Inductor and method of forming the same

Abstract

The application relates to an inductor and a forming method thereof. The forming method comprises the following steps: providing an inductor mold, a coil and magnetic metal powder; conveying the magnetic metal powder into a mold cavity, applying pressure on the surface of the magnetic metal powder to form a first magnetic body, the first magnetic body comprising a bearing part and a limiting part protruding from the bearing part, the limiting part being located at the edge of the bearing part; placing the coil on the bearing part and making the side of the coil abut against the limiting part; continuously conveying the magnetic metal powder into the mold cavity, applying pressure on the surface of the magnetic metal powder to form a second magnetic body, the second magnetic body being buckled on the first magnetic body and covering the coil to form the inductor. The forming method of the inductor provided by the application forms the first magnetic body and the second magnetic body in sections, and the coil is circumferentially positioned through the limiting part on the first magnetic body, so that the positioning reliability of the coil is high, thereby improving the inductance performance of the inductor.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of electrical component forming, in particular to an inductor and a forming method thereof. BACKGROUND

[0002] The inductor is the most commonly used component in electronic devices, which is widely used in various circuits. In the circuit, it mainly plays the roles of filtering, oscillation, delay, wave trapping, and the roles of signal screening, noise filtering, current stabilization, and electromagnetic wave interference suppression. With the continuous development of science and technology, the inductor is also upgraded, and the integrally formed inductor appears. The integrally formed inductor includes a winding and a magnetic body. The magnetic body is made of metal magnetic powder by die casting, and the winding is composed of a coil and a lead terminal connected to the end of the coil. The winding is embedded in the magnetic body, and the lead terminal is extended to the outside of the magnetic body to form an integrally formed inductor. The volume of the inductor can be reduced, and the inductor has the advantages of large current and high production efficiency.

[0003] In the forming process of the existing integrally formed inductor, in order to ensure that the coil is at the center position of the magnetic body, the following two methods are usually used to position the coil. One of them is to use a wire frame to position the coil, and then die cast the magnetic body around the coil to make the magnetic body cover the outside of the coil. However, the positioning cost of using the wire frame is too high, and the volume of the coil is limited by the wire frame, resulting in weak inductance performance of the inductor after forming. The other is to form the magnetic body in sections, first form a T column at the center position of one of the magnetic bodies, then wind the coil on the T column, and finally cover the other magnetic body on the outside of the coil. However, this coil positioning method has high requirements for the strength of the T column on the magnetic body. In the forming process of the inductor, the inductor is prone to T column fracture, which causes the position of the coil in the inductor after forming to deviate, seriously affecting the inductance performance of the inductor after forming. SUMMARY

[0004] Therefore, it is necessary to provide an inductor and a forming method thereof for solving the problems that the positioning method of the coil in the forming process of the existing inductor easily limits the setting volume of the coil in the inductor, or the position of the coil in the inductor after forming is prone to deviation.

[0005] A forming method of an inductor, comprising the following steps:

[0006] S110: providing an inductor mold, a coil, and magnetic metal powder, wherein the inductor mold has a model cavity;

[0007] S120: The magnetic metal powder is conveyed into the model cavity, and pressure is applied to the surface of the magnetic metal powder to form a first magnetic body. The first magnetic body includes a supporting part and a limiting part protruding from the supporting part. The limiting part is located at the edge of the supporting part.

[0008] S130: Place the coil on the support portion and make its side abut against the limiting portion;

[0009] S140: Continue to feed the magnetic metal powder into the model cavity, apply pressure to the surface of the magnetic metal powder to form a second magnetic body, the second magnetic body is fastened to the first magnetic body and covers the coil to form an inductor.

[0010] The aforementioned inductor molding method first involves conveying magnetic metal powder into a mold cavity, applying pressure to the surface of the magnetic metal powder to form a first magnetic body, then placing a coil on a support portion and having the side of the coil abut against a limiting portion. Finally, magnetic metal powder is continuously conveyed into the mold cavity, and pressure is applied to the surface of the magnetic metal powder to form a second magnetic body. The second magnetic body is then fastened onto the first magnetic body, and the second magnetic body covers the coil to form an inductor. The inductor molding method provided by this invention segments the first and second magnetic bodies, and uses the limiting portion on the first magnetic body to circumferentially position the coil. This ensures high coil positioning reliability, guaranteeing that the coil is located at the center of the molded inductor, and does not restrict the size of the coil within the inductor, thereby improving the inductance performance of the inductor.

[0011] In one embodiment, in step S120, the limiting portion includes a plurality of limiting posts, which are spaced apart along the circumferential direction of the first magnetic body at the periphery of the bearing portion.

[0012] In one embodiment, step S120 specifically involves: conveying the magnetic metal powder into the model cavity, and applying a 1000 kg / cm² pressure to the surface of the magnetic metal powder. 2 -1500kg / cm 2 The pressure causes the magnetic metal powder to be pressed into a first magnetic body.

[0013] In one embodiment, step S140 specifically involves: continuing to deliver the magnetic metal powder into the model cavity, and applying a 1000 kg / cm² pressure to the surface of the magnetic metal powder. 2 -1500kg / cm 2 The pressure causes the magnetic metal powder to be pressed into a second magnetic body.

[0014] In one embodiment, the method further includes the following step after step S140:

[0015] S150: preheating the inductor;

[0016] S160: pressing the preheated inductor under high temperature conditions.

[0017] In one embodiment, the step S150 specifically comprises preheating the inductor under temperature conditions of 160-180°C for 2-10s.

[0018] In one embodiment, the step S160 specifically comprises placing the preheated inductor under temperature conditions of 160-180°C and allowing the inductor to be cured under pressure conditions of 2000-2500kg / cm 2 2 for 5-120s.

[0019] An inductor is prepared by the forming method of the inductor according to any one of the above technical solutions.

[0020] The inductor is formed by segmenting the first magnetic body and the second magnetic body, and the coil is circumferentially positioned by the limiting portion on the first magnetic body, so that the positioning reliability of the coil is high, the coil is ensured to be located at the center position of the formed inductor, and the size of the coil in the inductor is not limited, so that the inductance performance of the inductor is improved.

[0021] In one embodiment, the inductor comprises a first magnetic body, a second magnetic body and a coil, the second magnetic body is buckled on the first magnetic body, the coil comprises a main body and two lead wires connected to the end of the main body, the main body is embedded in the first magnetic body and the second magnetic body, and at least part of the two lead wires extends outside the first magnetic body and the second magnetic body.

[0022] In one embodiment, the lead wire comprises a connecting portion, a first bending portion and a second bending portion connected in sequence, the connecting portion is connected to the end of the main body, and the included angle between the extension direction of the second bending portion and the extension direction of the connecting portion is 20-30°. BRIEF DESCRIPTION OF DRAWINGS

[0023] Figure 1 A flowchart of the forming method of the inductor provided by the present application is shown in the figure;

[0024] Figure 2 A schematic diagram of the inductor provided by the present application is shown in the figure.

[0025] Reference signs:

[0026] ​100. Inductor

[0027] 110. Coil; 111. Main body; 112. Lead wire; 1121. Connection part; 1122. First bending part; 1123. Second bending part; 120. First magnetic body; 121. Bearing part; 122. Limiting part; 130. Second magnetic body. DETAILED DESCRIPTION

[0028] In order to make the above objectives, features and advantages of the present application more clear and comprehensible, the specific embodiments of the present application will be described in detail below with reference to the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present application. It will be apparent, however, to one skilled in the art that the present application can be practiced in a variety of ways beyond the specific embodiments described herein without departing from the spirit of the present application, and it is intended that the present application cover all modifications and variations of this application within the scope of the appended claims.

[0029] In the description of the present application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the purpose of facilitating the description of the present application and simplifying the description, and therefore cannot be understood as indicating or implying that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application.

[0030] In addition, the terms "first", "second", "third", etc. are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined with "first", "second", etc. can explicitly or implicitly include at least one of the features. In the description of the present application, the meaning of "a plurality of" is at least two, such as two, three, etc., unless otherwise explicitly specified and limited.

[0031] In the present application, unless otherwise explicitly specified and limited, the terms "mounting", "connection", "connection", "fixing" and the like should be understood in a broad sense, for example, it can be fixedly connected, or it can be detachably connected, or it can be integrated; it can be mechanically connected, or it can be electrically connected; it can be directly connected, or it can be indirectly connected through an intermediate medium; it can be the internal communication of two elements or the interaction relationship between two elements, unless otherwise explicitly limited. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0032] In the present application, unless otherwise explicitly specified and limited, a first feature is "on" or "under" a second feature can be that the first and second features are in direct contact, or the first and second features are in indirect contact through an intermediate medium. Moreover, the first feature is "over", "above" and "on top of" the second feature can be that the first feature is directly above or obliquely above the second feature, or simply means that the first feature is horizontally higher than the second feature. The first feature is "under", "below" and "underneath" the second feature can be that the first feature is directly below or obliquely below the second feature, or simply means that the first feature is horizontally lower than the second feature.

[0033] It should be noted that when an element is referred to as "fixed to" or "disposed on" another element, it can be directly on the other element or there can be an intermediate element. When an element is referred to as "connected to" another element, it can be directly connected to the other element or there can be an intermediate element. The terms "vertical", "horizontal", "up", "down", "left", "right" and similar expressions used herein are for illustrative purposes only and are not intended to be the only implementation.

[0034] The technical solutions provided by the embodiments of the present application are described below with reference to the accompanying drawings.

[0035] As Figure 1 With Figure 2 As shown in the drawings, the present application provides a forming method of an inductor, the forming method of the inductor comprises the following steps.

[0036] Step S110: providing an inductor mold, a coil 110 and a magnetic metal powder, the inductor mold has a model cavity which can be used for carrying and containing the magnetic metal powder. In order to make the magnetic metal powder be pressed to form a first magnetic body 120, the model cavity has a structure which can form a carrying part 121 and a limiting part 122.

[0037] Step S120: conveying the magnetic metal powder into the model cavity, and applying pressure on the surface of the magnetic metal powder to form the first magnetic body 120. The first magnetic body 120 comprises the carrying part 121 and the limiting part 122, the limiting part 122 protrudes from the carrying part 121, and the limiting part 122 is located at the edge of the carrying part 121, in other words, the carrying part 121 is located at the middle position of the first magnetic body 120, and the limiting part 122 is located at the edge position of the first magnetic body 120. Specifically, an injection port is formed on the inductor mold, the injection port is in communication with the model cavity, and the magnetic metal powder can be conveyed into the model cavity by injection or the like, and a pressure of 1000kg / cm 2 -1500kg / cm 2one of 1000kg / cm 2 , 1100kg / cm 2 , 1200kg / cm 2 , 1300kg / cm 2 , 1400kg / cm 2 , 1500kg / cm 2 , to press the magnetic metal powder to form the first magnetic body 120, and the magnetic metal powder is better in quality under the pressure to form the first magnetic body 120. Of course, other materials can be used to press the first magnetic body 120, and other pressure conditions can be used for the press forming, which is not limited in the application.

[0038] Step S130: Place the coil 110 on the bearing part 121, and make the side of the coil 110 abut on the limiting part 122. The coil 110 is circumferentially positioned by the limiting part 122, so that the inductor 100 is formed, and the coil 110 is located at the center of the inductor 100, to ensure the inductance performance of the inductor 100.

[0039] Step S140: Continue to transport the magnetic metal powder into the mold cavity, and apply pressure on the surface of the magnetic metal powder to form the second magnetic body 130. The second magnetic body 130 is buckled on the first magnetic body 120, and the second magnetic body 130 covers the coil 110 to form the inductor 100. In the embodiment, the first magnetic body 120 and the second magnetic body 130 cover the outside of the coil 110, in other words, the coil 110 is embedded in the first magnetic body 120 and the second magnetic body 130 to form the inductor 100. Specifically, the magnetic metal powder can be continuously transported into the mold cavity by injection or the like, and a pressure of 1000kg / cm 2 -1500kg / cm 2 is applied to the surface of the magnetic metal powder to press the magnetic metal powder to form the second magnetic body 130. In the specific arrangement, the pressure applied to the surface of the magnetic metal powder can be 1000kg / cm 2 , 1100kg / cm 2 , 1200kg / cm 2 , 1300kg / cm 2 , 1400kg / cm 2 , 1500kg / cm 2One of the pressure values in the range of 100-300MPa, to press the magnetic metal powder to form the second magnetic body 130, and the magnetic metal powder is better in quality under the pressure condition to form the second magnetic body 130. Of course, other materials can be used to press the second magnetic body 130, and other pressure conditions can be used for press forming, and the application is not limited.

[0040] The forming method of the inductor is as follows: firstly, the magnetic metal powder is delivered into the mold cavity, and the first magnetic body 120 is formed by applying pressure on the surface of the magnetic metal powder; then, the coil 110 is placed on the bearing part 121, and the side of the coil 110 is abutted on the limiting part 122; finally, the magnetic metal powder is continuously delivered into the mold cavity, and the second magnetic body 130 is formed by applying pressure on the surface of the magnetic metal powder, so that the second magnetic body 130 is buckled on the first magnetic body 120, and the second magnetic body 130 covers the coil 110, thereby forming the inductor 100. The forming method of the inductor provided by the application forms the first magnetic body 120 and the second magnetic body 130 in sections, and the limiting part 122 on the first magnetic body 120 is used to circumferentially position the coil 110, so that the positioning reliability of the coil 110 is high, the coil 110 is guaranteed to be located at the center position of the inductor 100, and the size of the coil 110 in the inductor 100 is not limited, so as to improve the inductance performance of the inductor 100.

[0041] In an embodiment, as shown in Figure 1 As shown in Figure 2 The limiting part 122 includes a plurality of limiting columns. The plurality of limiting columns protrude from the bearing part 121, and are spaced apart and distributed around the four edges of the bearing part 121 along the circumferential direction of the first magnetic body 120. When the coil 110 is placed on the bearing part 121, the plurality of limiting columns cooperatively completely circumferentially position the coil 110, so as to improve the positioning reliability of the coil 110, guarantee the coil 110 to be located at the center position of the inductor 100 after forming, and further guarantee the inductance performance of the inductor 100 after forming. In this embodiment, the limiting columns are four, and the four limiting columns are spaced apart and arranged at four opposite corners of the first magnetic body 120, and the limiting columns are conical bodies. Since the conical body has an inclined surface, a coil 110 with a larger volume can be accommodated on the bearing part 121, so that the coil 110 can be designed to be larger in the inductor 100 of the same size, and the inductance performance of the inductor 100 is further improved. Of course, in other embodiments, the number of limiting columns can also be three, five, six or other numbers, the plurality of limiting columns are spaced apart and distributed around the first magnetic body 120 along the circumferential direction, and the limiting columns can also be cylindrical bodies, cuboids or other shapes. The specific number and specific shape of the limiting columns are not limited in the application, and can be specifically set according to user requirements and the forming process of the inductor 100.

[0042] In order to solidify the inductor 100, a preferred embodiment comprises the following steps after step S140 as shown in FIG. 2: Figure 1 Figure 2

[0043] Step S150: preheating the inductor 100. Specifically, the inductor 100 is preheated at a temperature of 160-180°C for 2-10s, so as to soften the magnetic metal powder in the first magnetic body 120 and the second magnetic body 130, facilitating the subsequent pressing solidification of the inductor 100. In a specific setting, the inductor 100 can be placed in a hot press, and the temperature in the hot press is maintained at one of 160°C, 165°C, 170°C, 175°C, and 180°C, and the inductor 100 is preheated at the temperature for one of 2s, 4s, 6s, 8s, and 10s, so as to soften the magnetic metal powder in the first magnetic body 120 and the second magnetic body 130, facilitating the subsequent pressing solidification of the inductor 100. It should be noted that the temperature and time for preheating the inductor 100 can be set according to the materials of the first magnetic body 120 and the second magnetic body 130, and the present application does not make any limitation. In the present application, the preheating temperature of the inductor 100 is set to 160-180°C, and the hot press does not need to be heated or cooled during the subsequent pressing solidification of the inductor 100, thereby improving the forming efficiency of the inductor 100.

[0044] Step S160: pressing the preheated inductor 100 at a high temperature. Specifically, the preheated inductor 100 is placed in a temperature of 160-180°C, and the inductor 100 is pressed at a pressure of 2000kg / cm 2 -2500kg / cm 2 for 5-120s, so as to solidify the inductor 100 and further improve the inductance performance of the inductor 100. In a specific setting, the inductor 100 can be continuously placed in the hot press, and the temperature in the hot press is continuously maintained at one of 160°C, 165°C, 170°C, 175°C, and 180°C, and the pressure acting on the inductor 100 is 2000kg / cm 2 , 2100kg / cm 2 , 2200kg / cm 2 , 2300kg / cm 2 , 2400kg / cm 2 , and 2500kg / cm 2 ​​one of the pressure values, the inductor 100 is cured under the above temperature and pressure conditions for a certain period of time, and the curing time is maintained as one of 5s, 30s, 60s, 90s, and 120s. It should be noted that the temperature, pressure, and time for curing the inductor 100 can be specifically set according to the materials of the first magnetic body 120 and the second magnetic body 130, and the present application is not limited thereto.

[0045] In addition, as shown in Figure 2 the present application provides an inductor 100. The inductor 100 is made by the molding method of the inductor according to any one of the above technical solutions.

[0046] The inductor 100 is segmented and molded by the first magnetic body 120 and the second magnetic body 130, and the coil 110 is circumferentially positioned by the limiting portion 122 on the first magnetic body 120. The positioning reliability of the coil 110 is high, which ensures that the coil 110 is located at the center position of the inductor 100 after molding, and does not limit the size of the volume of the coil 110 in the inductor 100, thereby improving the inductance performance of the inductor 100.

[0047] In an embodiment, as shown in Figure 2 the inductor 100 includes a first magnetic body 120, a second magnetic body 130, and a coil 110, and the second magnetic body 130 is buckled on the first magnetic body 120. The coil 110 includes a main body 111 and two leads 112, and the two leads 112 are respectively connected to the two ends of the main body 111. In this embodiment, after the main body 111 is formed by winding the copper wire, the two ends of the copper wire are reserved to a certain length to form the two leads 112. In other feasible embodiments, the main body 111 can also be formed by winding a wire made of other metal materials with good electrical conductivity, such as silver, aluminum, etc. The main body 111 is embedded inside the first magnetic body 120 and the second magnetic body 130, and at least part of the two leads 112 extends outside the first magnetic body 120 and the second magnetic body 130, so as to facilitate the connection of the two leads 112 with external components.

[0048] In order to improve the stability of the coil 110 in the inductor 100, specifically, as shown in Figure 2As shown, the lead wire 112 includes a connecting portion 1121, a first bending portion 1122 and a second bending portion 1123 connected in sequence, and the connecting portion 1121 is connected to the end portion of the main body 111. In the embodiment, the connecting portion 1121 and the first bending portion 1122 can be embedded in the first magnetic body 120 and the second magnetic body 130, and the second bending portion 1123 extends out of the first magnetic body 120 and the second magnetic body 130, and the connection between the coil 110 and external components can be facilitated through the second bending portion 1123. The connecting portion 1121 and the first bending portion 1122 are embedded in the first magnetic body 120 and the second magnetic body 130, which can increase the bonding area between the lead wire 112 and the first magnetic body 120 and the second magnetic body 130, thereby improving the bonding strength between the lead wire 112 and the first magnetic body 120 and the second magnetic body 130, and improving the stability of the coil 110 in the inductor 100. During the transportation and subsequent process of the inductor 100, the coil 110 is less likely to be loose and shake.

[0049] The angle between the extension direction of the second bending portion 1123 and the extension direction of the connecting portion 1121 is 20°-30°. In a specific arrangement, the angle between the extension direction of the second bending portion 1123 and the extension direction of the connecting portion 1121 is one of 20°, 22°, 24°, 26°, 28° and 30°. Of course, the angle between the extension direction of the second bending portion 1123 and the extension direction of the connecting portion 1121 is not limited to the specific values in the above range, but can also be other values in the range. The specific value of the angle between the extension direction of the second bending portion 1123 and the extension direction of the connecting portion 1121 can be arranged according to the forming process of the inductor 100 and user demand, and the present application does not limit it.

[0050] The technical features of the above-described embodiments can be combined in any manner. To make the description concise, all possible combinations of the technical features in the above-described embodiments are not described, but as long as the combinations of the technical features do not contradict, they should be considered within the scope of the present application.

[0051] The above-described embodiments only express several embodiments of the present application, and the description is more specific and detailed, but it should not be understood as limiting the scope of the patent. It should be noted that for ordinary skilled in the art, without departing from the concept of the present application, a number of modifications and improvements can be made, which are within the scope of the present application. Therefore, the protection scope of the present application should be subject to the appended claims.

Claims

1. A method of forming an inductor, characterized by, The method comprises the following steps: S110: providing an inductor mold, a coil and magnetic metal powder, the inductor mold having a mold cavity; S120: feeding the magnetic metal powder into the mold cavity, and applying pressure on the surface of the magnetic metal powder to form a first magnetic body, the first magnetic body comprising a bearing portion and a limiting portion protruding from the bearing portion, the limiting portion being located at the edge of the bearing portion, the limiting portion comprising a plurality of limiting columns, the limiting columns being conical bodies having inclined surfaces; S130: placing the coil on the bearing portion with its side abutting against the limiting portion; S140: continuing to feed the magnetic metal powder into the mold cavity, and applying pressure on the surface of the magnetic metal powder to form a second magnetic body, the second magnetic body being fitted on the first magnetic body and covering the coil to form an inductor; The conical bodies have inclined surfaces, so that a larger volume of the coil can be accommodated on the bearing portion, and the coil can be designed to be larger in the same size of the inductor.

2. The method of forming an inductor according to claim 1, wherein, In the step S120, the plurality of limiting columns are distributed along the circumferential direction of the first magnetic body at the four peripheral edges of the bearing portion.

3. The method of forming an inductor of claim 1, wherein, The step S120 is specifically: delivering the magnetic metal powder into the mold cavity, applying a pressure of 1000 kg / cm 2 -1500 kg / cm 2 on the surface of the magnetic metal powder, so that the magnetic metal powder is pressed to form a first magnetic body.

4. The method of forming an inductor of claim 1, wherein, The step S140 is specifically: continue to transport the magnetic metal powder into the mold cavity, apply a pressure of 1000 kg / cm 2 -1500 kg / cm 2 on the surface of the magnetic metal powder, so that the magnetic metal powder is pressed to form a second magnetic body.

5. The method of forming an inductor of claim 1, wherein, The method further comprises the following steps after the step S140: S150: preheating the inductor; S160: pressing the preheated inductor at a temperature of 160-180°C.

6. The method of forming an inductor according to claim 5, wherein, The step S150 specifically comprises preheating the inductor at a temperature of 160-180°C for 2-10 seconds.

7. The method of forming an inductor of claim 5, wherein, The step S160 is specifically: placing the preheated inductor under temperature condition of 160-180℃, and making the inductor keep pressure for 5-120s under pressure condition of 2000kg / cm 2 -2500kg / cm 2 to solidify the inductor.

8. An inductor characterized by The inductor is made by the forming method of the inductor according to any one of claims 1-7.

9. The inductor of claim 8, wherein, The inductor comprises a first magnetic body, a second magnetic body and a coil, the second magnetic body being fitted on the first magnetic body, the coil comprising a main body and two lead wires connected to the end of the main body, the main body being embedded in the first magnetic body and the second magnetic body, and at least part of the two lead wires extending out of the first magnetic body and the second magnetic body.

10. The inductor of claim 9, wherein, The lead wire comprises a connecting portion, a first bending portion and a second bending portion connected in sequence, the connecting portion being connected to the end of the main body, and the angle between the extension direction of the second bending portion and the extension direction of the connecting portion being 20-30°.

Images