Inductor and method of making the same

Abstract

The application provides an inductor and a manufacturing method thereof. The inductor comprises a first magnetic core, a second magnetic core and a U-shaped end pole piece. The first end of the first magnetic core is provided with a first groove and a second groove which are parallel to each other. The first end of the second magnetic core is connected with the first end of the first magnetic core, and the first magnetic core and the second magnetic core form a first air gap and a second air gap. The middle part of the end pole piece is arranged in the first groove and the second groove. The three ends of the end pole piece respectively extend to the outside of the second end of the first magnetic core. The manufacturing method of the inductor comprises sequentially processing the first magnetic core, the second magnetic core and the end pole piece, and then bonding and fixing. The end pole piece is processed into a U shape by using a metal sheet, and the end part of the end pole piece sequentially undergoes flattening, bending and electroplating processes. In the application, the first air gap and the second air gap are arranged, the anti-saturation capability of the inductor is improved, the end pole piece is adopted, the direct current resistance of the inductor is reduced, and the rated current of the inductor is improved.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of electronic components, and more particularly to an inductor and a manufacturing method thereof. BACKGROUND

[0002] With the continuous progress of science and technology and the rapid development of the information industry, large-scale and very large-scale integrated circuits have become the mainstream and trend of development. Inductors have the characteristics of high energy storage, small size, large current, ultra-low direct current resistance, etc., are suitable for surface mounting and high-density mounting, and are dedicated to large-current power high-frequency noise and peak interference, and absorbing static pulse. However, the existing inductors often have poor magnetic saturation resistance, low structural stability and other shortcomings. SUMMARY

[0003] The purpose of the embodiments of the present application is to provide an inductor and a manufacturing method thereof to solve the technical problems of poor magnetic saturation resistance and low structural stability of the inductor in the prior art.

[0004] To achieve the above-mentioned purpose, the technical scheme adopted by the present application is to provide an inductor, comprising a first magnetic core, a second magnetic core and an end pole piece; the first end of the first magnetic core is provided with a first groove and a second groove which are parallel to each other; the first end of the second magnetic core is connected with the first end of the first magnetic core, and a first air gap is formed between the first end of the second magnetic core and the first groove, and a second air gap is formed between the first end of the second magnetic core and the second groove; the end pole piece is in the shape of a U, the middle part of the end pole piece is arranged in the first groove and the second groove, and the end pole piece is connected with the first magnetic core at the first groove and the second groove; the three ends of the end pole piece respectively extend out of the first magnetic core and extend to the outside of the second end of the first magnetic core.

[0005] Optionally, the end pole piece comprises a body, a first pin, a second pin and a third pin; the body is in the shape of a U, and the body is connected with the bottom surface of the first groove and the second groove; the first pin is arranged at the first end of the body by bending; the second pin is arranged at the second end of the body by bending, and the first pin and the second pin are located on the same side of the first magnetic core; the third pin is arranged at the middle end of the body by bending; the first pin, the second pin and the third pin all extend out of the end surface of the second end of the first magnetic core.

[0006] Optionally, the first pin comprises a first connecting part and a first lead-out end; the first end of the first connecting part is arranged at the first end of the body by bending; the first lead-out end is arranged at the second end of the first connecting part by bending and is connected to the second end of the first magnetic core;

[0007] The second pin includes a second connecting portion and a second lead-out end; the first end of the second connecting portion is bent and disposed at the second end of the body; the second lead-out end is bent and disposed at the second end of the second connecting portion and connected to the second end of the first magnetic core.

[0008] The third pin includes a third connecting portion and a third lead-out end; the first end of the third connecting portion is bent and disposed at the middle end of the body; the third lead-out end is bent and disposed at the second end of the third connecting portion and connected to the second end of the first magnetic core.

[0009] Optionally, the first side of the first magnetic core is provided with a first recess and a second recess; the first recess is connected to the first pin, and the second recess is connected to the second pin.

[0010] The second side of the first magnetic core is provided with a third recess, which is connected to the third pin.

[0011] Optionally, the surface of the first lead-out end is sequentially covered with a heat-insulating protective layer and a solderable layer; the surface of the second lead-out end is sequentially covered with a heat-insulating protective layer and a solderable layer; and the surface of the third lead-out end is sequentially covered with a heat-insulating protective layer and a solderable layer.

[0012] Optionally, the heat insulation layer is a nickel layer; the solderable layer is a gold layer or a tin-lead layer.

[0013] Optionally, the inductor further includes an adhesive layer, through which the first magnetic core and the second magnetic core are connected; and through which the first magnetic core and the terminal plate are connected.

[0014] Optionally, the inductor further includes a pad disposed between the first magnetic core and the second magnetic core.

[0015] Optionally, the surface dimensions of the pad are larger than the dimensions of the first end surface of the second magnetic core.

[0016] This application also provides a method for manufacturing the above-mentioned inductor, the method comprising:

[0017] The first magnetic core is made by machining a metal block to form the first groove and the second groove.

[0018] Another metal block is machined to a specified size to create the second magnetic core;

[0019] The metal sheet is laser-cut into a Z-shape, and then the three ends of the Z-shaped metal sheet are successively flattened, bent and electroplated to form the terminal electrode sheet;

[0020] The middle portion of the end electrode is placed in the first groove and the second groove and fixed with adhesive; the first end of the second magnetic core is fixed to the first end of the first magnetic core with adhesive.

[0021] The beneficial effects of the inductor provided in this application are as follows: Compared with the prior art, the inductor of this application, by setting a first groove and a second groove on the first magnetic core, forms a first air gap and a second air gap between the first magnetic core and the second magnetic core, which improves the inductor's anti-magnetic saturation capability; the terminal plate is connected to the first magnetic core at the first groove and the second groove, which can reduce the wobble of the terminal plate and improve the stability of the overall structure; the separate structure of the first magnetic core and the second magnetic core is more conducive to the processing of the first groove and the second groove, as well as the assembly of the terminal plate, reducing the processing difficulty and improving the production efficiency; the terminal plate has a large cross-sectional area, which can reduce the DC resistance, making the inductor less prone to heat generation when the current passes through it during operation, thus increasing the rated current of the inductor; the terminal plate is designed in a Z-shape, so that the terminal plate has three ends, thereby forming a three-legged inductor.

[0022] The beneficial effects of the inductor manufacturing method provided in this application are as follows: Compared with the prior art, the inductor manufacturing method of this application uses a cutting process to manufacture the first magnetic core and the second magnetic core, which is simple and convenient; the laser cutting process is used to process the Z-shaped terminal plates, which has high processing accuracy, fast speed, smooth cut, and is not easily deformed, greatly improving product quality and production efficiency; the first magnetic core, the second magnetic core, and the terminal plates are fixed together with adhesive, which improves the stability of the overall structure and reduces the noise caused by the shaking of components during the use of the inductor. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 This is a three-dimensional structural diagram of the inductor provided in Embodiment 1 of this application;

[0025] Figure 2 This is an exploded structural diagram of the inductor provided in Embodiment 1 of this application;

[0026] Figure 3 This is a cross-sectional structural diagram of the inductor provided in Embodiment 1 of this application;

[0027] Figure 4 This is a three-dimensional structural diagram of the inductor provided in Embodiment 2 of this application;

[0028] Figure 5 This is an exploded structural diagram of the inductor provided in Embodiment 2 of this application;

[0029] Figure 6 A three-dimensional structural diagram of the first magnetic core in the inductor provided in the embodiments of this application;

[0030] Figure 7 A top view of the first magnetic core in an inductor provided in an embodiment of this application;

[0031] Figure 8 A three-dimensional structural schematic diagram of the terminal plate of the inductor provided in Embodiment 1 of this application;

[0032] Figure 9 This is a top view of the terminal plate of the inductor provided in Embodiment 1 of this application;

[0033] Figure 10 This is a three-dimensional structural diagram of the terminal plate of the inductor provided in Embodiment 2 of this application.

[0034] The following are the labeling elements in the figure:

[0035] 100 - First magnetic core; 110 - First groove; 120 - Second groove; 130 - First recessed portion; 140 - Second recessed portion; 150 - Third recessed portion;

[0036] 200 - Second magnetic core; 210 - First air gap; 220 - Second air gap;

[0037] 300 - Terminal plate; 310 - Body; 320 - First pin; 321 - First connection part; 322 - First lead-out terminal; 330 - Second pin; 331 - Second connection part; 332 - Second lead-out terminal; 340 - Third pin; 341 - Third connection part; 342 - Third lead-out terminal. Detailed Implementation

[0038] To make the technical problems, technical solutions, and beneficial effects to be solved by this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and are not intended to limit the scope of this application.

[0039] It should be noted that when a component is referred to as being "fixed to" or "set on" another component, it can be directly on or indirectly on that other component. When a component is referred to as being "connected to" another component, it can be directly connected to or indirectly connected to that other component.

[0040] It should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0041] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0042] Please refer to the following: Figures 1 to 10 The inductor provided in the embodiments of this application will now be described. The inductor can be applied in aerospace, aviation, shipbuilding, electronics, communications, weaponry, and other fields related to electronic circuits. This inductor includes a first magnetic core 100, a second magnetic core 200, and terminal plates 300; the first end of the first magnetic core 100 has a first groove 110 and a second groove 120 that are parallel to each other; the first end of the second magnetic core 200 is connected to the first end of the first magnetic core 100, forming a first air gap 210 with the first groove 110 and a second air gap 220 with the second groove 120; the terminal plates 300 are in a Z-shape (e.g., ...). Figure 9 As shown, the middle part of the end plate 300 is disposed in the first groove 110 and the second groove 120, and is connected to the first magnetic core 100 at the first groove 110 and the second groove 120; the three ends of the end plate 300 extend out of the first magnetic core 100 and extend to the outside of the second end of the first magnetic core 100.

[0043] Compared with the prior art, the inductor provided in this embodiment improves the inductor's anti-magnetic saturation capability by providing a first groove 110 and a second groove 120 on the first magnetic core 100, thereby forming a first air gap 210 and a second air gap 220 between the first magnetic core 100 and the second magnetic core 200. The terminal plate 300 is connected to the first magnetic core 100 at the first groove 110 and the second groove 120, which reduces the shaking of the terminal plate 300 and improves the stability of the overall structure. The use of a first magnetic core 100 and a second magnetic core 200... The split structure of the 00 is more conducive to the processing of the first groove 110 and the second groove 120, as well as the assembly of the terminal plate 300, reducing the processing difficulty and improving production efficiency; the terminal plate 300 has a large cross-sectional area, which can reduce the DC resistance, making the inductor less prone to heat generation when the current passes through it, and increasing the rated current of the inductor (the DC resistance can be as low as 0.726mΩ, the saturation current is 120A, and the temperature rise current is 20A); the terminal plate 300 is designed in a Z-shape, so that the terminal plate 300 has three ends, thus forming a three-legged inductor.

[0044] In one embodiment of this application, please refer to the following: Figure 2 , Figure 8 and Figure 9 The terminal plate 300 includes a body 310, a first pin 320, a second pin 330, and a third pin 340. The body 310 is shaped like a "Z" and is connected to the bottom surfaces of the first groove 110 and the second groove 120. The first pin 320 is bent and disposed at the first end of the body 310. The second pin 330 is bent and disposed at the second end of the body 310. The first pin 320 and the second pin 330 are located on the first side of the first magnetic core 100. The third pin 340 is bent and disposed at the middle end of the body 310. The third pin 340 is located on the second side of the first magnetic core 100. The first pin 320, the second pin 330, and the third pin 340 all extend out of the end face of the second end of the first magnetic core 100.

[0045] In this embodiment, the first side and the second side of the first magnetic core 100 are two parallel and opposite sides, both adjacent to the first end of the first magnetic core 100. The first pin 320, the second pin 330, and the third pin 340 are located outside the first magnetic core 100, providing protection and effectively enhancing its resistance to external forces, thereby improving the reliability of the inductor. The first pin 320, the second pin 330, and the third pin 340 all extend beyond the end face of the second end of the first magnetic core 100. This inductor can be used as a through-hole inductor; when applied to a circuit board, the first pin 320, the second pin 330, and the third pin 340 can be inserted into the circuit board to achieve inductor assembly and use.

[0046] In another embodiment of this application, please refer to [the relevant document / reference]. Figure 5 and Figure 10 The first pin 320 includes a first connecting portion 321 and a first lead-out terminal 322; the first end of the first connecting portion 321 is bent and disposed at the first end of the body 310; the first lead-out terminal 322 is bent and disposed at the second end of the first connecting portion 321 and connected to the second end of the first magnetic core 100; the second pin 330 includes a second connecting portion 331 and a second lead-out terminal 332; the first end of the second connecting portion 331 is bent and disposed at the second end of the body 310; the second lead-out terminal 332 is bent and disposed at the second end of the second connecting portion 331 and connected to the second end of the first magnetic core 100; the third pin 340 includes a third connecting portion 341 and a third lead-out terminal 342; the first end of the third connecting portion 341 is bent and disposed at the middle end of the body 310; the third lead-out terminal 342 is bent and disposed at the second end of the third connecting portion 341 and connected to the second end of the first magnetic core 100. The first lead 322, the second lead 332 and the third lead 342 are located on the same plane and can be used as pads to mount the inductor onto the circuit board.

[0047] In one embodiment of this application, please refer to the following: Figure 6 and Figure 7 The first magnetic core 100 has a first recess 130 and a second recess 140 on its first side; the first recess 130 is connected to the first pin 320, and the second recess 140 is connected to the second pin 330; the first magnetic core 100 has a third recess 150 on its second side, and the third recess 150 is connected to the third pin 340. By providing the first recess 130, the second recess 140, and the third recess 150, the space occupied by the first pin 320, the second pin 330, and the third pin 340 during assembly can be reduced, thus reducing the overall size of the inductor.

[0048] In another embodiment of this application, the second end of the first magnetic core 100 is provided with a first slot (not shown), and the first lead-out end 322 is connected to the first slot; the second end of the first magnetic core 100 is provided with a second slot (not shown), and the second lead-out end 332 is connected to the second slot; the second end of the first magnetic core 100 is provided with a third slot (not shown), and the third lead-out end 342 is connected to the third slot. By providing the first slot, the assembly of the first lead-out end 322 and the first magnetic core 100 can be positioned; by providing the second slot, the assembly of the second lead-out end 332 and the first magnetic core 100 can be positioned; by providing the third slot, the assembly of the third lead-out end 342 and the first magnetic core 100 can be positioned.

[0049] In one embodiment of this application, a heat-insulating protective layer and a solderable layer are sequentially applied to the surface of the first lead 322; a heat-insulating protective layer and a solderable layer are sequentially applied to the surface of the second lead 332; and a heat-insulating protective layer and a solderable layer are sequentially applied to the surface of the third lead 342. By providing the heat-insulating protective layer, the internal structure of the first lead 322, second lead 332, and third lead 342 can be protected from heat damage during soldering, thus improving their service life. By providing the solderable layer, the soldering performance of the first lead 322, second lead 332, and third lead 342 as solder pads can be improved, resulting in a more secure soldering during inductor assembly and use.

[0050] In one embodiment of this application, the heat-insulating protective layer is a nickel layer, as nickel (Ni) has good heat insulation properties; the solderable layer is a gold layer or a tin-lead layer, as gold (Au) or tin-lead (Sn / Pb) has good solderability. That is, a layer of nickel can be plated on the surface of the first lead 322 first, and then a layer of gold or tin-lead can be plated on it; similarly, a layer of nickel can be plated on the surfaces of the second lead 332 and the third lead 342 first, and then a layer of gold or tin-lead can be plated on them respectively.

[0051] In one embodiment of this application, the inductor further includes an adhesive layer (not shown), through which the first magnetic core 100 and the second magnetic core 200 are connected; the first magnetic core 100 and the terminal plate 300 are also connected via the adhesive layer. The first magnetic core 100, the second magnetic core 200, and the terminal plate 300 are bonded and fixed in pairs via the adhesive layer, improving the overall structural stability and reducing noise caused by component vibration during inductor use. The adhesive layer can be made of epoxy resin, which forms a film with strong adhesion to metals and can be heated to 80-120 degrees Celsius during use for rapid curing.

[0052] In one embodiment of this application, the inductor further includes a pad (not shown) disposed between the first magnetic core 100 and the second magnetic core 200. The impedance of the inductor is mainly related to the initial permeability of the magnetic core and the air gap in the magnetic circuit. However, due to inconsistencies (±25%) in the initial permeability of raw materials between different batches, the pad is used to adjust the heights of the first air gap 210 and the second air gap 220 to ensure that the impedance meets standard requirements. This allows for effective control of the inductor's impedance and current withstand performance. The height of the first air gap 210 refers to the distance from the bottom surface of the first groove 110 to the end face of the first end of the second magnetic core 200, i.e. Figure 3 The distance indicated by A; the height of the second air gap 220 refers to the distance from the bottom surface of the second groove 120 to the end face of the first end of the second magnetic core 200, that is Figure 3 The distance indicated by B in the diagram can have the same values ​​for A and B.

[0053] In one embodiment of this application, the surface size of the pad is larger than the size of the first end surface of the second magnetic core 200. Because the surface size of the pad is larger than the size of the first end surface of the second magnetic core 200, the exposed second magnetic portion of the pad can be used as a handle, facilitating the insertion or removal of the pad between the first magnetic core 100 and the second magnetic core 200. Multiple pads can be provided, stacked sequentially to adjust to suitable heights for the first air gap 210 and the second air gap 220.

[0054] In one embodiment of this application, the first magnetic core 100 and the second magnetic core 200 use the same material, both of which can be soft magnetic cores or non-magnetic cores. The soft magnetic core can be a ferrite core, a permalloy core, an iron powder core, or a core of a polymer material doped with a soft magnetic material, etc.; the non-magnetic core can be an alumina ceramic core, a dielectric ceramic core, a polymer material core, etc.

[0055] In one embodiment of this application, the terminal electrode 300 can be a metal terminal electrode or a plastic-metal composite terminal electrode. The metal terminal electrode can be a phosphor bronze tin-plated terminal electrode, a phosphor bronze gold-plated terminal electrode, a copper-clad steel tin-plated terminal electrode, a copper-clad steel gold-plated terminal electrode, etc.; the plastic-metal composite terminal electrode can be a bakelite-based metal-coated terminal electrode, a PPS-based metal-coated terminal electrode, a surface-metallized terminal electrode, etc.

[0056] In one embodiment of this application, inductor markings can be formed on the surface of the first magnetic core 100, the surface of the second magnetic core 200, or the surface of the terminal plate 300 by additive manufacturing (printing ink, spraying paint) or in-situ modification (laser engraving, mechanical precision carving).

[0057] This application also provides a method for manufacturing the above-mentioned inductor, the method comprising the following steps:

[0058] Step 1: A rectangular metal block is machined to form a first groove 110 and a second groove 120, thus creating a first magnetic core 100;

[0059] Step 2: Machin another rectangular metal block to the specified dimensions to create the second magnetic core 200;

[0060] Step 3: The metal sheet is laser-cut into a Z-shape, and then the three ends of the Z-shaped metal sheet are flattened, bent and electroplated in sequence to make the terminal electrode 300.

[0061] Step 4: Place the middle part of the end plate 300 in the first groove 110 and the second groove 120, and fix it with adhesive; fix the first end of the second magnetic core 200 to the first end of the first magnetic core 100 with adhesive.

[0062] Compared with the prior art, the inductor manufacturing method provided in this application uses a cutting process to manufacture the first magnetic core 100 and the second magnetic core 200, which is simple and convenient. The Z-shaped terminal plate 300 is processed by laser cutting, which has high processing accuracy, fast speed, smooth cut, and is not easily deformed, greatly improving product quality and production efficiency. The first magnetic core 100, the second magnetic core 200 and the terminal plate 300 are fixed together with adhesive, which improves the stability of the overall structure and reduces the noise caused by the shaking of components during the use of the inductor.

[0063] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. An inductor, characterized in that, include: A first magnetic core, wherein a first end of the first magnetic core is provided with a first groove and a second groove that are parallel to each other; The second magnetic core has a first end connected to the first end of the first magnetic core, and forms a first air gap with the first groove and a second air gap with the second groove; as well as The end electrode is shaped like a "Z" and its middle part is disposed in the first groove and the second groove, and is connected to the first magnetic core at the first groove and the second groove; the three ends of the end electrode extend out of the first magnetic core and extend to the outside of the second end of the first magnetic core. The end plate includes a body, a first pin, a second pin, and a third pin; the body is shaped like a zigzag and is connected to the bottom surfaces of the first groove and the second groove; the first pin is bent at the first end of the body; the second pin is bent at the second end of the body, and the first pin and the second pin are located on the same side of the first magnetic core; the third pin is bent at the middle end of the body; the first pin, the second pin, and the third pin all extend beyond the end face of the second end of the first magnetic core. The first pin includes a first connecting portion and a first lead-out end; the first end of the first connecting portion is bent and disposed at the first end of the body; the first lead-out end is bent and disposed at the second end of the first connecting portion and connected to the second end of the first magnetic core; a heat insulation protective layer and a solderable layer are sequentially attached to the surface of the first lead-out end. The second pin includes a second connecting portion and a second lead-out end; the first end of the second connecting portion is bent and disposed at the second end of the body; the second lead-out end is bent and disposed at the second end of the second connecting portion and connected to the second end of the first magnetic core; a heat insulation protective layer and a solderable layer are sequentially attached to the surface of the second lead-out end. The third pin includes a third connecting portion and a third lead-out end; the first end of the third connecting portion is bent and disposed at the middle end of the body; the third lead-out end is bent and disposed at the second end of the third connecting portion and connected to the second end of the first magnetic core; the surface of the third lead-out end is sequentially covered with a heat insulation protective layer and a solderable layer. The first magnetic core has a first recess and a second recess on its first side; the first recess is connected to the first pin, and the second recess is connected to the second pin; the first magnetic core has a third recess on its second side, and the third recess is connected to the third pin.

2. The inductor as described in claim 1, characterized in that, The heat insulation protective layer is a nickel layer; the solderable layer is a gold layer or a tin-lead layer.

3. The inductor as described in claim 1, characterized in that, The inductor further includes an adhesive layer, through which the first magnetic core and the second magnetic core are connected; the first magnetic core and the terminal plate are connected through the adhesive layer.

4. The inductor as described in claim 1, characterized in that, The inductor also includes a pad disposed between the first magnetic core and the second magnetic core.

5. The inductor as described in claim 4, characterized in that, The surface dimensions of the pad are larger than the dimensions of the first end surface of the second magnetic core.

6. A method for manufacturing an inductor as described in any one of claims 1-5, characterized in that, The method includes: The first magnetic core is made by machining a metal block to form the first groove and the second groove. Another metal block is machined to a specified size to create the second magnetic core; The metal sheet is laser-cut into a Z-shape, and then the three ends of the Z-shaped metal sheet are successively flattened, bent and electroplated to form the terminal electrode sheet; The middle portion of the end electrode is placed in the first groove and the second groove and fixed with adhesive; the first end of the second magnetic core is fixed to the first end of the first magnetic core with adhesive.

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