A high-performance and high-quality integrated inductor component and its production process

Abstract

The present invention discloses a high-performance and high-quality integrated inductor component and its production process, which includes two groups of inductor unit components, and each group of inductor unit components includes an upper soft magnetic coated component and a lower soft magnetic coated component; wherein the upper soft magnetic coated component includes a soft magnetic coated base and a coil, the coil is installed on the soft magnetic coated base, the coil is provided with a first lead pin and a second lead pin, the soft magnetic coated base includes a base plate, a limiting groove is opened in the middle of the top surface of the base plate, and a limiting opening is provided at one end of the limiting groove, and an installation column is arranged at the center of the bottom surface of the limiting groove; the lower soft magnetic coated component includes a soft magnetic coated cover plate and an insulating isolation plate; by adopting the above structure, it is possible to reduce the damage to the coil wire package caused by unprotected positioning pressing, the short circuit of the component caused by displacement, and the bad cracking and breakage, and improve the inductance and saturation temperature rise performance of the formed inductor component, and improve the reliability and performance of the formed inductor component.

Description

Technical Field

[0001] The present invention relates to the technical field of electronic components, and particularly relates to a high-performance and high-quality integrated inductor element and its production process. Background Art

[0002] The original model of an inductor element is a wire wound into a cylindrical coil. When a current i passes through the coil, a magnetic flux Φ will be generated in the coil and energy will be stored. The electromagnetic induction of the inductor element is divided into self-induction and mutual induction. The electromagnetic induction phenomenon caused by the change of the magnetic flux generated by the self-magnetic field in the coil is called the "self-induction" phenomenon; the electromagnetic induction phenomenon caused by the change of the magnetic flux generated by the external magnetic field in the coil is called the "mutual induction" phenomenon.

[0003] However, in the existing inductor elements, there is no protective positioning and pressing during the installation of the coil, resulting in the displacement of the coil position, and then causing uneven wall thickness on both sides, resulting in the problem of too small wall thickness on one side. When the wall thickness becomes smaller, the structural strength will become worse, so cracking will occur, resulting in damage to the wire package of the coil and short circuit of the element caused by the displacement, resulting in damage and poor quality of the inductor element. This poses a great test to the quality and service life of the inductor element product, and the quality of the produced inductor element is insufficient, lacking competitiveness in the market for similar products. Summary of the Invention

[0004] In order to overcome the above technical problems, the purpose of the present invention is to provide a high-performance and high-quality integrated inductor element and its production process.

[0005] The purpose of the present invention can be achieved by the following technical solutions:

[0006] A high-performance and high-quality integrated inductor element includes two groups of inductor unit components, which are symmetrically distributed. Each group of inductor unit components includes an upper soft magnetic coating component and a lower soft magnetic coating component;

[0007] Among them, the upper soft magnetic coating component includes a soft magnetic coating base and a coil. The coil is installed on the soft magnetic coating base. The coil is provided with a first lead pin and a second lead pin. The soft magnetic coating base includes a base plate. A limiting groove is opened in the middle of the top surface of the base plate, and a limiting opening is provided at one end of the limiting groove. An installation post is provided at the center of the bottom surface of the limiting groove;

[0008] The lower soft magnetic coating component includes a soft magnetic coating cover plate and an insulating isolation plate. The insulating isolation plate is located on the top surface of the soft magnetic coating cover plate.

[0009] As a further scheme of the present invention: the height of the installation post is higher than the height of the coil.

[0010] As a further scheme of the present invention: the height of the installation post is equal to the height of the coil.

[0011] As a further solution of the present invention: the height of the mounting post is less than the height of the coil.

[0012] As a further solution of the present invention: the soft magnetic coating body cover plate and the insulating isolation plate are integrally formed.

[0013] As a further solution of the present invention: the soft magnetic coating body cover plate and the insulating isolation plate are separately formed.

[0014] As a further solution of the present invention: both the soft magnetic coating body base and the soft magnetic coating body cover plate are made of soft magnetic powder.

[0015] As a further solution of the present invention: a production process of a high-performance and high-quality integrated inductor element includes the following steps:

[0016] Step 1: Slip the coil onto the mounting post of the soft magnetic coating body base and place it in the limiting groove. Then bend the first lead pin and the second lead pin, and limit the corresponding limiting opening with the first lead pin to obtain the upper component of the soft magnetic coating body.

[0017] Step 2: Place an upper component of the soft magnetic coating body in an extrusion mold, and then place a prefabricated lower component of the soft magnetic coating body upright in the extrusion mold.

[0018] Step 3: Place another prefabricated inverted lower component of the soft magnetic coating body in the extrusion mold again, and then place an inverted upper component of the soft magnetic coating body, where the orientations of the two first lead pins and the second lead pin are on the same side.

[0019] Step 4: Perform extrusion to obtain a semi-finished inductor element. Take out the semi-finished inductor element, and electroplate and tin the exposed first lead pin and second lead pin to obtain a finished inductor element.

[0020] Advantages of the present invention:

[0021] 1. By pre-forming the soft magnetic coating body base and setting the mounting post, the present invention ensures positioning and protection during coil installation. During pressing, the coil is fixed by the mounting post, ensuring the stability of the coil position during the pressing process, and reducing coil wire package damage, component short circuit caused by displacement, and poor cracking and breakage caused by non-protective positioning pressing.

[0022] 2. The present invention further reduces the external dimensions of the finished inductor element, especially the thickness is reduced by 3 mm. The manufactured small integrated inductor element provides better space utilization preconditions for connecting more components on a small circuit board, and at the same time reduces the consumption of raw materials such as iron powder, copper material, and tin required for manufacturing.

[0023] 3. While achieving the miniaturization of the integrated inductor component, the fabricated structure of the inductor component of the present invention increases the inductance of the integrated inductor component by about 14%, the saturation performance by 10%, and the DCR characteristic by 50%, further improving the reliability and performance of the molded inductor component. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The present invention will be further described below in conjunction with the accompanying drawings.

[0025] Figure 1 is a schematic structural diagram of the finished inductor component of the present invention;

[0026] Figure 2 is a schematic diagram of the coil structure in the present invention;

[0027] Figure 3 is a schematic diagram of the overall structure of the soft magnetic coating base in the first embodiment of the present invention;

[0028] Figure 4 is a schematic diagram of the overall structure of the lower component of the soft magnetic coating in the first embodiment of the present invention;

[0029] Figure 5 is a schematic diagram of the overall structure of the upper component of the soft magnetic coating in the first embodiment of the present invention;

[0030] Figure 6 is a schematic diagram of the extrusion position in the production process of the first embodiment of the present invention;

[0031] Figure 7 is a schematic diagram of the overall structure of the soft magnetic coating base in the second embodiment of the present invention;

[0032] Figure 8 is a schematic diagram of the overall structure of the lower component of the soft magnetic coating in the second embodiment of the present invention;

[0033] Figure 9 is a schematic diagram of the overall structure of the upper component of the soft magnetic coating in the second embodiment of the present invention;

[0034] Figure 10 is a schematic diagram of the extrusion position in the production process of the second embodiment of the present invention;

[0035] Figure 11 is a schematic diagram of the structural deformation of the soft magnetic coating cover in the second embodiment of the present invention Figure 1 ;

[0036] Figure 12 is a schematic diagram of the structural deformation of the soft magnetic coating base in the second embodiment of the present invention Figure 1 ;

[0037] Figure 13 is a schematic diagram of the structural deformation of the soft magnetic coating cover in the second embodiment of the present invention Figure 2 ;

[0038] Figure 14 Schematic diagram of the structural deformation of the soft magnetic coating base in the second embodiment of the present invention Figure 2 ;

[0039] Figure 15 Schematic diagram of the structural deformation of the soft magnetic coating cover in the second embodiment of the present invention Figure 3 ;

[0040] Figure 16 Schematic diagram of the structural deformation of the soft magnetic coating base in the second embodiment of the present invention Figure 3 ;

[0041] Figure 17 Schematic diagram of the structural deformation of the soft magnetic coating cover in the second embodiment of the present invention Figure 4 ;

[0042] Figure 18 Schematic diagram of the structural deformation of the soft magnetic coating base in the second embodiment of the present invention Figure 4 ;

[0043] Figure 19 Schematic diagram of the structural deformation of the soft magnetic coating base in the second embodiment of the present invention Figure 5 。

[0044] In the figure: 1. Coil; 101. First lead pin; 102. Second lead pin; 2. Soft magnetic coating base; 21. Mounting post; 22. Base plate; 23. Limiting groove; 24. Limiting opening; 202. Bottom flat plate; 203. First groove; 204. Second groove; 3. Soft magnetic coating lower assembly; 30. Soft magnetic coating cover plate; 31. Soft magnetic coating cover; 311. Placing groove; 312. Positioning opening; 32. Insulating separator; 4. Soft magnetic coating upper assembly; 5. Inductive element. Specific embodiments

[0045] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without making creative efforts belong to the scope of protection of the present invention.

[0046] Embodiment 1:

[0047] Such as Figures 1 - 6As shown, a high-performance and high-quality integrated inductor component includes two groups of inductor unit components 5. The two groups of inductor unit components 5 are symmetrically distributed about the joint surface. Each group of inductor unit components 5 includes a soft magnetic coated upper component 4 and a soft magnetic coated lower component 3. The inductor unit component 5 is assembled by the corresponding soft magnetic coated upper component 4 and soft magnetic coated lower component 3. Then, the two groups of inductor unit components 5 are placed in an extrusion die and pressed into one body to form the inductor component.

[0048] Further, as shown in Figure 2 , Figure 3 and Figure 5 The soft magnetic coated upper component 4 includes a soft magnetic coated base 2 and a coil 1. The coil 1 is installed on the soft magnetic coated base 2. The coil 1 is provided with a first lead pin 101 and a second lead pin 102. The above-mentioned soft magnetic coated base 2 includes a base plate 22. A limit groove 23 is opened in the middle of the top surface of the base plate 22. One end of the limit groove 23 is arc-shaped and the other end is rectangular. A limit opening 24 is opened at one end of the rectangular surface for positioning and restricting the position of the installed first lead pin 101 or second lead pin 102, which is convenient for subsequent pressing. Further, a mounting post 21 is provided at the center of the bottom surface of the limit groove 23 for assembly positioning. The shape of the mounting post 21 includes but is not limited to circular and oval. The soft magnetic coated upper component 4 is formed by assembling the coil 1 and the soft magnetic coated base 2. During the installation process of the coil 1, the first lead pin 101 and the second lead pin 102 need to be bent twice. The first bending makes the first lead pin 101 and the second lead pin 102 bend to the side surface of the corresponding base plate 22, and the second bending bends the first lead pin 101 and the second lead pin 102 to the bottom surface of the base plate 22 and closely fits with the bottom surface of the base plate 22.

[0049] Even further, as shown in Figure 3 the height of the mounting post 21 in

[0050] can be higher than the height of the coil 1, equal to the height of the coil 1, or lower than the height of the coil 1, and various sizes are available. Figure 4 Further, as shown in

[0051] Furthermore, both the soft magnetic coated body base 2 and the soft magnetic coated body cover plate 30 are made of soft magnetic powder. Commonly used soft magnetic materials include ferrite, iron powder core, amorphous alloy, etc., which can deform under pressure. The material of the above-mentioned insulating separator 32 is ceramic, polymer, nano, and metal particles after insulating coating.

[0052] Furthermore, during the prefabrication process of the above-mentioned soft magnetic coated body cover plate 30 and the insulating separator 32, powder filling prefabrication or block cutting prefabrication can be carried out.

[0053] Furthermore, the production process of this high-performance and high-quality integrated inductor element includes the following several schemes:

[0054] Scheme 1:

[0055] Step A1: Put the coil 1 on the mounting post 21 of the soft magnetic coated body base 2 and place it in the limit groove 23. Then bend the first lead pin 101 and the second lead pin 102. Among them, the limit opening 24 is corresponding to the limit of the first lead pin 101, and the number of bends is two. The first bend bends the first lead pin 101 and the second lead pin 102 to the side of the base plate 22 where the limit opening 24 is provided. The second bend bends the first lead pin 101 and the second lead pin 102 to the bottom surface of the base plate 22 and closely fits with the bottom surface of the base plate 22 to obtain the upper component 4 of the soft magnetic coated body;

[0056] Step A2: Place an upper component 4 of the soft magnetic coated body in the extrusion die. Then place a prefabricated lower component 3 of the soft magnetic coated body (where the soft magnetic coated body cover plate 30 and the insulating separator 32 are integrally formed) upright in the extrusion die;

[0057] Step A3: Place another inverted prefabricated lower component 3 of the soft magnetic coated body (where the soft magnetic coated body cover plate 30 and the insulating separator 32 are integrally formed) in the extrusion die again. Then place an inverted upper component 4 of the soft magnetic coated body, where the orientations of the two first lead pins 101 and the second lead pin 102 are on the same side;

[0058] Step A4: Extrude to obtain a semi-finished inductor element. Take out the semi-finished inductor element and electroplate and tin the exposed first lead pin 101 and second lead pin 102 to obtain a finished inductor element (where the size of the tin plating is based on the longer lead pin).

[0059] Scheme 2:

[0060] Step B1: Slip the coil 1 onto the mounting post 21 of the soft magnetic coated body base 2 and place it in the limiting groove 23. Then bend the first lead pin 101 and the second lead pin 102. Align the limiting opening 24 with the first lead pin 101 for limiting. The number of bends is two. The first bend bends the first lead pin 101 and the second lead pin 102 to the side of the base plate 22 where the limiting opening 24 is provided. The second bend bends the first lead pin 101 and the second lead pin 102 to the bottom surface of the base plate 22 and closely adheres them to the bottom surface of the base plate 22 to obtain the upper component 4 of the soft magnetic coated body;

[0061] Step B2: Place an upper component 4 of the soft magnetic coated body in the extrusion die. Then invert and place a prefabricated combined body of lower components of the soft magnetic coated body (where the combined body of lower components of the soft magnetic coated body is pre-pressed integrally from two lower components 3 of the soft magnetic coated body) into the extrusion die;

[0062] Step B3: Place another inverted upper component 4 of the soft magnetic coated body in the extrusion die, where the orientations of the two first lead pins 101 and the second lead pin 102 are on the same side;

[0063] Step B4: Perform extrusion to obtain a semi-finished inductance component. Take out the semi-finished inductance component and electroplate and tin the exposed first lead pin 101 and second lead pin 102 to obtain a finished inductance component (where the size of the tinning is based on the longer lead pin).

[0064] Solution Three:

[0065] Step C1: Slip the coil 1 onto the mounting post 21 of the soft magnetic coated body base 2 and place it in the limiting groove 23. Then bend the first lead pin 101 and the second lead pin 102. Align the limiting opening 24 with the first lead pin 101 for limiting. The number of bends is two. The first bend bends the first lead pin 101 and the second lead pin 102 to the side of the base plate 22 where the limiting opening 24 is provided. The second bend bends the first lead pin 101 and the second lead pin 102 to the bottom surface of the base plate 22 and closely adheres them to the bottom surface of the base plate 22 to obtain the upper component 4 of the soft magnetic coated body;

[0066] Step C2: Place an upper component 4 of the soft magnetic coated body in the extrusion die. Then invert and place a prefabricated soft magnetic coated body cover plate 30 (where the soft magnetic coated body cover plate 30 and the insulating separator 32 are formed separately) into the extrusion die;

[0067] Step C3: Place two prefabricated insulating separator plates 32 in the extrusion die, and then place a prefabricated soft magnetic cladding cover plate 30 placed upright (where the soft magnetic cladding cover plate 30 and the insulating separator plate 32 are separately formed). Then place an inverted upper component 4 of the soft magnetic cladding, with the orientations of the two first lead pins 101 and the second lead pins 102 on the same side;

[0068] Step C4: Perform extrusion to obtain a semi-finished inductor component. Take out the semi-finished inductor component, and electroplate and tin the exposed first lead pins 101 and second lead pins 102 to obtain a finished inductor component (where the tinning size is based on the longer lead pin).

[0069] Embodiment 2:

[0070] Compared with Embodiment 1, the difference in this embodiment is that, as Figures 7 - 10 shown, the structure of the soft magnetic cladding base 2 is different. The soft magnetic cladding base 2 in this embodiment includes a bottom flat plate 202. An installation post 21 identical to that in Embodiment 1 is provided in the middle of the top surface of the bottom flat plate 202. A first groove 203 and a second groove 204 are formed on one side surface of the bottom flat plate 202, and the first groove 203 and the second groove 204 are symmetrically distributed about the longitudinal center line of the bottom flat plate 202. The upper component 4 of the soft magnetic cladding is formed by assembling the coil 1 and the soft magnetic cladding base 2. During the installation of the coil 1, the first lead pin 101 and the second lead pin 102 need to be bent twice. The first bending makes the first lead pin 101 and the second lead pin 102 bend into the corresponding first groove 203 and second groove 204, and the second bending bends the first lead pin 101 and the second lead pin 102 to the bottom surface of the bottom flat plate 202 and closely fits with the bottom surface of the bottom flat plate 202.

[0071] Similarly, the height of the installation post 21 in Embodiment 2 can also be higher than the height of the coil 1, equal to the height of the coil 1, or lower than the height of the coil 1, and various sizes are available.

[0072] Furthermore, the difference in this embodiment is that, as Figure 8As shown, in the lower component 3 of the soft magnetic coating body, the soft magnetic coating body cover 31 replaces the soft magnetic coating body cover plate 30. A placement groove 311 is provided on one side of the soft magnetic coating body cover 31 for assembling with the coil 1 in the upper component 4 of the soft magnetic coating body. Further, a positioning opening 312 is provided at one end of the placement groove 311 to facilitate positioning of the first lead pin 101 or the second lead pin 102. The insulating separator 32 is located on the opposite side of the soft magnetic coating body cover 31 where the placement groove 311 is provided. It should be noted that the soft magnetic coating body cover 31 and the insulating separator 32 are integrally formed or separately formed. When finally forming the inductive component, they can be placed and pressed in sequence, and the soft magnetic coating body cover 31 and the soft magnetic coating body cover plate 30 are made of the same material.

[0073] Furthermore, as Figures 11 - 18 shown, the soft magnetic coating body cover 31 and the soft magnetic coating body base 2 of this embodiment can adopt a variety of corresponding structures for cooperation:

[0074] A: As Figure 11 and Figure 12 shown, the mounting posts 21 are the same as in this embodiment, and the positioning opening 312 is a fully through opening and is connected to the placement groove 311;

[0075] B: As Figure 13 and Figure 14 shown, mounting posts 21 are provided on both the placement groove 311 and the bottom flat plate 202, and the sizes of the two mounting posts 21 are matched with each other. The positioning opening 312 is a fully through opening and is connected to the placement groove 311. Two grooves are provided below the positioning opening 312 to correspond to the first groove 203 and the second groove 204;

[0076] C: As Figures 15 - 16 shown, mounting posts 21 are provided on both the placement groove 311 and the bottom flat plate 202, and the sizes of the two mounting posts 21 are matched with each other. The rest is the same as in Embodiment 2;

[0077] D: As Figures 17 - 18 shown, the mounting posts 21 remain unchanged. The difference is that the end of the bottom flat plate 202 away from the positioning protrusion 205 is rounded. A step surface is formed on the side of the soft magnetic coating body cover 31 where the placement groove 311 is provided. The step height is equal to the thickness of the bottom flat plate 202, and the bottom flat plate 202 with a rounded corner is adapted to the stepped soft magnetic coating body cover 31.

[0078] E: As Figure 19 shown, the mounting posts 21 remain unchanged. The difference is that the bottom flat plate 202 is cross-shaped, and the corresponding soft magnetic coating body cover 31 can be of any shape.

[0079] Except for the structural features of the above differences, this embodiment is the same as Embodiment 1 in other structures.

[0080] Furthermore, the production process of this high-performance and high-quality integrated inductor component includes the following several solutions:

[0081] Solution Four:

[0082] Step D1: Put the coil 1 onto the mounting post 21 of the soft magnetic coating base 2. Then bend the first lead pin 101 and the second lead pin 102 twice. For the first bend, bend the first lead pin 101 and the second lead pin 102 into the corresponding first groove 203 and second groove 204. For the second bend, bend the first lead pin 101 and the second lead pin 102 to the bottom surface of the bottom flat plate 202 and closely fit with the bottom surface of the bottom flat plate 202 to obtain the upper component 4 of the soft magnetic coating body;

[0083] Step D2: Place an upper component 4 of the soft magnetic coating body in the extrusion die. Then invert and place a prefabricated lower component 3 of the soft magnetic coating body (where the soft magnetic coating cover 31 and the insulating separator 32 are integrally formed) into the extrusion die, and limit the positioning opening 312 corresponding to the first lead pin 101;

[0084] Step D3: Place another upright prefabricated lower component 3 of the soft magnetic coating body (where the soft magnetic coating cover 31 and the insulating separator 32 are integrally formed) into the extrusion die again. Then place an inverted upper component 4 of the soft magnetic coating body, where the orientations of the two first lead pins 101 and the second lead pin 102 are on the same side;

[0085] Step D4: Perform extrusion to obtain a semi-finished inductor component. Take out the semi-finished inductor component and electroplate and tin the exposed first lead pin 101 and second lead pin 102 to obtain a finished inductor component (where the tinning size is based on the longer lead pin).

[0086] Solution Five;

[0087] Step E1: Put the coil 1 onto the mounting post 21 of the soft magnetic coating base 2. Then bend the first lead pin 101 and the second lead pin 102 twice. For the first bend, bend the first lead pin 101 and the second lead pin 102 into the corresponding first groove 203 and second groove 204. For the second bend, bend the first lead pin 101 and the second lead pin 102 to the bottom surface of the bottom flat plate 202 and closely fit with the bottom surface of the bottom flat plate 202 to obtain the upper component 4 of the soft magnetic coating body;

[0088] Step E2: Place an upper component 4 of the soft magnetic coating body in the extrusion die. Then invert and place a prefabricated soft magnetic coating cover 31 (where the soft magnetic coating cover 31 and the insulating separator 32 are separately formed) into the extrusion die, and limit the positioning opening 312 corresponding to the first lead pin 101;

[0089] Step E3: Place two prefabricated insulating separator plates 32 in the extrusion die, and then place a prefabricated soft magnetic coated body cover 31 placed upright (where the soft magnetic coated body cover 31 and the insulating separator plate 32 are formed separately), and then place an inverted upper component 4 of the soft magnetic coated body, with the orientations of the two first lead pins 101 and the second lead pins 102 on the same side;

[0090] Step E4: Perform extrusion to obtain a semi-finished inductance component. Take out the semi-finished inductance component, and electroplate and tin the exposed first lead pins 101 and second lead pins 102 to obtain a finished inductance component (where the tinning size is based on the longer lead pin).

[0091] Solution Six;

[0092] Step F1: Slip the coil 1 onto the mounting post 21 of the soft magnetic coated body base 2, and then bend the first lead pin 101 and the second lead pin 102 twice. The first bend places the first lead pin 101 and the second lead pin 102 into the corresponding first groove 203 and second groove 204, and the second bend places the first lead pin 101 and the second lead pin 102 onto the bottom surface of the bottom plate 202 and makes them fit tightly against the bottom surface of the bottom plate 202 to obtain the upper component 4 of the soft magnetic coated body;

[0093] Step F2: Place an upper component 4 of the soft magnetic coated body in the extrusion die, and then place an inverted prefabricated soft magnetic coated body cover 31 (where the soft magnetic coated body cover 31 and the insulating separator plate 32 are formed separately) into the extrusion die, and positionally limit the positioning opening 312 corresponding to the first lead pin 101;

[0094] Step F3: Place a prefabricated insulating separator plate 32 (where the thickness of this insulating separator plate 32 is twice that of the first embodiment and the second embodiment) in the extrusion die, and then place a prefabricated soft magnetic coated body cover 31 placed upright again (where the soft magnetic coated body cover 31 and the insulating separator plate 32 are formed separately), and then place an inverted upper component 4 of the soft magnetic coated body, with the orientations of the two first lead pins 101 and the second lead pins 102 on the same side;

[0095] Step F4: Perform extrusion to obtain a semi-finished inductance component. Take out the semi-finished inductance component, and electroplate and tin the exposed first lead pins 101 and second lead pins 102 to obtain a finished inductance component (where the tinning size is based on the longer lead pin).

[0096] Further performance tests were conducted on the integrated inductor element of the present invention and a traditional integrated inductor element. Among them, the thickness was detected using a vernier caliper, the inductance was detected using an inductance meter (model: HIOKI IM3536), the saturation inductance was measured using a winding element pulse tester (model: Chroma 3302), and the DC resistance was measured using a DCR meter (model: GW Instek GOM804). The experimental data obtained are shown in Tables 1 and 2 below;

[0097] Table 1 shows the data of the integrated inductor element of the present invention:

[0098]

[0099]

[0100]

[0101] Table 2 shows the data of the traditional integrated inductor element:

[0102]

[0103]

[0104]

[0105] From the comparison of the experimental data in Tables 1 and 2, it can be seen that the integrated inductor element of the present invention is more miniaturized in size compared to the traditional integrated inductor element. The thickness is reduced by 0.3 mm. The inductance of the integrated inductor element of the present invention is increased by about 14%. Under the condition of 6.6 A, the saturation characteristic of the integrated inductor element of the present invention is improved by about 10%, and further the DCR characteristic is improved by about 50%.

[0106] Among them, DCR is the DC resistance, and the unit is mΩ. For inductors of the same size, their DC resistance usually has the following characteristics: if the inductance value is higher, the DC resistance value is higher; and if the inductance value is lower, the DC resistance value is lower.

[0107] The above has described in detail one embodiment of the present invention, but the content described is only the preferred embodiment of the present invention and cannot be considered as limiting the scope of implementation of the present invention. All equivalent changes and improvements made according to the scope of the application of the present invention should still fall within the scope covered by the patent of the present invention.

Claims

1. A production process for a high-performance and high-quality integrated inductor component, characterized in that, It includes the following steps: Step 1: Put the coil (1) onto the mounting post (21) of the soft magnetic coating base (2) and place it in the limiting groove (23). Then bend the first lead pin (101) and the second lead pin (102), and limit the corresponding position of the limiting opening (24) and the first lead pin (101) to obtain the upper component (4) of the soft magnetic coating body; During the installation process of the coil (1), the first lead pin (101) and the second lead pin (102) need to be bent twice. The first bending makes the first lead pin (101) and the second lead pin (102) bend to the side of the corresponding base plate (22), and the second bending bends the first lead pin (101) and the second lead pin (102) to the bottom surface of the base plate (22) and makes them closely fit with the bottom surface of the base plate (22); Step 2: Place an upper component (4) of the soft magnetic coating body in the extrusion die, and then place a prefabricated lower component (3) of the soft magnetic coating body upright in the extrusion die; Step 3: Place another inverted prefabricated lower component (3) of the soft magnetic coating body in the extrusion die, and then place an inverted upper component (4) of the soft magnetic coating body, where the orientations of the two first lead pins (101) and the second lead pin (102) are on the same side; Step 4: Extrude to obtain a semi-finished inductance component. Take out the semi-finished inductance component, and electroplate and tin the exposed first lead pin (101) and the second lead pin (102) to obtain a finished inductance component; The high-performance and high-quality integrated inductance component includes two groups of inductance unit components (5), and the two groups of inductance unit components (5) are symmetrically distributed. Each group of inductance unit components (5) includes an upper component (4) of the soft magnetic coating body and a lower component (3) of the soft magnetic coating body; The upper component (4) of the soft magnetic coating body includes a soft magnetic coating base (2) and a coil (1). The coil (1) is installed on the soft magnetic coating base (2). The coil (1) is provided with a first lead pin (101) and a second lead pin (102). The soft magnetic coating base (2) includes a base plate (22). A limiting groove (23) is opened in the middle of the top surface of the base plate (22), and a limiting opening (24) is provided at one end of the limiting groove (23). The center of the bottom surface of the limiting groove (23) is provided with a mounting post (21); The orientations of the two first lead pins (101) and the second lead pin (102) are on the same side; The lower component (3) of the soft magnetic coating body includes a soft magnetic coating cover plate (30) and an insulating isolation plate (32), and the insulating isolation plate (32) is located on the top surface of the soft magnetic coating cover plate (30); The soft magnetic coating cover plate (30) and the insulating isolation plate (32) are integrally formed.

2. A high-performance and high-quality integrated inductor component, produced by using the production process of a high-performance and high-quality integrated inductor component as described in claim 1, wherein, It includes two groups of inductance unit components (5), and the two groups of inductance unit components (5) are symmetrically distributed. Each group of inductance unit components (5) includes an upper component (4) of the soft magnetic coating body and a lower component (3) of the soft magnetic coating body; Among them, the upper component (4) of the soft magnetic coating body includes a soft magnetic coating body base (2) and a coil (1). The coil (1) is installed on the soft magnetic coating body base (2). The coil (1) is provided with a first lead pin (101) and a second lead pin (102). The soft magnetic coating body base (2) includes a base plate (22). A limiting groove (23) is formed in the middle of the top surface of the base plate (22), and a limiting opening (24) is provided at one end of the limiting groove (23). An installation column (21) is provided at the center of the bottom surface of the limiting groove (23). The orientations of the two first lead pins (101) and the second lead pin (102) are on the same side. The lower component (3) of the soft magnetic coating body includes a soft magnetic coating body cover plate (30) and an insulating separator (32). The insulating separator (32) is located on the top surface of the soft magnetic coating body cover plate (30). The soft magnetic coating body cover plate (30) and the insulating separator (32) are integrally formed.

3. A high-performance and high-quality integrated inductor component according to claim 2, characterized in that The height of the installation column (21) is higher than the height of the coil (1).

4. A high-performance and high-quality integrated inductor component according to claim 2, characterized in that The height of the installation column (21) is equal to the height of the coil (1).

5. A high-performance and high-quality integrated inductor component according to claim 2, characterized in that, The height of the installation column (21) is less than the height of the coil (1).

6. The high-performance and high-quality integrated inductor component according to claim 2, characterized in that Both the soft magnetic coating body base (2) and the soft magnetic coating body cover plate (30) are made of soft magnetic powder.

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