A ceramic wire-wound chip inductor and its manufacturing method

Abstract

This invention discloses a ceramic wire-wound surface mount inductor and its manufacturing method. This method allows for the containment of conductive extensions via wire strips after the coil is wound, effectively preventing short circuits or inductor damage caused by contact between the coil and the bent conductive extensions during subsequent soldering. The inductor includes a ceramic base and magnetic posts. The ceramic base has mounting slots at the center of its top for the magnetic posts. Both sides of the top of the ceramic base are fitted with mounting pads, each with a wire groove communicating with the mounting slot. A coil is wound and mounted on the magnetic posts. A insertion slot is formed at the outer edge of the magnetic posts, and a wire strip is inserted into the insertion slot. A passage slot is formed on the outer edge of the wire strip for the conductive extension of the coil to pass through. A snap-fit ​​slot is formed at the top of one side of the passage slot, and the wire strip is fixed to the wire groove of the mounting pad by soldering.

Description

Technical Field

[0001] This invention belongs to the field of inductor manufacturing technology, and particularly relates to a ceramic wire-wound surface mount inductor, as well as a method for manufacturing a ceramic wire-wound surface mount inductor. Background Technology

[0002] New surface mount inductors, also known as power inductors, high-current inductors, and surface mount high-power inductors, feature miniaturization, high quality, high energy storage, and low resistance. Inductors in general electronic circuits are air-core coils or coils with magnetic cores, capable of handling only small currents and low voltages. Power inductors, however, can be either air-core or with magnetic cores. Their main characteristic is that they are wound with thick wire and can withstand tens, hundreds, thousands, or even tens of thousands of amperes. New power surface mount inductors come in two types: with and without magnetic shields. They are mainly composed of a magnetic core and copper wire, and primarily function as filters and oscillators in circuits.

[0003] Existing ceramic wire-wound surface mount inductors have the following problems:

[0004] 1. After the coil is wound, in order to facilitate welding, the conductive extension of the coil needs to be bent and welded onto the pad. During the bending and welding process, problems such as the bent conductive extension coming into contact with the wound coil may occur.

[0005] 2. When the coil is exposed to the outside, it is prone to scratches and other problems during operation, and the coil cannot be protected.

[0006] To address these issues, we propose a ceramic wire-wound chip inductor and its manufacturing method. Summary of the Invention

[0007] The purpose of this invention is to solve the problems in the existing ceramic wire-wound chip inductor, where the conductive extension of the coil needs to be bent and soldered onto the pad after winding to facilitate soldering. During the bending and soldering process, the bent conductive extension may come into contact with the wound coil, which can easily damage the inductor. Therefore, this invention proposes a ceramic wire-wound chip inductor and its manufacturing method.

[0008] To achieve the above objectives, the present invention adopts the following technical solution:

[0009] A ceramic wire-wound surface mount inductor includes a ceramic base and magnetic wire posts mounted on the top of the ceramic base. A mounting groove for mounting the magnetic wire posts is formed at the center of the top of the ceramic base. Pads are embedded on both sides of the top of the ceramic base, and wire grooves communicating with the mounting grooves are formed on the pads. A coil is wound and mounted on the magnetic wire posts. A insertion groove is formed on the outer edge of the magnetic wire posts, and a wire strip is inserted and mounted into the insertion groove. A through groove is formed on the outer side of the wire strip for the conductive extension of the coil to pass through. A snap-fit ​​groove is formed at the top of one side of the through groove. The two ends of the conductive extension of the coil are respectively disposed in the wire grooves and fixed in the wire grooves of the pads by soldering.

[0010] Thanks to the wire strips, the conductive extension section can be accommodated after the coil is wound. This effectively prevents the coil from coming into contact with the bent conductive extension section during the subsequent welding process, thus avoiding short circuits or inductor damage.

[0011] Furthermore, guide strips are symmetrically protruding on both sides of the conductor strip, and limiting grooves for sliding of the guide strips are symmetrically opened on the plug groove.

[0012] Thanks to the guide strip and limiting groove, the wire can be stably inserted into the insertion groove during installation, ensuring that the wire will not fall off naturally.

[0013] Furthermore, a magnetic cover is fitted around the outer edge of the magnetic wire post, and the magnetic wire post and the magnetic cover are at the same vertical height.

[0014] Furthermore, the magnetic cover has a vertically formed cavity for accommodating the magnetic wire column, the diameter of which is the same as the diameter of the magnetic wire column. A snap-fit ​​block is symmetrically fixed near the top of the cavity, and a snap-fit ​​hole is formed at the top of the magnetic wire column to cooperate with the snap-fit ​​block for positioning.

[0015] Thanks to the fit between the snap-fit ​​blocks and snap-fit ​​holes, the magnetic cover can be stably snapped onto the magnetic wire post during operation to provide auxiliary irradiation protection for the coil and other components.

[0016] Furthermore, the snap-fit ​​block has an L-shaped groove structure, and the snap-fit ​​hole and the snap-fit ​​block are engaged and fixed together.

[0017] Furthermore, a positioning block is protruding from the bottom of the magnetic wire post, and a positioning groove is provided on the mounting groove for the positioning block to be inserted. The magnetic wire post is bonded to the mounting groove with adhesive.

[0018] Thanks to the cooperation between the positioning block and the positioning slot, when the magnetic wire post needs to be positioned and installed during the working process, it will not rotate under manual rotation after the magnetic wire post is positioned and installed. This ensures the overall stability of the conductive extension section after installation and avoids damage to the coil caused by the rotation of the magnetic wire post.

[0019] Furthermore, the magnetic wire post is generally H-shaped, and an upper magnetic conductive sheet and a lower magnetic conductive sheet are fixed at both ends of the magnetic wire post, respectively.

[0020] S1. The coil is wound and mounted on the magnetic wire post, and powder is prepared to form the magnetic conductor;

[0021] S2. The main body with the coil wound is placed into a die-casting cavity, and the conductive extension of the coil extends out of the die-casting cavity.

[0022] S3. Add magnetic conductor powder into the die-casting cavity and perform die-casting to make the powder tightly fill the interior of the main body and tightly cover the exterior of the main body;

[0023] S4. Insert the wire strip into the insertion slot, and snap one end of the coil into the wire slot of the wire strip through the snap-fit ​​slot;

[0024] S5. Install the magnetic cover in the magnetic cover, and snap the snap block on the magnetic cover into the snap hole. Rotate the magnetic cover to make the snap block stably snap into the snap hole, and then make the magnetic cover stably snap onto the magnetic wire post.

[0025] S6. Pour the hot melt adhesive into the snap-fit ​​hole;

[0026] S7. Pull out the magnetic wire posts from the two conductive extension sections of the coil through the insertion slot and the through hole respectively, and snap the magnetic wire posts into the wire slot;

[0027] S8. Apply adhesive to the bottom of the magnetic wire post and insert the positioning block into the positioning groove to complete the installation and positioning of the ceramic base and the magnetic wire post.

[0028] Furthermore, the powder of the magnetic conductor is composed of a mixture of high flux alloy magnetic powder and low flux alloy magnetic powder in appropriate proportions.

[0029] Furthermore, the preparation of the powder for the magnetic conductor includes the following steps:

[0030] A1. Insulators and diluents are added to these two alloy magnetic powders for insulation treatment. The mixture is thoroughly stirred and then placed in a baking oven for baking, so that the insulation can be completely hardened and form an insulating film on the surface of the alloy magnetic powder.

[0031] A2. Add epoxy resin to the mixed material that has undergone the above insulation treatment, stir it thoroughly to make it into a paste, and then granulate it with a granulator and screen it with a screening machine to obtain fine particles.

[0032] A3. Place the processed mixture into a baking oven for baking, and after baking, add the lubricant and mix evenly to obtain the powder of the magnetic conductor.

[0033] In summary, the technical effects and advantages of this invention are as follows:

[0034] 1. The present invention, through the setting of magnetic wire posts and the insertion slots opened on the magnetic wire posts and the wire strips inserted and installed in the insertion slots, can accommodate the conductive extension section through the wire strips after the coil is wound. It can effectively avoid the coil from contacting the bent conductive extension section during the subsequent welding process, thus preventing short circuits or inductor damage.

[0035] 2. Through the cooperation between the mounting groove on the ceramic base and the wire groove on the solder pad, the conductive extension section can be stably soldered onto the solder pad through the wire groove even when the magnetic cover is completely covered, which can effectively protect the coil. Attached Figure Description

[0036] Figure 1 This is a disassembly and assembly diagram of the present invention;

[0037] Figure 2 This is a schematic diagram of the structure of the magnetic wire column of the present invention;

[0038] Figure 3 For the present invention Figure 1 Enlarged view of point A in the middle;

[0039] Figure 4 This is a bottom view of the magnetic wire column of the present invention;

[0040] Figure 5 This is a schematic diagram of the ceramic base structure of the present invention;

[0041] Figure 6 This is a flowchart of the present invention;

[0042] Figure 7 This is a flowchart illustrating the process of preparing the powder for the magnetic conductor of the present invention.

[0043] In the diagram: 1. Ceramic base; 2. Mounting groove; 3. Solder pad; 4. Positioning groove; 5. Magnetic wire post; 51. Through hole; 6. Coil; 7. Insertion groove; 8. Wire strip; 81. Guide strip; 82. Snap-fit ​​groove; 9. Snap-fit ​​hole; 10. Magnetic cover; 101. Snap-fit ​​block; 11. Positioning block. Detailed Implementation

[0044] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0045] Reference Figure 1 and Figure 2 As shown, a ceramic wire-wound surface mount inductor includes a ceramic base 1 and magnetic wire posts 5 mounted on the top of the ceramic base 1. The magnetic wire posts 5 are generally I-shaped, with an upper magnetic guide plate and a lower magnetic guide plate fixed at both ends of the magnetic wire posts 5. Mounting grooves 2 for mounting the magnetic wire posts 5 are opened at the center of the top of the ceramic base 1. Pads 3 are embedded on both sides of the top of the ceramic base 1. Through the embedded pads 3, the conductive extension section on the subsequent coil 6 can be stably soldered onto it during operation. The pads 3 have wire grooves that communicate with the mounting grooves 2. Through the wire grooves, the conductive extension section can be stably soldered onto the pads 3 even when the magnetic cover 10 is completely covered. At the same time, the design of the guide groove can effectively protect the conductive extension section and avoid the wire being exposed and damaged during installation and other work. A coil 6 is wound and mounted on the magnetic wire posts 5.

[0046] A magnetic cover 10 is fitted around the outer edge of the magnetic wire post 5. The magnetic wire post 5 and the magnetic cover 10 have the same vertical height. A receiving cavity for the magnetic wire post 5 is vertically opened on the magnetic cover 10. The diameter of the receiving cavity is the same as the diameter of the magnetic wire post 5. A snap-fit ​​block 101 is symmetrically fixed near the top of the receiving cavity. A snap-fit ​​hole 9 is opened on the top of the magnetic wire post 5 to cooperate with the snap-fit ​​block 101 for positioning.

[0047] In addition, the snap-fit ​​block 101 has an L-shaped groove structure, and the snap-fit ​​hole 9 is engaged and fixed with the snap-fit ​​block 101. Through the engagement between the snap-fit ​​block 101 and the snap-fit ​​hole 9, the magnetic cover 10 can be stably snapped onto the magnetic wire post 5 during operation to provide auxiliary irradiation protection for the coil 6, etc.

[0048] Reference Figure 1 , Figure 2 and Figure 3 As shown, a wire strip 8 is inserted and installed on the insertion slot 7. A through slot is provided on the outer side of the wire strip 8 for the conductive extension section of the coil 6 to pass through. A snap-fit ​​slot 82 is provided at the top of one side of the through slot. The two ends of the conductive extension section of the coil 6 are respectively set in the wire slot and fixed to the wire slot of the pad 3 by soldering.

[0049] The conductive strip 8 can accommodate the conductive extension section after the coil 6 is wound. This effectively prevents the coil 6 from coming into contact with the bent conductive extension section during the subsequent welding process, thus avoiding short circuits or inductor damage.

[0050] Guide bars 81 are symmetrically protruding on both sides of the aforementioned conductor bar 8, and limiting grooves for sliding of the guide bars 81 are symmetrically opened on the insertion groove 7.

[0051] By cooperating with the guide bar 81 and the limiting groove, the wire bar 8 can be stably inserted into the insertion groove 7 during installation, ensuring that the wire bar 8 will not fall off naturally.

[0052] Reference Figure 1 , Figure 4 and Figure 5 As shown, a positioning block 11 is protruding from the bottom of the magnetic wire post 5, and a positioning groove 4 is provided on the mounting groove 2 for the positioning block 11 to be inserted. The magnetic wire post 5 is bonded to the mounting groove 2 with adhesive.

[0053] By cooperating with the positioning block 11 and the positioning groove 4, when the magnetic wire post 5 needs to be positioned and installed during the working process, it will not rotate under manual rotation after the magnetic wire post 5 is positioned and installed. This ensures the overall stability of the conductive extension section after installation and avoids damage to the coil 6 caused by the rotation of the magnetic wire post 5.

[0054] Reference Figure 6 As shown, a method for manufacturing a ceramic wire-wound surface mount inductor includes the following steps:

[0055] S1. The coil 6 is wound and installed on the magnetic wire post 5, and powder is prepared to form the magnetic conductor. To ensure the insulation between the coils 6, the coil is made of enameled wire.

[0056] S2. Place the main body with the coil wound into a die-casting cavity, and the conductive extension of the coil extends out of the die-casting cavity.

[0057] S3. Add magnetic material powder to the die-casting cavity and perform die-casting to make the powder tightly fill the interior of the main body and tightly cover the exterior of the main body. By die-casting the outer surface of the coil to form a dense magnetic layer, the overall magnetic permeability of the inductor can be improved. At the same time, the magnetic material will form a closed magnetic circuit structure, and the magnetic lines of force will be confined inside the magnetic material, thereby improving the overall anti-interference effect of the inductor.

[0058] S4. Insert the wire strip 8 into the insertion slot 7, and snap one end of the coil 6 into the wire slot of the wire strip 8 through the snap-fit ​​slot 82;

[0059] S5. Install the magnetic cover 10 in the magnetic cover 10, and snap the snap block 101 on the magnetic cover 10 into the snap hole 9. Rotate the magnetic cover 10 to make the snap block 101 stably snap into the snap hole 9, and thus make the magnetic cover 10 stably snap onto the magnetic wire post 5.

[0060] S6. Pour hot melt adhesive into the snap-fit ​​hole 9;

[0061] S7. Pull out the magnetic wire post 5 through the insertion slot 7 and the through hole 51 at both ends of the coil 6, and snap the magnetic wire post 5 into the wire groove.

[0062] S8. Apply adhesive to the bottom of the magnetic wire post 5 and insert the positioning block 11 into the positioning groove 4 to complete the installation and positioning of the ceramic base 1 and the magnetic wire post 5.

[0063] Specifically, the powder of the magnetic conductor is composed of a mixture of high flux alloy magnetic powder and low flux alloy magnetic powder in appropriate proportions.

[0064] Reference Figure 7 As shown, the preparation of the powder for the magnetic conductor includes the following process:

[0065] A1. Insulators and diluents are added to these two alloy magnetic powders for insulation treatment. The mixture is thoroughly stirred and then placed in a baking oven for baking, so that the insulation can be completely hardened and form an insulating film on the surface of the alloy magnetic powder.

[0066] A2. Add epoxy resin to the mixed material that has undergone the above insulation treatment, stir it thoroughly to make it into a paste, and then granulate it with a granulator and screen it with a screening machine to obtain fine particles.

[0067] A3. Place the processed mixture into a baking oven for baking, and after baking, add the lubricant and mix evenly to obtain the powder of the magnetic conductor.

[0068] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A ceramic wire-wound chip inductor, comprising a ceramic base (1) and magnetic wire posts (5) mounted on the top of the ceramic base (1), characterized in that, The ceramic base (1) has mounting grooves (2) at the center of the top for mounting magnetic wire posts (5). The ceramic base (1) has mounting pads (3) on both sides of the top. The mounting pads (3) have wire grooves that communicate with the mounting grooves (2). The magnetic wire posts (5) have coils (6) wound around them. The magnetic wire posts (5) have insertion grooves (7) at the outer edge. The insertion grooves (7) have wire strips (8) inserted into them. The outer side of the wire strips (8) has a through groove for the conductive extension of the coil (6) to pass through. The top of one side of the through groove has a snap-fit ​​groove (82). The two ends of the conductive extension of the coil (6) are respectively set in the wire grooves and fixed in the wire grooves of the mounting pads (3) by soldering.

2. The ceramic wire-wound chip inductor according to claim 1, characterized in that, Guide bars (81) are symmetrically protruding on both sides of the conductor bar (8), and limiting grooves for sliding of the guide bars (81) are symmetrically opened on the plug groove (7).

3. A ceramic wire-wound surface mount inductor according to claim 1, characterized in that, A magnetic cover (10) is fitted around the outer edge of the magnetic wire post (5), and the magnetic wire post (5) and the magnetic cover (10) have the same vertical height.

4. A ceramic wire-wound chip inductor according to claim 3, characterized in that, The magnetic cover (10) has a vertical cavity for accommodating the magnetic wire column (5). The diameter of the cavity is the same as the diameter of the magnetic wire column (5). A snap-fit ​​block (101) is symmetrically fixed near the top of the cavity. A snap-fit ​​hole (9) is provided on the top of the magnetic wire column (5) to cooperate with the snap-fit ​​block (101) for positioning.

5. A ceramic wire-wound chip inductor according to claim 4, characterized in that, The snap-fit ​​block (101) has an L-shaped groove structure, and the snap-fit ​​hole (9) and the snap-fit ​​block (101) are engaged and fixed together.

6. A ceramic wire-wound chip inductor according to claim 1, characterized in that, A positioning block (11) is provided at the bottom of the magnetic wire post (5), and a positioning groove (4) is provided on the mounting groove (2) for the positioning block (11) to be inserted. The magnetic wire post (5) is glued to the mounting groove (2) with adhesive.

7. A ceramic wire-wound chip inductor according to claim 6, characterized in that, The magnetic wire post (5) is in the shape of an I-beam, and an upper magnetic sheet and a lower magnetic sheet are fixed at both ends of the magnetic wire post (5).

8. A method for producing a ceramic wire-wound surface mount inductor, used to produce the ceramic wire-wound surface mount inductor according to any one of claims 1-7, characterized in that, Includes the following steps: S1. The coil (6) is wound and installed on the magnetic wire post (5), and powder is prepared to form the magnetic conductor; S2. The main body with the coil wound is placed into a die-casting cavity, and the conductive extension of the coil extends out of the die-casting cavity. S3. Add magnetic conductor powder into the die-casting cavity and perform die-casting to make the powder tightly fill the interior of the main body and tightly cover the exterior of the main body; S4. Insert the wire strip (8) into the insertion slot (7) and insert one end of the coil (6) into the wire slot of the wire strip (8) through the snap-fit ​​slot (82); S5. Install the magnetic cover (10) in the magnetic cover (10), and snap the snap block (101) on the magnetic cover (10) into the snap hole (9). Rotate the magnetic cover (10) to make the snap block (101) stably snap into the snap hole (9), and then make the magnetic cover (10) stably snap onto the magnetic wire post (5). S6. Pour hot melt adhesive into the snap-fit ​​hole (9); S7. Pull out the magnetic wire post (5) through the plug slot (7) and the through hole (51) of the two conductive extension sections of the coil (6) respectively, and snap the magnetic wire post (5) into the wire groove; S8. Apply adhesive to the bottom of the magnetic wire post (5) and insert the positioning block (11) into the positioning groove (4) to complete the installation and positioning of the ceramic base (1) and the magnetic wire post (5).

9. A method for producing a ceramic wire-wound chip inductor according to claim 8, characterized in that, The powder of the magnetic conductor is composed of a mixture of high flux alloy magnetic powder and low flux alloy magnetic powder in appropriate proportions.

10. A method for producing a ceramic wire-wound chip inductor according to claim 8, characterized in that, The preparation of the powder of the magnetic conductor includes the following process: A1. Insulators and diluents are added to these two alloy magnetic powders for insulation treatment. The mixture is thoroughly stirred and then placed in a baking oven for baking, so that the insulation can be completely hardened and form an insulating film on the surface of the alloy magnetic powder. A2. Add epoxy resin to the mixed material that has undergone the above insulation treatment, stir it thoroughly to make it into a paste, and then granulate it with a granulator and screen it with a screening machine to obtain fine particles. A3. Place the processed mixture into a baking oven for baking, and after baking, add the lubricant and mix evenly to obtain the powder of the magnetic conductor.

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