Inductor and method for manufacturing the same

Abstract

The present invention relates to an inductor and a manufacturing method thereof. The inductor comprises a magnetic solid body, a coil, and a lead frame. The lead frame comprises a first electrode pin and a second electrode pin disposed on either side of the magnetic solid body. The magnetic solid body comprises a bottom surface and a plurality of side surfaces connected to the bottom surface. The coil is embedded in the magnetic solid body and comprises two leads, which are electrically connected to the first electrode pin and the second electrode pin, respectively. The first electrode pin and the second electrode pin each comprise a first end located on one side of the bottom surface, a second end located on one side of the side surface, and at least one protrusion, the protrusion being located on the first end and / or the second end and at least partially embedded in the corresponding surface. The inductor reduces the space occupied by the lead frame within the magnetic solid body, thereby improving inductor performance. Furthermore, the first electrode pin and the second electrode pin do not need to be formed within the magnetic solid body, thereby reducing the risk of cracking of the inductor during the molding process.

Description

Technical Field

[0001] The present invention relates to the technical field of electronic devices, and in particular to an inductor and a manufacturing method thereof. Background Art

[0002] With the continuous development of electronic technology, inductors, as one of the basic components of electronic circuits, have emerged in an endless variety. One-piece molded inductors are increasingly favored in the field of electronic devices due to their small size, large current, and high production efficiency.

[0003] During the molding process of existing one-piece molded inductors, the lead frame crosses the magnetic solid body, causing the lead frame to occupy a large space inside the magnetic solid body. The volume of the coil inside the magnetic solid body cannot be maximized, limiting the magnetic performance of the inductor. In addition, during the molding process, the compressive stress on the electrode surface is relatively concentrated, which easily causes the electrode surface to crack, making the inductor scrapped. Summary of the Invention

[0004] Based on this, it is necessary to provide an inductor and a manufacturing method thereof to address the problems of poor magnetic properties of the inductor and easy cracking of the electrode surface during the molding process.

[0005] An inductor includes a magnetic solid body, a coil, and a lead frame, wherein the lead frame includes a first electrode pin and a second electrode pin arranged on both sides of the magnetic solid body, wherein:

[0006] The magnetic solid body has a bottom surface and a plurality of side surfaces connected to the bottom surface;

[0007] The coil is embedded in the magnetic solid body and has two leads, and the two leads are electrically connected to the first electrode pin and the second electrode pin respectively;

[0008] The first electrode foot and the second electrode foot each have a first end located on one side of the bottom surface, a second end located on one side of the side surface, and at least one protrusion, wherein the protrusion is located on the first end and / or the second end and is at least partially buried in the surface corresponding thereto.

[0009] In the aforementioned inductor, each of the first and second electrode pins has a first end located on the bottom surface, a second end located on the side surface, and at least one protrusion. The protrusion is located on the first and / or second end, and at least partially embedded in the corresponding surface. This secures the first and second electrode pins to the magnetic solid body, effectively strengthening the bonding strength between the first and second electrode pins and the magnetic solid body, and improving the inductor's vibration resistance. Furthermore, two lead wires are electrically connected to the first and second electrode pins, respectively, securing the first and second electrode pins, the coil, and the magnetic solid body. The first and second electrode legs are arranged outside the magnetic solid body, thereby reducing the space occupied by the lead frame within the magnetic solid body. This increases the space available for the coil, expands the proportion of the inductor's center leg, and improves inductor performance. Furthermore, the first and second electrode legs do not need to be formed inside the magnetic solid body, thereby avoiding large compressive stress on the first and second electrode legs during the molding process, thereby reducing the risk of cracking along the cross-section of the inductor along the first and second electrode legs.

[0010] In one embodiment, the first end portion and the second end portion are interconnected flexible conductive plates.

[0011] In one embodiment, the first end portion is attached to the bottom surface, and the second end portion is attached to the side surface.

[0012] In one embodiment, the lead frame is a flexible conductive plate, and is made of at least one of copper alloy, aluminum alloy, and conductive rubber.

[0013] In one embodiment, the first end portion has at least one bent portion, and the bent portion is embedded in the magnetic solid body.

[0014] In one embodiment, a limiting groove is provided on the bending portion, and the lead is embedded in the limiting groove.

[0015] In one embodiment, the bent portion is L-shaped and has an end surface parallel to the first end portion.

[0016] In one embodiment, the angle formed between the first end portion and the bent portion is 120°-150°.

[0017] In one embodiment, the angle formed between the first end portion and the bent portion is 30°-60°.

[0018] In one embodiment, the angle formed by the first end and the second end is the same as the angle formed by the bottom surface and the side surface, and the angle formed by the bottom surface and the side surface is 95°-125°.

[0019] A method for manufacturing an inductor according to any of the above technical solutions, the manufacturing method comprising the steps of:

[0020] Providing the lead frame and the coil, wherein the lead frame has the protrusion and the coil has the two lead wires;

[0021] electrically connecting the two lead wires to the first electrode pin and the second electrode pin respectively;

[0022] Placing the lead frame, the coil, and a certain amount of metal granulation powder in a mold to complete preforming of the inductor;

[0023] The preformed inductor is cured and cut to obtain the inductor.

[0024] The above-mentioned manufacturing method completes the preforming of the lead frame by providing a lead frame with a protrusion and a coil with a lead, reduces the subsequent processing process of the lead frame, avoids damage to the formed inductor in the subsequent processing process, causes waste of raw materials, and improves production efficiency. The two leads are electrically connected to the first electrode pin and the second electrode pin respectively, so as to achieve a fixed connection between the coil and the lead frame. By placing the lead frame, the coil and a certain amount of metal granulation powder in the mold, the fixed forming of the lead frame, the coil and the magnetic solid body is achieved, and the preforming of the inductor is completed. The preformed inductor is then cured and cut to obtain the inductor. The above-mentioned manufacturing method has a simple process, high raw material utilization rate, and improves production efficiency.

[0025] In one embodiment, before electrically connecting the two lead wires to the first electrode pin and the second electrode pin respectively, the method further includes performing surface treatment on the lead frame and the coil. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 A schematic diagram of an explosion of an inductor in one embodiment of the present invention;

[0027] Figure 2 A schematic diagram of an inductor explosion in another embodiment of the present invention;

[0028] Figure 3 A schematic diagram of the structure of a preformed inductor provided by the present invention;

[0029] Figure 4 A schematic structural diagram of the preformed inductor provided by the present invention from another perspective;

[0030] Figure 5 A schematic structural diagram of a lead frame in an inductor provided by the present invention;

[0031] Figure 6 This is a schematic structural diagram of a module composed of a lead frame and a coil in the inductor provided by the present invention;

[0032] Figure 7 This is a cross-sectional view of the inductor structure provided by the present invention.

[0033] Reference numerals:

[0034] 100. Inductor;

[0035] 110, lead frame; 111, first electrode pin; 112, second electrode pin; 113, first end portion; 114, second end portion; 115, protrusion; 116, bent portion; 117, limiting groove; 118, outer frame; 119, end face;

[0036] 120, coil; 121, lead wire;

[0037] 130. Magnetic solid body; 131. Bottom surface; 132. Side surface. DETAILED DESCRIPTION

[0038] To make the above-mentioned objects, features, and advantages of the present invention more readily apparent, specific embodiments of the present invention are described in detail below with reference to the accompanying drawings. The following description sets forth numerous specific details to facilitate a full understanding of the present invention. However, the present invention can be implemented in many other ways than those described herein, and those skilled in the art may make similar modifications without departing from the scope of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0039] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential" and the like to indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying 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 should not be understood as limiting the present invention.

[0040] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of the technical features being referred to. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one such feature. In the description of the present invention, "plurality" means at least two, such as two, three, etc., unless otherwise specifically defined.

[0041] In the present invention, unless otherwise specified or limited, the terms "installed," "connected," "connect," "fixed," etc. should be understood in a broad sense. For example, they can refer to fixed connection, detachable connection, or integration; mechanical connection, electrical connection; direct connection, or indirect connection through an intermediate medium; internal communication between two components, or interaction between two components, unless otherwise specified. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0042] In the present invention, unless otherwise expressly specified or limited, when a first feature is "above" or "below" a second feature, it may mean that the first and second features are in direct contact, or that the first and second features are in indirect contact through an intermediary. Furthermore, when a first feature is "above," "above," or "above" a second feature, it may mean that the first feature is directly above or diagonally above the second feature, or simply means that the first feature is at a higher level than the second feature. When a first feature is "below," "below," or "below" a second feature, it may mean that the first feature is directly below or diagonally below the second feature, or simply means that the first feature is at a lower level than the second feature.

[0043] It should be noted that when an element is referred to as being "fixed to" or "disposed on" another element, it may be directly on the other element or there may be an intermediate element. When an element is considered to be "connected to" another element, it may be directly connected to the other element or there may be an intermediate element. The terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only implementation methods.

[0044] The technical solutions provided by the embodiments of the present invention are described below with reference to the accompanying drawings.

[0045] like Figure 1 、 Figure 2 As shown, the present invention provides an inductor 100 for converting electrical energy into magnetic energy for storage. The inductor 100 includes a magnetic solid body 130, a coil 120, and a lead frame 110, wherein:

[0046] like Figure 3 、 Figure 4 As shown, the magnetic solid body 130 has a bottom surface 131 and a plurality of side surfaces 132 . The plurality of side surfaces 132 are connected to the bottom surface 131 , and the plurality of side surfaces 132 are disposed around the bottom surface 131 .

[0047] like Figure 5As shown, the lead frame 110 includes a first electrode pin 111 and a second electrode pin 112. The first electrode pin 111 is located on one side of the magnetic solid body 130, and the second electrode pin 112 is located on the other side of the magnetic solid body 130. The first electrode pin 111 and the second electrode pin 112 each have a first end 113, a second end 114, and at least one protrusion 115. The first end 113 is located on one side of the bottom surface 131, and the second end 114 is located on one side of the side surface 132. The protrusion 115 is located on the first end 113 and / or the second end 114, and at least a portion of the protrusion 115 is embedded in the corresponding bottom surface 131 and / or side surface 132. It should be noted that the lead frame 110 also includes an outer frame 118. The outer frame 118 and the first electrode pins 111 and the second electrode pins 112 can be integrally formed by stamping, forging, casting, etc., or can be connected to the outer frame 118 and the first electrode pins 111 and the second electrode pins 112 as a whole by welding. The outer frame 118 can simultaneously connect multiple groups of first electrode pins 111 and second electrode pins 112, which can significantly improve the production efficiency of the inductor 100. When the protrusion 115 is made of the same material as the first electrode pin 111 and the second electrode pin 112, the protrusion 115 can be integrally formed with the first electrode pin 111 and the second electrode pin 112 by stamping, forging, casting, or the like. Alternatively, after the first electrode pin 111 and the second electrode pin 112 are formed, the protrusion 115 can be formed on the first end portion 113 and / or the second end portion 114 by additive manufacturing. The present invention does not limit the specific forming method of the protrusion 115 and the first electrode pin 111 and the second electrode pin 112, as long as the protrusion 115 is distributed on both the first electrode pin 111 and the second electrode pin 112. The structure of the protrusion 115 has various forms, and the cross-section of the protrusion 115 includes at least one of a prismatic, honeycomb-briquette-shaped, rectangular, and hexagonal shape. Of course, the cross-section of the protrusion 115 can also be other structural forms such as a circular, butterfly-shaped, or torpedo-shaped structure. The present invention does not limit the specific structural form of the protrusion 115.

[0048] like Figure 6As shown, the coil 120 is a ring structure with one or more layers, and the metal wires forming the coil 120 are insulated from each other. The coil 120 is embedded in the magnetic solid body 130. The coil 120 has two leads 121, and the two leads 121 are electrically connected to the first electrode pin 111 and the second electrode pin 112 respectively. Among them, when a portion of the protrusion 115 is embedded in the magnetic solid body 130, that is, the first end 113 and the second end 114 are both located outside the magnetic solid body 130, one of the leads 121 is electrically connected to the protrusion 115 of the first electrode pin 111, and the other lead 121 is electrically connected to the protrusion 115 of the second electrode pin 112; when the protrusion 115 is completely embedded in the magnetic solid body 130, one of the leads 121 can be electrically connected to the protrusion 115 of the first electrode pin 111, or to the first end 113 or the second end 114 of the first electrode pin 111. Similarly, the other lead 121 can be electrically connected to the protrusion 115 of the second electrode pin 112, or to the first end 113 or the second end 114 of the second electrode pin 112.

[0049] In the aforementioned inductor 100, both the first electrode pin 111 and the second electrode pin 112 have a first end 113 located on the bottom surface 131, a second end 114 located on the side surface 132, and at least one protrusion 115. The protrusion 115 is located on the first end 113 and / or the second end 114, and at least a portion of the protrusion 115 is embedded in the corresponding surface. This ensures a secure connection between the first and second electrode pins 111, 112 and the magnetic solid body 130, effectively enhancing the bonding strength between the first and second electrode pins 111, 112 and the magnetic solid body 130 and improving the vibration resistance of the inductor 100. Furthermore, two lead wires 121 are electrically connected to the first and second electrode pins 111, 112, respectively, securing the first and second electrode pins 111, 112, the coil 120, and the magnetic solid body 130. The first electrode pin 111 and the second electrode pin 112 are disposed outside the magnetic solid body 130 , thereby reducing the space occupied by the lead frame 110 within the magnetic solid body 130 . Consequently, the space available for the coil 120 is increased, thereby increasing the proportion of the inductor's center leg, and improving the performance of the inductor 100 . Furthermore, the first electrode pin 111 and the second electrode pin 112 do not need to be formed inside the magnetic solid body 130 , thereby preventing the first electrode pin 111 and the second electrode pin 112 from being subjected to high compressive stress during the molding process, thereby reducing the risk of cracking in the inductor 100 along the cross-section of the first electrode pin 111 and the second electrode pin 112 .

[0050] To further improve the anti-vibration performance of the inductor 100, a preferred embodiment is as follows: Figure 3 、 Figure 4 and Figure 5As shown, the first end portion 113 and the second end portion 114 are flexible conductive plates connected to each other. The first end portion 113 and the second end portion 114 can be connected to each other as a whole by bending or welding sheet metal, and the protrusion 115 at the first end portion 113 is completely embedded in the magnetic solid body 130. The first end portion 113 is attached to the bottom surface 131, and the protrusion 115 at the second end portion 114 is completely embedded in the magnetic solid body 130. The second end portion 114 is attached to the side surface 132. Figure 7 In this case, protrusions 115 are spaced apart on the first end 113 and the second end 114, and all of the protrusions 115 are embedded in the magnetic solid body 130. This increases the bonding strength between the first electrode pin 111, the second electrode pin 112, and the magnetic solid body 130. This prevents the first electrode pin 111 and the second electrode pin 112 from easily falling off the magnetic solid body 130 during long-term service or in an operating environment with high external vibration, which could cause the inductor 100 to fail. This improves the vibration resistance of the inductor 100. Furthermore, the first end portion 113 and the second end portion 114 are both configured as flexible conductors to avoid a gap between the first end portion 113 and the bottom surface 131 during the bonding process, thereby ensuring a higher degree of bonding between the first end portion 113 and the bottom surface 131. Similarly, the second end portion 114 is prevented from having a gap between the second end portion 114 and the side surface 132 during the bonding process, thereby ensuring a higher degree of bonding between the second end portion 114 and the side surface 132, thereby further improving the anti-vibration performance of the inductor 100.

[0051] In order to facilitate the processing and forming of the lead frame 110, a preferred embodiment is as follows: Figure 5 As shown, the lead frame 110 is a flexible conductive plate, which is convenient for processing and forming the lead frame 110 and can conduct the coil 120. The lead frame 110 is made of at least one of copper alloy, aluminum alloy, and conductive rubber. Copper alloy, aluminum alloy and conductive rubber all have excellent conductivity, which can improve the conduction effect of the coil 120. Aluminum alloy has high specific strength and good corrosion resistance, and can be used in industrial fields such as aerospace, military industry, etc.

[0052] In order to improve the anti-vibration performance of the first electrode pin 111 and the second electrode pin 112, a preferred embodiment is as follows: Figure 1 、 Figure 2 、 Figure 3 and Figure 5As shown, the first end portion 113 has at least one bent portion 116, and the bent portion 116 is embedded in the magnetic solid body 130. It should be noted that when the first end portion 113 has one bent portion 116 and the bent portion 116 is embedded in the magnetic solid body 130, the bonding strength between the first electrode pin 111, the second electrode pin 112, and the magnetic solid body 130 can be enhanced, thereby improving the anti-vibration performance of the inductor 100. In addition, the molding process of one bent portion 116 is relatively simple, which can reduce the production cost of the inductor 100. When the first end portion 113 has multiple bent portions 116, the multiple bent portions 116 are spaced apart on the first end portion 113, and the multiple bent portions 116 are all embedded in the magnetic solid body 130. The bonding strength between the first electrode pin 111, the second electrode pin 112, and the magnetic solid body 130 is further increased, and the anti-vibration performance of the inductor 100 is further improved.

[0053] To prevent the lead wire 121 from falling off the first electrode pin 111 and / or the second electrode pin 112, specifically, Figure 5 、 Figure 6 As shown, a limiting groove 117 is formed on the bent portion 116, and the lead 121 is embedded in the limiting groove 117. This can prevent the lead 121 from falling off the first electrode pin 111 and / or the second electrode pin 112 or from poor contact during long-term service or in an operating environment with high external vibration. This can prevent the external power supply from being able to conduct electricity to the coil 120 through the first electrode pin 111 and / or the second electrode pin 112, resulting in failure of the inductor 100. The limiting groove 117 can be a U-shaped groove, a circular groove, or other structural form that can embed the lead 121. The limiting groove 117 and the first electrode pin 111 and the second electrode pin 112 can be integrally formed by stamping, forging, casting, etc., or can be formed by other groove-making auxiliary tools after the first electrode pin 111 and the second electrode pin 112 are formed. The specific structural form and forming method of the limiting groove 117 are not limited by the present invention.

[0054] In order to improve the anti-vibration performance of the first electrode pin 111 and the second electrode pin 112 and enrich the types of the inductor 100, in one embodiment, as shown in FIG. Figure 2 、 Figure 5 and Figure 6As shown, the bent portion 116 is L-shaped and has an end surface 119 that is parallel to the first end portion 113. The bent portion 116 is formed by bending or stamping the first end portion 113 from a sheet metal, or by welding the bent portion 116 to the first end portion 113. The bent portion 116 is entirely embedded within the magnetic solid body 130. In this case, embedding the lead 121 in the bent portion 116 can significantly improve the vibration resistance of the inductor 100. Furthermore, when the end surface 119 of the L-shaped bent portion 116 is parallel to the first end portion 113 and a certain distance is spaced from the first end portion 113, and the retaining groove 117 is provided on the end surface 119, the filling thickness of the magnetic solid body 130 can be greatly increased, and the thickness of the inductor 100 can also be increased accordingly, thereby enriching the types of inductors 100.

[0055] In order to further improve the anti-vibration performance of the first electrode pin 111 and the second electrode pin 112 and enrich the types of the inductor 100, in another embodiment, as shown in FIG. Figure 1 、 Figure 5 and Figure 6 As shown, the angle between the first end 113 and the bent portion 116 is 120°-150°. This means that the projected outer contour of the bent portion 116 is located outside the first end 113. This allows the bent portion 116 to be embedded deeper into the magnetic solid body 130, increasing the bonding strength between the first and second electrode pins 111, 112, and the magnetic solid body 130, and improving the vibration resistance of the inductor 100. In specific configurations, the angle between the first end 113 and the bent portion 116 can be one of 120°, 125°, 130°, 135°, 140°, 145°, or 150°. Of course, the angle between the first end 113 and the bent portion 116 is not limited to the aforementioned range and can also be other values within the range of 120°-150°. In addition, when the vibration resistance of the inductor 100 is not required to be high, the angle between the first end portion 113 and the bent portion 116 is not limited to the above-mentioned setting range, and the angle between the first end portion 113 and the bent portion 116 can be set according to the specific bending forming equipment.

[0056] To further improve the vibration resistance of the first and second electrode pins 111, 112, and to enrich the variety of inductor types, in another embodiment, the angle between the first end 113 and the bent portion 116 is 30°-60°. Specifically, the projected outer contour of the bent portion 116 is located on the first end 113. This allows the bent portion 116 to be embedded deeper into the magnetic solid body 130, thereby increasing the bonding strength between the first and second electrode pins 111, 112, and the magnetic solid body 130, and improving the vibration resistance of the inductor 100. In specific configurations, the angle between the first end 113 and the bent portion 116 can be one of 30°, 35°, 40°, 45°, 50°, 55°, or 60°. Of course, the angle between the first end 113 and the bent portion 116 is not limited to the aforementioned range and can also be other values within the range of 30°-60°. In addition, when the vibration resistance of the inductor 100 is not required to be high, the angle between the first end portion 113 and the bent portion 116 is not limited to the above-mentioned setting range, and the angle between the first end portion 113 and the bent portion 116 can be set according to the specific bending forming equipment.

[0057] In order to improve the demoulding efficiency of the inductor 100, a preferred embodiment is as follows: Figure 4 、 Figure 5 As shown, the angle formed by the first end 113 and the second end 114 is the same as the angle formed by the bottom surface 131 and the side surface 132. The mold has good contact with the first and second electrode pins 111 and 112. The angle formed by the bottom surface 131 and the side surface 132 is 95°-125°. The contact surface between the second end 114 and the side surface 132 is inclined, which facilitates demolding. During the molding process of the inductor 100, the raw material of the magnetic solid body 130 has good fluidity, and the finished magnetic solid body 130 has a more uniform and dense texture. In specific configurations, the angle between the bottom surface 131 and the side surface 132 can be one of 95°, 100°, 105°, 110°, 115°, 120°, or 125°. Of course, the angle between the bottom surface 131 and the side surface 132 is not limited to the aforementioned range and can also be other values within the range of 95°-125°. In addition, the angle between the bottom surface 131 and the side surface 132 is not limited to the above-mentioned setting range, and the angle between the bottom surface 131 and the side surface 132 can be set according to the specific molding mold.

[0058] In addition, the present invention further provides a method for manufacturing the inductor 100 according to any one of the above technical solutions, and the manufacturing method comprises the following steps:

[0059] Step 1: Provide a lead frame 110 and a coil 120, such as Figure 5 As shown, the lead frame 110 has a protrusion 115, as shown in FIG. Figure 6 As shown, the coil 120 has two lead wires 121 .

[0060] A protrusion 115 is punched out on the smooth flexible conductive plate, and the excess portion of the punched flexible conductive plate is cut off by a cutting device. The flexible conductive plate is then punched again, so that the flexible conductive plate has a first end 113, a second end 114, a protrusion 115, a bent portion 116, and a limiting groove 117, thereby achieving pre-forming of the lead frame 110.

[0061] Step 2: Connect the two leads 121 to the first electrode pin 111 and the second electrode pin 112 respectively. Figure 6 shown.

[0062] One of the leads 121 is welded to the first electrode pin 111 , and the other lead 121 is welded to the second electrode pin 112 , thereby completing the fixed connection between the lead frame 110 and the leads 121 .

[0063] Step 3: Place the lead frame 110, the coil 120, and a certain amount of metal granulation powder in the mold, such as Figure 3 、 Figure 4 As shown, the preforming of the inductor 100 is completed.

[0064] Adhesive, curing agent and diluent are added to the soft magnetic alloy powder, and the powder is processed into a density of 2.5g / cm through mixing, granulation and drying. 3 -3.5g / cm 3 , metal granulated powder with a fluidity of 30 sec-50 sec and a particle size of 80 mesh-200 mesh; and filling a certain amount of metal granulated powder into a mold, placing the welded lead frame 110 and coil 120 in the mold, and again filling a certain amount of metal granulated powder so that the coil 120 is completely covered with the metal granulated powder, molding for a certain time, and demolding to complete the pre-forming of the inductor 100.

[0065] Step 4: Curing the preformed inductor 100 and cutting it to obtain the inductor 100, such as Figure 1 、 Figure 2 shown.

[0066] The preformed inductor 100 is placed in an oven for baking to complete the curing process of the preformed inductor 100 , and then the excess portion is cut off by a cutting device to obtain the inductor 100 .

[0067] In a preferred embodiment, step 2 further includes the following steps:

[0068] The surface of the preformed lead frame 110 is tinned to prevent oxidation of the lead frame 110 when directly exposed to air. The metal wire is then insulated and wound around a circular center column to form a coil 120. The lead wire 121 is then stripped of its insulation layer.

[0069] The above-described manufacturing method preforms the lead frame 110 by providing a lead frame 110 having a protrusion 115 and a coil 120 having a lead wire 121. This reduces subsequent processing steps for the lead frame 110, avoids damage to the formed inductor 100 during subsequent processing, and avoids waste of raw materials, thereby improving production efficiency. The lead wire 121 is welded to the first electrode pin 111 and the second electrode pin 112, respectively, to securely connect the coil 120 to the lead frame 110. The lead frame 110, coil 120, and a certain amount of metal granulated powder are placed in a mold to securely form the lead frame 110, coil 120, and magnetic solid body 130, completing the preformation of the inductor 100. The preformed inductor 100 is then cured and cut to obtain the inductor 100. The above-described manufacturing method is simple in process, highly utilizes raw materials, and improves production efficiency.

[0070] The technical features of the above-mentioned embodiments can be combined arbitrarily. In order to make the description concise, not all possible combinations of the technical features in the above-mentioned embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0071] The above-described embodiments merely illustrate several implementations of the present invention, and while their descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent. It should be noted that a person skilled in the art would be able to make numerous variations and improvements without departing from the spirit of the present invention, all of which fall within the scope of protection of the present invention. Therefore, the scope of protection of the patent for this invention shall be determined by the appended claims.

Claims

1. An inductor, characterized in that: The invention comprises a magnetic solid body, a coil and a lead frame, wherein the lead frame comprises a first electrode pin and a second electrode pin arranged on both sides of the magnetic solid body, and the first electrode pin and the second electrode pin are arranged outside the magnetic solid body, wherein: The magnetic solid body has a bottom surface and a plurality of side surfaces connected to the bottom surface; The coil is embedded in the magnetic solid body and has two leads, and the two leads are electrically connected to the first electrode pin and the second electrode pin respectively; The first electrode foot and the second electrode foot each have a first end located on one side of the bottom surface, a second end located on one side of the side surface, and at least one protrusion, the first end being attached to the bottom surface, the second end being attached to the side surface, and the protrusion being located on the first end and / or the second end, and being at least partially buried in the surface corresponding thereto.

2. The inductor according to claim 1, wherein The first end portion and the second end portion are flexible conductive plates connected to each other.

3. The inductor according to claim 2, wherein: The first end portion is attached to the bottom surface, and the second end portion is attached to the side surface.

4. The inductor according to claim 1, wherein The lead frame is a flexible conductive plate and is made of at least one of copper alloy, aluminum alloy and conductive rubber.

5. The inductor according to claim 1, wherein The first end portion has at least one bent portion, and the bent portion is embedded in the magnetic solid body.

6. The inductor according to claim 5, wherein: A limiting groove is provided on the bending portion, and the lead wire is embedded in the limiting groove.

7. The inductor according to claim 6, wherein: The bent portion is L-shaped and has an end surface parallel to the first end portion.

8. The inductor according to claim 6, wherein: The angle formed between the first end portion and the bent portion is 120°-150°.

9. The inductor according to claim 6, wherein: The angle formed between the first end portion and the bent portion is 30°-60°.

10. The inductor according to claim 1, wherein The included angle between the first end and the second end is the same as the included angle between the bottom surface and the side surface, and the included angle between the bottom surface and the side surface is 95°-125°.

11. A method for manufacturing an inductor according to any one of claims 1 to 10, characterized in that: The production method comprises the steps of: Providing the lead frame and the coil, wherein the lead frame has the protrusion and the coil has two lead wires; electrically connecting the two lead wires to the first electrode pin and the second electrode pin respectively; Placing the lead frame, the coil, and a certain amount of metal granulation powder in a mold to complete preforming of the inductor; The preformed inductor is cured and cut to obtain the inductor.

12. The manufacturing method according to claim 11, characterized in that: Before the two lead wires are electrically connected to the first electrode pin and the second electrode pin respectively, the method further includes performing surface treatment on the lead frame and the coil.

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