Monolithic magnetic device and method of manufacturing the same

Abstract

The application relates to the technical field of electronic components, and discloses an integrated magnetic device and a preparation method thereof. The integrated magnetic device comprises a framework, a winding part provided on the framework, a middle line of the winding part extending along a first direction, at least one magnetic core integrally injection molded with the framework and connected in the framework, a wire package wound on the winding part, a terminal group integrally injection molded with the framework and connected to two ends of the framework, and electrically connected with wire joints of the wire package, and a magnetic column provided on a side edge of the framework and connected with the magnetic core. The magnetic core comprises an integrally formed middle column body extending along the first direction in the framework and a connecting body provided on an end of the middle column body and extending along a second direction. The first direction and the second direction have an included angle, and the end of the connecting body is connected with the magnetic column. The application improves the reliability, safety, structural strength and insulation performance of the magnetic device.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of electronic components, in particular to an integrated magnetic device and a preparation method thereof. BACKGROUND

[0002] The magnetic device is a key electronic component for realizing energy conversion, transmission and storage by using electromagnetic induction principle, and is widely used in the fields of power management, signal processing and electromagnetic compatibility, including transformers, inductors and the like, and in specific structures can include a magnetic core, a coil, a skeleton, a terminal and packaging and the like. In the related art, taking a transformer product as an example, due to the existing process preparation conditions, the device is prone to serious heating in a high-frequency working environment, and the magnetic core of the device is prone to cracking, resulting in product failure and damage, and the product volume of the existing device is large. The above-mentioned situations have a great influence on the working performance and safety performance of the product, and this situation needs to be changed. SUMMARY

[0003] In view of this, the present application provides an integrated magnetic device and a preparation method thereof to solve the above-mentioned technical problems.

[0004] To achieve the above purpose, according to the first aspect, the technical scheme adopted is:

[0005] An integrated magnetic device comprises:

[0006] A skeleton, wherein a winding part is arranged on the skeleton, and a center line of the winding part extends along a first direction;

[0007] At least one magnetic core, wherein the magnetic core is integrally injection molded with the skeleton, and the magnetic core is connected in the skeleton;

[0008] A wire package, wherein the wire package is wound on the winding part;

[0009] A terminal group, wherein the terminal group is integrally injection molded with the skeleton, the terminal group is connected to both ends of the skeleton, and the terminal group is electrically connected with wire joints of the wire package;

[0010] A magnetic column, wherein the magnetic column is arranged on a side of the skeleton and connected with the magnetic core;

[0011] The magnetic core comprises an integrally formed middle column body and a connecting body, the middle column body extends along the first direction in the skeleton, the connecting body is arranged at an end of the middle column body and extends along a second direction, the first direction and the second direction have an included angle, and an end of the connecting body is connected with the magnetic column.

[0012] The present application further provides that: the number of the magnetic cores is one, the connecting bodies of the one magnetic core are symmetrically arranged at both ends of the middle column body, and the magnetic column is respectively connected with the ends of the connecting bodies.

[0013] The application is further provided that the number of the magnetic cores is two, a first air gap ceramic body is arranged between the two magnetic cores, and the first air gap ceramic body is fixedly connected with the middle column of the two magnetic cores, wherein the first air gap ceramic body has a first set length in the first direction, and the first set length is adjustable.

[0014] The application is further provided that the two magnetic cores, the first air gap ceramic body, and the terminal group are integrally injection molded with the framework, and the magnetic cores and the first air gap ceramic body are synchronously connected in the framework.

[0015] The application is further provided that the two magnetic cores, the first air gap ceramic body, and the terminal group are integrally injection molded with the framework, and the magnetic cores and the first air gap ceramic body are synchronously connected in the framework.

[0016] The application is further provided that the end of the framework has a connection platform, the terminal group includes a plurality of connection terminals, the plurality of connection terminals are linearly arranged on the connection platform in the second direction, and the wire package has a plurality of wire joints, and the wire joints correspond to the connection terminals one by one.

[0017] The application is further provided that the framework is provided with an auxiliary guard plate, the auxiliary guard plate is symmetrically connected on the connection platform and forms a containing groove with the side of the framework, and the magnetic column is matched in the containing groove.

[0018] The application is further provided that a second air gap ceramic body is arranged between the magnetic column and the end of the connection body, the second air gap ceramic body has a second set length in the second direction, and the second set length is adjustable.

[0019] The application is further provided that the integrally injection molding is at least once, and the injection molding material of the framework includes at least one of bakelite, nylon, polyphenylene sulfide, polyethylene terephthalate, polybutylene terephthalate, and polycarbonate.

[0020] According to a second aspect, the technical solution adopted is:

[0021] A preparation method of an integrated magnetic device, comprising:

[0022] providing a framework, a terminal group, and at least one magnetic core;

[0023] Synchronously integrally injection-mold the skeleton, the terminal group and the at least one magnetic core, wherein the skeleton is formed with a winding part, a middle line of the winding part extends along a first direction, the magnetic core is connected in the skeleton after integrally injection-molding, the terminal group is connected to two ends of the skeleton, the magnetic core comprises an integrally formed middle column body and a connecting body, the middle column body extends along the first direction in the skeleton, the connecting body is arranged at an end of the middle column body and extends along a second direction, the first direction and the second direction have an included angle;

[0024] Winding a wire package on the winding part;

[0025] Assembling a magnetic column to a side of the skeleton, and connecting an end of the connecting body with the magnetic column;

[0026] Welding and fixing the wire joint of the wire package and the terminal group.

[0027] Compared with the prior art, the application discloses an integrated magnetic device and a preparation method thereof. The integrated magnetic device has a skeleton, at least one magnetic core, a wire package, a terminal group and a magnetic column. The magnetic core, the terminal group and the skeleton are integrally injection-molded, the magnetic core is connected in the skeleton, the terminal group is connected to two ends of the skeleton and the terminal group is electrically connected with a wire joint of the wire package. The magnetic core comprises an integrally formed middle column body and a connecting body. The middle column body extends along a first direction in the skeleton, the connecting body is arranged at an end of the middle column body and extends along a second direction, the first direction and the second direction have an included angle, and an end of the connecting body is connected with the magnetic column. Through the above arrangement, the middle column body and the connecting body of the magnetic core are integrally injection-molded in the skeleton, the terminal group is integrally injection-molded at two ends of the skeleton, and the magnetic column is connected with the magnetic core at a side of the skeleton. Therefore, the structural strength, the insulation strength and the heat dissipation effect of the magnetic device are improved, and the performance of the magnetic device is improved. BRIEF DESCRIPTION OF DRAWINGS

[0028] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the following will briefly introduce the drawings needed to be used in the embodiment description. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative labor.

[0029] Figure 1 is a schematic diagram of the three-dimensional structure of the integrated magnetic device of the present embodiment;

[0030] Figure 2 is a schematic diagram of part of the internal structure of the integrated magnetic device of the present embodiment;

[0031] Figure 3 is a schematic diagram of the top view structure of the integrated magnetic device of the present embodiment;

[0032] Figure 4 is Figure 3 a schematic diagram of an A-A cross-sectional structure of the magnetic core;

[0033] Figure 5 is a schematic diagram of a three-dimensional structure of the magnetic core of the embodiment;

[0034] Figure 6 is a process flow diagram of a preparation method of the integrated magnetic device of the embodiment. DETAILED DESCRIPTION

[0035] The exemplary embodiments will be described in detail herein with reference to the attached drawings. In the following description, unless otherwise indicated, like numbers in the attached drawings refer to the same or similar elements. The following detailed description includes specific details for the purpose of providing a thorough understanding of the exemplary embodiments. However, it will be apparent to those skilled in the art that the exemplary embodiments can be practiced without these specific details. In some instances, well-known structures and components are not described in detail in order to avoid obscuring the understanding of the exemplary embodiments.

[0036] It should be noted that, in this document, the terms "comprise", "comprising", or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but can also include other elements not expressly listed or inherent to such process, method, article, or apparatus. Without further limitation, an element preceded by "comprises a" does not, without more constraints, foreclose the existence of additional identical elements in the process, method, article, or apparatus that includes the element. Also, components having the same name in different embodiments of the application can have the same meaning or different meanings, which will be determined by their interpretation in the context of the specific embodiment.

[0037] It should be further understood that the terms "comprise", "comprising", indicate the presence of stated features, steps, operations, elements, components, items, groups, and / or any other aspect, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, items, groups, and / or aspects. The terms "or", "and / or", "at least one of", and the like as used herein, can be interpreted as inclusive or as meaning any one or any combination. For example, "at least one of A, B, and C" means "A; B; C; A and B; A and C; B and C; or A and B and C". As another example, "A, B, or C" or "A, B, and / or C" means "A; B; C; A and B; A and C; B and C; or A and B and C". Only when a combination of elements, functions, steps, or operations are in some way inherently mutually exclusive, will an exception to this definition apply.

[0038] It should be understood that, although the terms first, second, third, etc. can be employed in this text to describe various information, the information should not be limited to these terms. These terms are only used to distinguish one type of information from another type of information. For example, without departing from the scope of this text, the first information can also be referred to as the second information, and similarly, the second information can also be referred to as the first information. Depending on the context, as used herein, the singular forms "a", "an" and "the" are intended to include plural forms as well, unless the context clearly indicates otherwise.

[0039] It should be understood that the terms "top", "bottom", "upper", "lower", "vertical", "horizontal" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application.

[0040] For the convenience of description, in the following embodiments, the orthogonal space formed by the horizontal plane and the vertical direction is taken as an example for description, and this precondition should not be understood as a limitation on the present application.

[0041] As described in the background, the magnetic device in the related art, taking the transformer product as an example, is limited by the existing process preparation conditions. The device is prone to serious heating in a high-frequency working environment, and the magnetic core of the device is prone to cracking, resulting in product failure and damage. In addition, the existing device has a large product volume. The above-mentioned situations have a great impact on the working performance and safety performance of the product. Based on this, the present application discloses an integrated magnetic device and a preparation method thereof.

[0042] Please refer to Figures 1 to 5 The integrated magnetic device of the present application comprises a framework 1, at least one magnetic core 2, a wire package 3, a terminal group 4 and a magnetic column 5. The at least one magnetic core 2 is integrally injection molded with the framework 1, and the magnetic core 2 is connected in the framework 1. The framework 1 is provided with a winding part 11, the center line of the winding part 11 extends along the first direction, the wire package 3 is wound on the winding part 11, the terminal group 4 is integrally injection molded with the framework 1, the terminal group 4 is connected at both ends of the framework 1, and the terminal group 4 is electrically connected with the wire joint of the wire package 3. The magnetic column 5 is arranged at the side of the framework 1 and connected with the magnetic core 2.

[0043] In the implementation process, due to the change of working frequency, the magnetic loss and eddy current loss in the magnetic device, the temperature of the magnetic device will rise sharply, and under the influence of thermal stress, mechanical stress or vibration, the magnetic core of the device is prone to cracking. The at least one magnetic core 2 is integrally injection molded with the skeleton 1 as a whole, the magnetic core 2 is connected in the skeleton 1, and the magnetic column 5 is connected with the magnetic core 2 at the side of the skeleton 1. Therefore, the mechanical connection between the separated parts is reduced, the overall mechanical strength is improved, the risk of cracking of the magnetic core 2 caused by stress concentration or external force impact is reduced, and through integral injection molding, the manual assembly process of multiple parts in the traditional assembly process is reduced, the production efficiency is improved, and the assembly error is reduced. In addition, due to the integral forming of the parts, the internal layout of the magnetic device can be designed more compactly, which helps to reduce the overall size of the device and meet the miniaturization requirement. In particular, the integrally injection molded magnetic core 2 and skeleton 1 can better control the relative position between the wire package 3 and the magnetic core 2 and the terminal group 4, reduce the parasitic inductance and magnetic leakage phenomenon, and improve the electrical performance at high frequency.

[0044] The magnetic core 2 of the embodiment includes an integral formed middle column body 21 and a connecting body 22. The middle column body 21 extends in the skeleton 1 along a first direction, and the connecting body 22 is arranged at the end of the middle column body 21 and extends along a second direction. The first direction and the second direction have an included angle, and the end of the connecting body 22 is connected with the magnetic column 5. Thus, the complete magnetic loop is formed to effectively guide the magnetic flux. The external design of the magnetic column 5, that is, the magnetic column 5 is arranged at the side of the skeleton 1 and connected with the end of the connecting body 22, can effectively reduce the cutting of the wire package 3 caused by magnetic leakage and reduce the wire loss caused by magnetic leakage, thereby slowing down the temperature rise of the device and improving the performance of the magnetic device.

[0045] It should be noted that, in order to ensure the overall structural strength and insulation strength of the magnetic device, the skeleton 1, the at least one magnetic core 2 and the terminal group 4 can be integrally injection molded as a whole. The magnetic core 2 is connected in the skeleton 1, the terminal group 4 is connected at both ends of the skeleton 1, the magnetic column 5 is connected with the end of the connecting body 22 at the side of the skeleton 1, and the terminal group 4 is electrically connected with the wire joint of the wire package 3.

[0046] The first direction and the second direction of the embodiment have an included angle, that is, the first direction and the second direction are not parallel to each other in the same plane. The embodiment can also have a third direction which is perpendicular to the first direction and the second direction. The included angle between the first direction and the second direction can be 90° or other preset angles. When the first direction, the second direction and the third direction are perpendicular to each other, the magnetic core 2 can be arranged in the skeleton 1 along the first direction, the connecting body 22 is arranged at the end of the magnetic core 2 and extends along the second direction, and the magnetic column 5 is arranged at the side of the skeleton 1 and connected with the end of the connecting body 22. Figure 1The X-Y-Z space coordinates are constructed, and the X-axis direction can be regarded as the first direction, the Y-axis direction can be regarded as the second direction, and the Z-axis direction can be regarded as the third direction. The first direction can also be regarded as the left-right extension direction of the skeleton 1, the second direction can also be regarded as the front-rear extension direction of the skeleton 1, and the third direction can also be regarded as the up-down extension direction of the skeleton 1. Of course, the present embodiment is not limited to this, and X-Y-Z can also be other arbitrary directions perpendicular to each other in space according to actual requirements, and details are not described herein again.

[0047] In one embodiment, in order to ensure that the overall structure of the magnetic device is stable and has good heat dissipation effect, the injection molding material of the skeleton 1 can include at least one of bakelite, nylon, polyphenylene sulfide, polyethylene terephthalate, polybutylene terephthalate, and polycarbonate.

[0048] Specifically, bakelite is a kind of phenolic resin, which has excellent electrical insulation, heat resistance and corrosion resistance, high mechanical strength and strong anti-deformation ability, that is, bakelite has good electrical insulation and high temperature resistance, and also has corrosion resistance and strong moisture resistance, so that the magnetic core 2 can be wrapped by the injection molding material of the skeleton 1 to improve the structural strength and insulation strength of the magnetic device; and nylon (PA, Polyamide) is a material with strong toughness and wear resistance, which has good electrical insulation performance and heat resistance, that is, nylon has high mechanical strength, good toughness, good impact resistance and wear resistance, and low cost, so that the magnetic core 2 can be wrapped by the injection molding material of the skeleton 1 to improve the structural strength and insulation strength of the magnetic device; and polyphenylene sulfide (PPS, Polyphenylene Sulfide) is a high-performance engineering plastic, which has excellent heat resistance, chemical resistance and good dimensional stability, and has a wide working temperature range, usually between 180℃-240℃, and can maintain high mechanical strength for a long time, that is, PPS still has good electrical insulation in high temperature environment and is not easy to deform, which is suitable for harsh high temperature and high power applications, so that the magnetic core 2 can be wrapped by the injection molding material of the skeleton 1 to improve the structural strength and insulation strength of the magnetic device; and polyethylene terephthalate (PET, Polyethylene Terephthalate) is a crystalline plastic, which has excellent heat resistance, wear resistance and mechanical strength, good electrical insulation performance and good dimensional stability, and can maintain performance in a wide temperature range, that is, PET has high temperature resistance and strong anti-aging ability, and also has good chemical resistance and moisture resistance; and polybutylene terephthalate (PBT, Polybutylene Terephthalate) is a crystalline engineering plastic, which has good mechanical strength, heat resistance and electrical performance, and good dimensional stability, especially in a humid environment, it still has good insulation performance; and polycarbonate (PC, Polycarbonate) is an impact-resistant and high-temperature-resistant engineering plastic, which has excellent electrical insulation performance and heat resistance, and has good optical transparency and mechanical strength, so that the magnetic core 2 can be wrapped by the injection molding material of the skeleton 1 to improve the structural strength and insulation strength of the magnetic device.

[0049] On the other hand, according to the actual environmental requirements, the skeleton 1 can also use high-CTI (Comparative Tracking Index) material or high-thermal-conductivity material as the injection molding material to further ensure the heat dissipation effect and safety of the magnetic device, wherein the high-CTI material can include the aforementioned PPS or PBT material.

[0050] In one embodiment, the number of magnetic cores 2 is one, the connecting bodies 22 of one magnetic core 2 are symmetrically arranged at the two ends of the middle column body 21, and the magnetic columns 5 are connected to the ends of the connecting bodies 22, so that the single magnetic core 2 is integrally injection molded with the skeleton 1 as a whole, the magnetic core 2 is connected in the skeleton 1, and the magnetic columns 5 are connected to the connecting bodies 22 at the side edges of the skeleton 1. Thus, the mechanical connection between separated parts is reduced, the mechanical strength of the magnetic device is improved, the production efficiency is improved through integral injection molding, the assembly error is reduced, the internal layout of the magnetic device can be designed more compactly to meet the requirement of miniaturization of the device, the integral injection molding of the magnetic core 2 and the skeleton 1 helps to better control the relative positions between the wire winding 3 and the magnetic core 2 and the terminal group 4, reduce the parasitic inductance and magnetic leakage phenomenon, and improve the electrical performance at high frequency.

[0051] In one embodiment, the number of magnetic cores 2 is two, and the first air gap ceramic body 6 is arranged between the two magnetic cores 2, and the first air gap ceramic body 6 is fixedly connected with the middle column bodies 21 of the two magnetic cores 2, so that the two magnetic cores 2 are connected through the first air gap ceramic body 6. The first air gap ceramic body 6 has a first set length in the first direction, and the first set length is adjustable, that is, by adjusting the first set length of the first air gap ceramic body 6 in the first direction, the air gap of the magnetic core 2 magnetic circuit can be adjusted, so that the magnetic circuit performance is optimized, the adjustment flexibility of the device is improved, and the magnetic response and electromagnetic compatibility of the device can also be improved by controlling the air gap length.

[0052] Preferably, the first air gap ceramic body 6 can also include a plurality of stacked sub-ceramic pieces, so that the air gap of the magnetic core 2 magnetic circuit can be adjusted by controlling the number of stacked sub-ceramic pieces in this embodiment.

[0053] It should be noted that the two magnetic cores 2 and the first air gap ceramic body 6 are integrally injection molded with the skeleton 1, and the magnetic core 2 and the first air gap ceramic body 6 are synchronously connected in the skeleton 1, so that the mechanical connection between separated parts is reduced, the mechanical strength of the whole is improved, and it is also convenient to adjust the air gap of the magnetic circuit through the first air gap ceramic body 6.

[0054] In the specific implementation process, the two magnetic cores 2, the first air gap ceramic body 6, and the terminal group 4 are integrally injection molded with the frame 1. The magnetic cores 2 and the first air gap ceramic body 6 are synchronously connected in the frame 1, and the terminal group 4 is synchronously connected to both ends of the frame 1. Based on this, the mechanical connection between the separated parts can be reduced, the overall mechanical strength can be improved, and the risk of cracking of the magnetic core 2 due to stress concentration or external impact can be reduced. Furthermore, the integral injection molding reduces assembly errors. Also, since the parts are integrally molded, the internal layout of the magnetic device can be designed more compactly, the overall size of the device can be reduced, and the miniaturization requirements can be met. The integrally injection molded magnetic core 2, frame 1, and terminal group 4 help to better control the relative position between the coil 3 and the magnetic core 2 and terminal group 4, reduce parasitic inductance and leakage flux, and improve the electrical performance at high frequencies.

[0055] Of course, the number of magnetic cores 2 in this application can also be multiple, and multiple magnetic cores 2 can be connected by the first air gap ceramic body 6.

[0056] It should be noted that the magnetic core 2 of this application can be designed in the form of an "I". When there is one magnetic core 2, the connecting body 22 of one magnetic core 2 is symmetrically arranged at both ends of the central column 21 to form an I-shaped structure. Or when there are two magnetic cores 2, the first air gap ceramic body 6 between the two magnetic cores 2 is fixedly connected to the central column 21 of the two magnetic cores 2 respectively, that is, the two magnetic cores 2 are arranged opposite to each other to form an I-shaped structure.

[0057] In one embodiment, the number of magnetic cores 2 is at least two. A single magnetic core 2 can also have an E-shaped structure or an F-shaped structure. Thus, the magnetic core 2 can be an EE-type magnetic core or an EF-type magnetic core, etc. On the other hand, the magnetic core 2 can also be a PQ-type magnetic core. Specifically, the PQ-type magnetic core has a magnetic core column with a square cross-section and a magnetic core shape that is a combination of square and round.

[0058] In one embodiment, the end of the frame 1 has a connecting platform 12, wherein the terminal group 4 includes a plurality of connecting terminals 41, which are linearly arranged on the connecting platform 12 along a second direction to facilitate the connection of the inner wiring package 3 and external electronic devices, etc. Specifically, the wiring package 3 has a plurality of wire connectors, which correspond one-to-one with the connecting terminals 41, wherein the wire connectors and the connecting terminals 41 can be fixed by welding.

[0059] In the specific implementation process, the skeleton 1 is provided with an auxiliary guard plate 13. The auxiliary guard plate 13 is symmetrically connected to the connecting platform 12 and forms a receiving groove 7 with the side of the skeleton 1. The magnetic column 5 is matched in the receiving groove 7 to facilitate the installation of the magnetic column 5 and the structural stability of the overall magnetic device.

[0060] In one embodiment, a second air gap ceramic body 8 is arranged between the magnetic column 5 and the end of the connecting body 22, the second air gap ceramic body 8 has a second set length in the second direction, and the second set length is adjustable. In combination with the external design of the magnetic column 5 described above, the magnetic column 5 is arranged at the side of the framework 1 and connected with the end of the connecting body 22, that is, the air gap is arranged externally. The size of the external air gap can be adjusted according to the application, which can effectively reduce the cutting of the leakage magnetic on the wire package 3, reduce the line loss caused by the leakage magnetic, slow down the temperature rise of the device, and improve the performance of the magnetic device.

[0061] It should be noted that the one-time integral injection molding of the application is at least one time, that is, the framework 1, the at least one magnetic core 2 and the terminal group 4 can be synchronously subjected to one-time integral injection molding to become an integral whole, the magnetic core 2 is connected in the framework 1, the terminal group 4 is connected at both ends of the framework 1, and the framework 1, the at least one magnetic core 2 and the terminal group 4 can also be synchronously subjected to multiple integral injection moldings according to the environmental requirements or air gap adjustment requirements.

[0062] Therefore, the integral magnetic device of the application has the framework 1, the at least one magnetic core 2, the wire package 3, the terminal group 4 and the magnetic column 5, the magnetic core 2, the terminal group 4 and the framework 1 are integrally injection molded, the middle column body 21 and the connecting body 22 of the magnetic core 2 are connected in the framework 1, and the first air gap ceramic body 6 can also be connected between the magnetic cores 2, the first air gap ceramic body 6 has a first set length in the first direction, and the first set length is adjustable. The terminal group 4 including a plurality of connecting terminals 41 is connected at both ends of the framework 1, and is linearly arranged along the second direction on the connecting platform 12 and electrically connected with the wire joint of the wire package 3, the wire package 3 is wound on the winding part 11 of the framework 1, the auxiliary guard plate 13 is symmetrically connected on the connecting platform 12 and forms a containing groove 7 with the side of the framework 1, the magnetic column 5 is matched in the containing groove 7, and the magnetic column 5 is connected with the end of the connecting body 22. A second air gap ceramic body 8 is arranged between the magnetic column 5 and the end of the connecting body 22, the second air gap ceramic body 8 has a second set length in the second direction, and the second set length is adjustable. Therefore, the middle column body 21 and the connecting body 22 of the magnetic core 2 are integrally injection molded in the framework 1, the terminal group 4 is integrally injection molded at both ends of the framework 1, and the magnetic column 5 is connected with the magnetic core 2 at the side of the framework 1, which improves the structural strength, insulation strength and heat dissipation effect of the magnetic device, and improves the performance of the magnetic device.

[0063] The embodiment also discloses a preparation method of the integral magnetic device. Figure 6 , Figure 6 is a process flow chart of the preparation method of the integral magnetic device of the embodiment, and in combination with Figures 1 to 5 , the preparation method of the integral magnetic device comprises the following steps.

[0064] S101, providing a framework 1, a terminal group 4 and at least one magnetic core 2.

[0065] In this step, the terminal group 4 can include several connection terminals 41, wherein the connection terminals 41 can be designed in a U-shaped structure.

[0066] The injection molding material of the skeleton 1 can include at least one of bakelite, nylon, polyphenylene sulfide, polyethylene terephthalate, polybutylene terephthalate, and polycarbonate.

[0067] S102, synchronously integrally injection molding the skeleton 1, the terminal group 4, and at least one magnetic core 2, wherein the skeleton 1 is formed with a winding part 11, the center line of the winding part 11 extends along a first direction, the magnetic core 2 is connected in the skeleton 1 after integrally injection molding, the terminal group 4 is connected to both ends of the skeleton 1, the magnetic core 2 includes an integrally formed middle column body 21 and a connecting body 22, the middle column body 21 extends along the first direction in the skeleton 1, the connecting body 22 is arranged at the end of the middle column body 21 and extends along a second direction, and the first direction and the second direction have an included angle.

[0068] In this step, the number of the magnetic core 2 can be one, the connecting body 22 of the one magnetic core 2 is symmetrically arranged at both ends of the middle column body 21, and the magnetic column 5 is respectively connected to the end of the connecting body 22.

[0069] On the other hand, the number of the magnetic core 2 can also be two, a first air gap ceramic body 6 is arranged between the two magnetic cores 2, the first air gap ceramic body 6 is fixedly connected with the middle column body 21 of the two magnetic cores 2, wherein the first air gap ceramic body 6 has a first set length in the first direction, and the first set length is adjustable.

[0070] S103, winding a wire package 3 on the winding part 11.

[0071] It can be understood that the wire package 3 is wound on the winding part 11 according to a predetermined rule, and the predetermined rule can be that a plurality of coil winding directions are the same, or an alternating direction design is adopted, or the number of layers of the coil, the winding density of the coil, and the wire material used by the coil are specified, and the like, wherein the wire can be a copper enameled wire, an insulating wire, a mica wire, and the like, thereby completing the connection of the wire package 3 and the winding part 11.

[0072] S104, assembling the magnetic column 5 to the side of the skeleton 1, and connecting the end of the connecting body 22 to the magnetic column 5.

[0073] In this step, the end of the skeleton 1 has a connecting platform 12, the skeleton 1 is provided with an auxiliary guard plate 13, the auxiliary guard plate 13 is symmetrically connected to the connecting platform 12 and forms a containing groove 7 with the side of the skeleton 1, the magnetic column 5 is matched in the containing groove 7, and the plurality of connection terminals 41 are linearly arranged on the connecting platform 12 along the second direction.

[0074] The second air gap ceramic body 8 is provided between the magnetic column 5 and the end of the connecting body 22, and has a second set length in the second direction, which is adjustable.

[0075] S105, the wire joint of the wire package 3 and the terminal group 4 are welded and fixed.

[0076] In this step, the wire joint of the wire package 3 corresponds to the connecting terminal 41 one by one, wherein the wire joint and the connecting terminal 41 are electrically connected by welding.

[0077] For other working principles and processes of the preparation method of the integrated magnetic device of the present application, see the foregoing description of the integrated magnetic device of the embodiments of the present application, which will not be repeated here.

[0078] The integrated magnetic device and the preparation method thereof provided by the present application are described in detail above, and the principles and implementation manners of the present application are described by applying specific examples. It should be noted that the description of each embodiment in the present application has its own emphasis, and the parts not described or recorded in detail in a certain embodiment can be seen from the related description of other embodiments.

[0079] The above is only the preferred embodiment of the present application, and does not limit the patent scope of the present application, and each technical feature of the technical solution of the present application can be combined arbitrarily. In order to make the description simple, each technical feature in the above embodiments is not described all possible combinations, and any equivalent structure or equivalent flow conversion made by using the content of the present application and the drawings, or directly or indirectly applied in other related technical fields, as long as the combination of these technical features does not exist contradiction, all are included in the patent protection scope of the present application.

Claims

1. An integrated magnetic device, characterized by, include: A skeleton, wherein a winding portion is provided on the skeleton, and the centerline of the winding portion extends along a first direction; At least one magnetic core, the magnetic core being integrally injection molded with the frame, and the magnetic core being connected in the frame; A coil, the coil being wound on the winding portion; A terminal assembly, which is integrally injection molded with the frame, and the terminal assembly is connected to both ends of the frame, and the terminal assembly is electrically connected to the wire connector of the coil; A magnetic post, which is disposed on the side of the frame and connected to the magnetic core; The magnetic core includes an integrally formed central column and a connecting body. The central column extends in the skeleton along the first direction, and the connecting body is disposed at the end of the central column and extends along the second direction. The first direction and the second direction have an angle between them, and the end of the connecting body is connected to the magnetic column. The frame has a connecting platform at its end and an auxiliary guard plate. The auxiliary guard plate is symmetrically connected to the connecting platform and forms a receiving groove with the side of the frame. The magnetic column is matched in the receiving groove.

2. The integrated magnetic device of claim 1, wherein, The number of magnetic cores is one, and the connecting bodies of the magnetic cores are symmetrically arranged at both ends of the central column, and the magnetic columns are respectively connected to the ends of the connecting bodies.

3. The integrated magnetic device of claim 1, wherein, The number of magnetic cores is two, and a first air gap ceramic body is provided between the two magnetic cores. The first air gap ceramic body is fixedly connected to the central column of each of the two magnetic cores. The first air gap ceramic body has a first set length in the first direction, and the first set length is adjustable.

4. The integrated magnetic device of claim 3, wherein, The two magnetic cores and the first air gap ceramic body are integrally injection molded with the skeleton, and the magnetic cores and the first air gap ceramic body are synchronously connected in the skeleton.

5. The integrated magnetic device of claim 4, wherein, The two magnetic cores, the first air gap ceramic body, and the terminal group are integrally injection molded with the frame, and the magnetic cores and the first air gap ceramic body are synchronously connected to the frame, and the terminal group is synchronously connected to both ends of the frame.

6. The integrated magnetic device of claim 1, wherein, The terminal group includes a plurality of connection terminals, which are linearly arranged along the second direction on the connection platform, and the coil has a plurality of wire connectors, which correspond one-to-one with the connection terminals.

7. The integrated magnetic device of claim 1, wherein, A second air gap ceramic body is provided between the ends of the magnetic column and the connector. The second air gap ceramic body has a second set length in the second direction, and the second set length is adjustable.

8. The integrated magnetic device according to any one of claims 1 to 7, wherein the magnetic material is a magnetic material having a Curie temperature of 300 °C or higher. The integral injection molding is at least once, and the injection molding material of the skeleton includes at least one of Bakelite, Nylon, Polyphenylene sulfide, Polyethylene terephthalate, Polybutylene terephthalate, and Polycarbonate.

9. A method of manufacturing an integrated magnetic device, characterized by, include: Provides a frame, terminal assembly, and at least one magnetic core; The skeleton, the terminal group and at least one magnetic core are synchronously integrally injection molded, wherein the skeleton is formed with a winding part, a middle line of the winding part extends along a first direction, the magnetic core is connected in the skeleton after integrally injection molding, the terminal group is connected to two ends of the skeleton, the magnetic core comprises an integrally formed middle column body and a connecting body, the middle column body extends along the first direction in the skeleton, the connecting body is arranged at an end of the middle column body and extends along a second direction, the first direction and the second direction have an included angle; Winding a wire package on the winding part; Assembling a magnetic column to a side of the skeleton, and an end of the connecting body is connected with the magnetic column; Welding and fixing the wire joint of the wire package and the terminal group.

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