove has a side opening, and the connecting segment is bent from the first surface of the bottom plate to the second surface through the side opening of the first groove.

[0013] In one embodiment, a second limiting portion is provided on the second surface of the bottom plate, and the connecting segment located on the second surface is located within the second limiting portion.

[0014] In one embodiment, the second limiting portion is a second groove provided on the second surface of the bottom plate, and the shape of the second groove matches the shape of the connecting segment located on the second surface.

[0015] In one embodiment, the length of the connecting segment located on the second surface of the bottom plate is not greater than 2 / 3 of the width of the bottom plate.

[0016] In one embodiment, the material of the magnetic core is one or more of alloy magnetic materials, amorphous materials, ferrites, and carbonyl iron.

[0017] In one embodiment, the magnetic body is formed by mixing at least two materials among iron-based amorphous powder, iron-silicon-aluminum alloy powder, permalloy powder, iron-silicon alloy powder, and nanocrystalline alloy powder.

[0018] In one embodiment, a positioning portion is provided on the second surface of the bottom plate.

[0019] A method for manufacturing the above magnetic element includes:

[0020] Winding a wire to form a coil segment and leading out a connecting segment from the end of the coil segment;

[0021] Placing the coil segment within the first limiting portion of the bottom plate of the magnetic core, and limiting and connecting the connecting segment with the magnetic core to complete the assembly of the wire and the magnetic core;

[0022] Placing the assembled wire and magnetic core into a mold, filling the mold with a magnetic material, and obtaining a magnetic body that completely covers the magnetic core and the wire through a hot pressing process;

[0023] Grind the magnetic body so as to expose the connecting section part of the wire.

[0024] In one embodiment, before the step of grinding the magnetic body, the method further includes:

[0025] Bake the magnetic body.

[0026] In one embodiment, the wire is an enameled wire; after the step of grinding the magnetic body, the method further includes:

[0027] Remove the enamel on the connecting section of the exposed wire;

[0028] Form a metal layer on the surface of the connecting section from which the enamel has been removed.

[0029] The above-mentioned magnetic component includes a magnetic core, a wire and a magnetic body. The magnetic core includes a bottom plate, a first side plate and a second side plate. The wire includes a coil section and a connecting section. The coil section is located within a first limiting portion on a first surface of the bottom plate. The connecting section is connected to the magnetic core in a limiting manner. The magnetic body at least covers the magnetic core and the coil section, and at least a part of the connecting section is exposed outside the magnetic body. With the above-mentioned arrangement of the magnetic core, on the one hand, the coil section is limited by the space formed by the first side plate, the second side plate and the bottom plate, and is further limited by the first limiting portion provided on the first surface of the bottom plate. Also, the connecting section can be limited by the bottom plate or the side plate, thereby realizing the positioning of the entire wire, avoiding the deformation or misalignment of the coil during the pressing process, and improving the finished product quality. On the other hand, since the connecting section does not need to be connected to the wire frame, the position of the connecting section is not restricted by the wire frame. That is, the end of the coil section is not restricted by the wire frame, and the coil section can be set to the actual required size because the coil section can be maximally set, further improving the magnetic performance of the magnetic component, and thus achieving the effect of optimizing its energy conversion and storage performance. Brief Description of the Drawings

[0030] Figure 1 Exploded view of the structure of the magnetic component provided for one embodiment;

[0031] Figure 2 Assembly diagram of the magnetic core and the wire in the magnetic component provided for one embodiment;

[0032] Figure 3 Assembly diagram of the magnetic component provided for one embodiment;

[0033] Figure 4 Structure diagram of the wire of the magnetic component provided for another embodiment;

[0034] Figure 5Schematic structural diagram of the magnetic core of the magnetic component provided for another embodiment;

[0035] Figure 6 Flow chart of the preparation method of the magnetic component provided for one embodiment;

[0036] Figure 7 Flow chart of the preparation method of the magnetic component provided for another embodiment;

[0037] Figure 8 Flow chart of the preparation method of the magnetic component provided for yet another embodiment.

[0038] Description of the reference numerals in the drawings:

[0039] 10. Magnetic core; 101. Bottom plate; 1011. First surface; 1012. Second surface; 102. First side plate; 1021. First concave surface; 103. Second side plate; 1031. Second concave surface; 104. First limiting portion; 105. Side opening; 106. Second limiting portion; 107. Positioning portion; 20. Lead wire; 201. Coil segment; 2011. First end; 2012. Second end; 202. Connection segment; 2021. First segment; 2022. Second segment; 30. Magnetic body. Detailed implementation manners

[0040] For the convenience of understanding the present invention, the present invention will be described more comprehensively below with reference to the relevant drawings. The preferred embodiments of the present invention are shown in the drawings. However, the present invention can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, these embodiments are provided to make the disclosure of the present invention more thorough and comprehensive.

[0041] It should be noted that when an element is referred to as being "fixed to" another element, it can be directly on the other element or there can also be an intermediate element. When an element is considered to be "connected" to another element, it can be directly connected to the other element or there may be an intermediate element at the same time. The terms "vertical", "horizontal", "left", "right", "up", "down", "front", "rear", "circumferential" and similar expressions used herein are based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation of the present invention.

[0042] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the technical field to which this invention belongs. The terms used in the description of this invention herein are for the purpose of describing specific embodiments only and are not intended to limit the invention. The term "and / or" used herein includes any and all combinations of one or more of the related listed items.

[0043] As described in the background art, the manufacturing process of existing inductors relies on lead frames. First, a wire is wound into a coil; then the leads at both ends of the coil are soldered to the lead frame; then the above structure is placed into a mold, powdered molding material is injected into the mold, and it is pressed into shape by a powder molding machine; finally, the lead frame is cut off to form the final inductor.

[0044] In the manufacturing of the above-mentioned inductor, since a lead frame needs to be applied and the two ends of the wire need to be soldered to the two extending ends of the lead frame, the size of the wound coil needs to adapt to the size of the lead frame and cannot be too large, thus restricting the magnetic properties of the manufactured inductor. In addition, before pressing, only the two ends of the coil are fixed by the lead frame, and the entire coil cannot be fixed, which makes the coil prone to damage, deformation, misalignment, etc. during the pressing and forming process, thereby affecting the quality of the finished product.

[0045] Similarly, various magnetic components such as transformers that are similar to the inductor manufacturing process also have the above problems.

[0046] To solve the above problems, the embodiments of the present application provide a magnetic component, which can be an inductor, a transformer, or other magnetic components. In this embodiment, an inductor is taken as an example for illustration.

[0047] As Figure 1-3 shown, the embodiments of the present application provide a magnetic component, including a magnetic core 10, a wire 20, and a magnetic body 30. Among them, the magnetic core 10 includes a bottom plate 101, a first side plate 102, and a second side plate 103. The bottom plate 101 includes opposite first and second surfaces 1011 and 1012. The first side plate 102 and the second side plate 103 are symmetrically arranged on the first surface 1011 of the bottom plate 101, and there is a gap between the first side plate 102 and the second side plate 103. A first limiting portion 104 is provided on the first surface 1011 of the bottom plate 101, and the first limiting portion 104 is located within the gap; the wire 20 has a coil section 201 and a connection section 202 led out from the end of the coil section 201. The coil section 201 is arranged within the first limiting portion 104, and the connection section 202 is in limiting connection with the magnetic core 10; the magnetic body 30 at least covers the magnetic core 10 and the coil section 201 of the wire 20, and at least a part of the connection section 202 of the wire 20 is exposed outside the magnetic body 30.

[0048] Specifically, the first surface 1011 and the second surface 1012 of the bottom plate 101 are the front and back surfaces of the bottom plate 101. In this embodiment, the first surface 1011 of the bottom plate 101 is defined as the front surface, and the second surface 1012 of the bottom plate 101 is defined as the back surface. The first side plate 102 and the second side plate 103 are symmetrically distributed on both sides of the first surface 1011. Generally, the first side plate 102 and the second side plate 103 are both perpendicular to the bottom plate 101. The first side plate 102, the second side plate 103 and the bottom plate 101 together form a U-shaped structure, and the first side plate 102 and the second side plate 103 respectively correspond to the two side parts of the U-shaped structure.

[0049] In one embodiment, the first side plate 102 has a first concave surface 1021, and the second side plate 103 has a second concave surface 1031. The first concave surface 1021 and the second concave surface 1031 are arranged opposite to each other, that is, the coil section 201 is arranged between the first concave surface 1021 and the second concave surface 1031. The surfaces of the first side plate 102 and the second side plate 103 facing the coil section 201 are arranged as concave surfaces, which increases the gap between the first side plate 102 and the second side plate 103 to ensure that the coil section 201 has sufficient placement space and is convenient for the setting of the first limiting portion 104. Wherein, the concave arcs of the first concave surface 1021 and the second concave surface 1031 can be circular arcs.

[0050] As an alternative embodiment, it is not necessary to set the entire surfaces of the first side plate 102 and the second side plate 103 facing the coil section 201 as concave surfaces. Concave areas can be provided only in partial areas of the first side plate 102 and the second side plate 103. For example, the lower half parts (i.e., close to the bottom plate 101) of the surfaces of the first side plate 102 and the second side plate 103 facing the coil section 201 are set as concave areas. The two concave areas are arranged opposite to each other, and the gap size between the first side plate 102 and the second side plate 103 can also be increased.

[0051] In one embodiment, the first limiting portion 104 is a first groove provided on the first surface 1011 of the bottom plate 101. Specifically, the first groove can be formed together when the magnetic core 10 is pressed, or can be grooved separately after the magnetic core 10 is pressed. The depth of the first groove should be less than the thickness of the bottom plate 101, but it should be avoided that it is too small to cause the coil section 201 to fall off from the first groove. In practical applications, the coil section 201 is arranged in the first groove, and the coil section 201 is limited by the first groove. This limiting method is relatively simple and effective.

[0052] In one embodiment, the first groove has a flat bottom surface, and the orthographic projection of the coil segment 201 on the bottom surface of the first groove is located within the bottom surface of the first groove. That is, the bottom surface of the first groove has sufficient area to carry the coil segment 201 to ensure the placement of the coil segment 201. At the same time, the orthographic projection of the coil segment 201 on the bottom surface of the first groove can be slightly smaller than the area of the bottom surface of the first groove. Thus, a certain adjustment space can be provided for the coil segment 201 within the first groove.

[0053] In addition, the shape of the first groove matches the shape of the coil segment 201. Specifically, when the coil segment 201 is in a cylindrical shape, the first groove can be set to a matching cylinder; when the coil segment 201 is in a cuboid shape, the first groove can be set to a matching cuboid. In practical applications, the shape of the coil segment 201 is not unique. Therefore, the shape of the first groove is also not unique, and will not be listed one by one here, as long as the reliable limiting effect of the first groove on the coil segment 201 can be ensured.

[0054] In one embodiment, the first groove has a side opening 105, and the connecting segment 202 is bent from the first surface 1011 of the bottom plate 101 to the second surface 1012 through the side opening 105 of the first groove. Among them, the side opening 105 is opened on one or both sides of the bottom plate 101 where no side plate is provided on the first surface 1011. When the coil segment 201 is disposed in the first groove, the connecting segment 202 at the end of the coil segment 201 can be bent along the side opening 105 and the side surface of the bottom plate 101 to the second surface 1012 of the bottom plate 101 to form a U-shaped structure, realizing the limiting connection between the connecting segment 202 and the magnetic core 10.

[0055] Specifically, the coil segment 201 includes opposite first end 2011 and second end 2012. The connecting segment 202 includes a first segment 2021 connected to the first end 2011 and a second segment 2022 connected to the second end 2012. The first segment 2021 and the second segment 2022 are symmetrically disposed on both sides of the coil segment 201. Correspondingly, the number of the side openings 105 of the first groove is set to two, corresponding to the first segment 2021 and the second segment 2022 of the connecting segment 202 respectively. Among them, the two side openings 105 are generally located on the same side of the bottom plate 101 and are symmetrically distributed on both sides of the first groove to adapt to the position arrangement between the coil segment 201 and the first segment 2021 and the second segment 2022, so that when the coil segment 201 is placed in the first groove, the first segment 2021 and the second segment 2022 can just correspond to the side openings 105 on both sides of the first groove, thereby realizing the limiting connection between the first segment 2021 and the bottom plate 101 and the limiting connection between the second segment 2022 and the bottom plate 101.

[0056] When two side openings 105 are provided on the same side of the bottom plate 101, the two side openings 105 at the opening are not completely connected, ensuring that the first groove is not completely connected to the outside on the side where the side opening 105 is provided, so that the coil segment 201 will not fall off from the first groove along the opening direction, ensuring the limiting effect on the coil segment 201.

[0057] In addition, it should be noted that the connecting segment 202 and the coil segment 201 can be an integral structure, that is, the connecting segment 202 is formed by processing the end of the coil segment 201. For example, the end of the coil segment 201 is bent to form the connecting segment 202; the connecting segment 202 and the coil segment 201 can also be a discrete structure, that is, the connecting segment 202 and the coil segment 201 are two independent components. In actual application, the two are combined and connected together.

[0058] In one embodiment, a second limiting portion 106 is provided on the second surface 1012 of the bottom plate 101, and the connecting segment 202 located on the second surface 1012 is located within the second limiting portion 106. The second limiting portion 106 is provided to limit the connecting segment 202 bent to the second surface 1012 of the bottom plate 101, so as to stabilize the connection between the connecting segment 202 and the bottom plate 101. Similarly, when the connecting segment 202 includes a first segment 2021 and a second segment 2022, the second surface 1012 of the bottom plate 101 is provided with second limiting portions 106 corresponding to the first segment 2021 and the second segment 2022 respectively.

[0059] In one embodiment, the second limiting portion 106 is a second groove provided on the second surface 1012 of the bottom plate 101, and the shape of the second groove matches the shape of the connecting segment 202 located on the second surface 1012. The width of the second groove should be greater than the width of the connecting segment 202 to ensure that the connecting segment 202 can be accommodated; the depth of the second groove should not be too thick to avoid penetrating through the first groove.

[0060] Generally, when the wire 20 and the magnetic core 10 are assembled and a magnetic member covering the wire 20 and the magnetic core 10 is formed through a hot pressing process, after processes such as grinding, the connecting segment 202 bent to the second surface 1012 of the bottom plate 101 is exposed to serve as an external wiring terminal of the magnetic component. The length of the wiring terminal directly affects the DC impedance of the magnetic component. The longer the wiring terminal, the greater the DC impedance value, and vice versa. Based on this, in this embodiment, preferably, the length of the connecting segment 202 located on the second surface 1012 of the bottom plate 101 is set to not be greater than 2 / 3 of the width of the bottom plate. Thus, the DC impedance of the magnetic component can be reduced. For example, when the width of the bottom plate is 15 mm, the length of the connecting segment 202 located on the second surface 1012 of the bottom plate 101 is set to be less than 10 mm.

[0061] As an alternative embodiment, the first limiting portion 104 and the second limiting portion 106 are not limited to the form of grooves, and other limiting means such as snap fasteners can also be used, which will not be enumerated one by one here.

[0062] In one embodiment, the material of the magnetic core 10 is one or more of alloy magnetic materials, amorphous materials, ferrites, and carbonyl iron. Specifically, the magnetic core 10 is formed by pressing a mixed material of one or more of alloy magnetic materials, amorphous materials, ferrites, and carbonyl iron. The magnetic core 10 formed by pressing with the above materials has lower losses. Of course, other materials can also be selected and mixed according to actual needs, which will not be enumerated one by one here.

[0063] In one embodiment, the magnetic body 30 is formed by mixing at least two of iron-based amorphous powder, iron-silicon-aluminum alloy powder, permalloy powder, iron-silicon alloy powder, and nanocrystalline alloy powder. Specifically, the magnetic body 30 is formed by hot pressing and molding at least two of iron-based amorphous powder, iron-silicon-aluminum alloy powder, permalloy powder, iron-silicon alloy powder, and nanocrystalline alloy powder. Among them, in addition to the above materials, a thermosetting material such as resin can be added and pressed together with the above materials.

[0064] The magnetic body 30 can be in the shape of a cuboid shell or other shapes, which depends on the shape of the mold used in the hot pressing and molding process, and will not be specifically limited here.

[0065] In one embodiment, the wire 20 is a strip-shaped wire 20 or a circular wire 20. Figure 1 The circular wire 20 is shown. Figure 4 The strip-shaped wire 20 is shown. Both the strip-shaped wire 20 and the circular wire 20 are applicable to this solution. As a preferred embodiment, the circular wire 20 is selected in this embodiment. The circular wire 20 is widely used and is more regular when wound into a coil. The wire 20 in this embodiment can be an enameled wire, which is composed of a conductor and an insulating layer coated on the periphery of the conductor.

[0066] In one embodiment, as Figure 5As shown, a positioning portion 107 is provided on the second surface 1012 of the bottom plate 101. The positioning portion 107 is generally disposed on the second surface 1012 avoiding the position of the second limiting portion 106, and can be disposed at the middle position of the second surface 1012. After the wire 20 and the magnetic core 10 are assembled, the assembled structure needs to be placed in a mold, and then a magnetic body is formed by filling a magnetic material and combining with a hot pressing process. To prevent the assembled structure from shifting during the hot pressing process, the positioning portion on the second surface of the bottom plate can be cooperatively and positionally connected with the corresponding positioning structure in the mold, thereby preventing the assembled structure from shifting in the mold and affecting the quality of the finished product. Among them, the positioning structure in the mold can be a convex structure, and the positioning portion on the second surface of the bottom plate is set as a groove structure corresponding to the convex structure; the positioning structure in the mold can be a groove structure, and the positioning portion on the second surface of the bottom plate is set as a convex structure corresponding to the groove structure. The structure of the positioning portion is not unique and is not absolutely limited herein, as long as the positioning of the two can be achieved.

[0067] The embodiment of the present application further provides a preparation method for the above-mentioned magnetic element. As Figure 6 shown, the preparation method for the magnetic element provided by the embodiment of the present application includes the following steps:

[0068] Step S20: Wind the wire 20 to form a coil segment 201, and lead out a connection segment 202 from the end of the coil segment 201.

[0069] Specifically, one end of the wire 20 can be kept stationary, and the other end of the wire 20 can be pulled to wind and form the coil segment 201 of the wire 20. It is also possible to keep the middle of the wire 20 fixed, and at the same time pull the two ends of the wire 20 to wind in opposite directions to form the coil segment 201 of the wire 20.

[0070] The coil segment 201 has a first end 2011 and a second end 2012 (which are the one end and the other end of the above-mentioned wire 20 respectively). The connection segment 202 can be formed by processing one end and the second end 2012 of the coil segment 201, or can be connected to the end of the coil segment 201. Corresponding to the first end 2011 and the second end 2012 of the coil segment 201, the connection segment 202 has a first segment 2021 connected to the first end 2011 and a second segment 2022 connected to the second end 2012. The first segment 2021 and the second segment 2022 of the connection segment 202 can be in a U-shaped structure, and this U-shaped structure is arranged in a manner close to the coil segment 201, and this U-shaped is in the vertical direction.

[0071] In one embodiment, the wire 20 is a strip-shaped wire or a circular wire. Both the strip-shaped wire and the circular wire are applicable to this solution. As a preferred implementation manner, a circular wire is selected in this embodiment. The circular wire is widely used and is more regular when wound into a coil. The wire 20 in this embodiment can be an enameled wire, which is composed of a conductor and an insulating layer coated on the periphery of the conductor.

[0072] Step S40: Place the coil segment 201 in the first limiting portion of the bottom plate 101 of the magnetic core 10, and limit and connect the connecting segment 202 to the magnetic core 10 to complete the assembly of the wire 20 and the magnetic core 10.

[0073] Taking the U-shaped connecting segment 202 as an example, when assembling the wire 20 and the magnetic core 10, the U-shaped connecting segment 202 is clamped on the bottom plate 101 along the direction close to the bottom plate 101, and at the same time, the coil segment 201 is fixedly placed in the first limiting portion of the bottom plate 101. For specific content, reference can be made to the relevant description of the magnetic component, which will not be elaborated here.

[0074] It should be noted that when the connecting segment is a U-shaped structure, the U-shaped structure can be pre-formed in step S20 and directly assembled with the magnetic core in step S40, or the U-shaped structure can not be formed in step S20, and only the connecting segments are led out from both ends of the coil segment. Then, the U-shaped structure is bent during the assembly in step S40. Both can achieve the purpose of the present invention.

[0075] Step S60: Place the assembled wire 20 and magnetic core 10 in a mold, fill the mold with a magnetic material, and obtain a magnetic body 30 that completely covers the magnetic core 10 and the wire 20 through a hot pressing process.

[0076] Among them, the mold is a structure with an opening on one side, generally in the shape of a cuboid. The magnetic material includes at least two of iron-based amorphous powder, iron-silicon-aluminum alloy powder, permalloy powder, iron-silicon alloy powder, and nanocrystalline alloy powder. In addition, the magnetic material also includes a thermosetting material, such as resin, etc. The magnetic material that completely covers the magnetic core 10 and the wire 20 is pressed through a hot pressing process to finally form a magnetic body 30 that completely covers the magnetic core 10 and the wire 20. The parameters involved in the hot pressing process, such as time and pressure, can be set according to actual requirements and will not be specifically limited here.

[0077] In addition, when the assembled wire 20 and the magnetic core 10 are placed in the mold, the positioning portion 107 on the second surface 1012 of the bottom plate 101 of the magnetic core 10 can be engaged with the positioning structure in the mold to prevent the assembled structure from shifting in the mold. Among them, the positioning structure in the mold can be a convex structure, and the positioning portion on the second surface of the bottom plate is set as a groove structure corresponding to the convex structure; the positioning structure in the mold can be a groove structure, and the positioning portion on the second surface of the bottom plate is set as a convex structure corresponding to the groove structure. The structure of the positioning portion is not unique and is not absolutely limited here, as long as the positioning of the two can be achieved.

[0078] Step S80: Grind the magnetic body 30 to expose a part of the connecting section 202 of the wire 20.

[0079] After the magnetic body 30 is pressed, the magnetic body 30 is ground by a grinding process. The grinding position is mainly the position where the connecting section 202 is located, so that a part of the connecting section 202 is exposed. Specifically, how much of the connecting section 202 is exposed can be determined according to actual needs. In a specific example, the magnetic body located on the second surface of the bottom plate is ground to expose the connecting section located on the second surface of the bottom plate.

[0080] In one embodiment, as Figure 7 shown, before step S80, that is, the step of grinding the magnetic body 30, the method for preparing the magnetic element provided by the embodiment of the present application further includes the following steps:

[0081] Step S70: Bake the magnetic body 30. After the magnetic body 30 is pressed, the magnetic body 30 needs to be baked and cured. The baking and curing time can be determined according to actual needs.

[0082] In one embodiment, the wire 20 is an enameled wire; as Figure 8 shown, after step S80, that is, the step of grinding the magnetic body 30 to expose a part of the connecting section 202 of the wire 20, the method for preparing the magnetic element provided by the embodiment of the present application further includes the following steps:

[0083] Step S81: Remove the paint on the exposed connecting section 202 of the wire 20. Since an enameled wire is used, there is an insulating paint layer on the outside of the exposed connecting section 202 of the wire 20. At this time, the insulating paint layer on the outside of the connecting section 202 can be removed by a laser paint stripping process.

[0084] Step S82: Form a metal layer on the surface of the connection section 202 from which the paint has been removed. After the paint is removed, a metal layer can be formed around the connection section 202 through an electroplating process, and the metal layer can be a silver layer. The setting of the metal layer realizes the electrical connection between the connection section 202 and the circuit, thereby playing the electrical role of the magnetic component.

[0085] For the preparation method of the above magnetic component, on the one hand, without relying on a lead frame, the coil section 201 can be set to the maximum, improving the magnetic performance of the magnetic component, and thus achieving the effect of optimizing its energy conversion and storage performance. On the other hand, with the setting of the magnetic core 10, the coil section 201 can be limited by the space enclosed by the first side plate 102, the second side plate 103 and the bottom plate 101, and further limited by the first limiting portion provided on the first surface of the bottom plate. Moreover, the connection section 202 can be limited by the bottom plate 101 or the side plate, thereby realizing the positioning of the entire wire 20 and avoiding the deformation or misalignment of the coil during the pressing process, improving the product quality.

[0086] The technical features of the above embodiments can be combined arbitrarily. For the sake of brevity of description, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, it should be considered as the scope described in this specification.

[0087] The above embodiments only represent several implementation manners of the present invention, and the description is relatively specific and detailed, but it should not be construed as a limitation on the scope of the invention patent. It should be noted that for those of ordinary skill in the art, without departing from the concept of the present invention, several modifications and improvements can be made, and these all belong to the protection scope of the present invention. Therefore, the protection scope of the present invention patent should be subject to the appended claims.

Claims

1. A magnetic component, characterized in that, Comprising: A magnetic core, including a bottom plate, a first side plate and a second side plate. The bottom plate includes opposite first and second surfaces. The first side plate and the second side plate are symmetrically arranged on the first surface of the bottom plate, and there is a gap between the first side plate and the second side plate. A first limiting portion is provided on the first surface of the bottom plate, and the first limiting portion is located within the gap; the first limiting portion is a first groove provided on the first surface of the bottom plate; the first groove has a flat bottom surface, and the orthographic projection of the coil segment on the bottom surface of the first groove is located within the bottom surface of the first groove, and the shape of the first groove matches the shape of the coil segment; a positioning portion is provided on the second surface of the bottom plate. A wire, having the coil segment and a connection segment led out from the end of the coil segment. The coil segment is arranged within the first limiting portion, and the connection segment is limit-connected to the magnetic core. A magnetic body, at least covering the magnetic core and the coil segment of the wire, and at least a part of the connection segment of the wire is exposed outside the magnetic body.

2. The magnetic component according to claim 1, characterized in that, The first side plate has a first concave surface, and the second side plate has a second concave surface, and the first concave surface and the second concave surface are arranged opposite to each other.

3. The magnetic component according to claim 1, characterized in that, The first groove has a side opening, and the connection segment is bent from the first surface of the bottom plate to the second surface through the side opening of the first groove.

4. The magnetic component according to claim 3, characterized in that, A second limiting portion is provided on the second surface of the bottom plate, and the connection segment located on the second surface is located within the second limiting portion.

5. The magnetic component according to claim 4, characterized in that, The second limiting portion is a second groove provided on the second surface of the bottom plate, and the shape of the second groove matches the shape of the connection segment located on the second surface.

6. The magnetic component according to claim 3, characterized in that, The length of the connection segment located on the second surface of the bottom plate is not greater than 2 / 3 of the width of the bottom plate.

7. The magnetic component according to any one of claims 1-6, characterized in that, The material of the magnetic core is one or more of alloy magnetic materials, amorphous materials, ferrites and carbonyl iron.

8. The magnetic component according to any one of claims 1-6, characterized in that, The magnetic body is formed by mixing at least two materials among iron-based amorphous powder, iron-silicon-aluminum alloy powder, permalloy powder, iron-silicon alloy powder, and nanocrystalline alloy powder.

9. A method for preparing a magnetic component according to any one of claims 1-8, characterized in that, The method includes: Winding a wire to form a coil segment, and leading out a connection segment from the end of the coil segment. Placing the coil segment within the first limiting portion of the bottom plate of the magnetic core, and limit-connecting the connection segment to the magnetic core to complete the assembly of the wire and the magnetic core. Placing the assembled wire and magnetic core into a mold, filling magnetic material in the mold, and obtaining a magnetic body that completely covers the magnetic core and the wire through a hot pressing forming process. Grinding the magnetic body to expose a part of the connection segment of the wire.

10. The method for preparing a magnetic component according to claim 9, characterized in that, Before the step of grinding the magnetic body, the method further includes: Baking the magnetic body.

11. The method for preparing a magnetic component according to claim 9, characterized in that, The wire is an enameled wire. After the step of grinding the magnetic body, the method further includes: Removing the enamel on the exposed connection segment of the wire. Forming a metal layer on the surface of the connection segment after removing the enamel.

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