Inductor and manufacturing method thereof
By changing the inductor's to vertical form, the problem of large area occupied by existing molded inductors is solved, miniaturization of inductors and high power density is achieved, the current path resistance is reduced, and the efficiency of inductors is improved .
Patent Information
- Application Number
- CN202310668445.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2023-06-07
- Publication Date
- 2024-12-10
AI Technical Summary
The horizontal lying coils of existing molded inductors have caused large area of circuit boards to be difficult to shrink, and cannot meet the demands of electronic devices for miniaturization and high power density.
Change the toroidal coil to an upright form, so that the central axis of the spiral coil is parallel to the bottom surface of the inductor body, reduce the area of the bottom surface of the inductor body, increase the height and performance of the inductor, and extend in the same direction through the lead portion to increase the length and efficiency of the coil.
It effectively reduces the circuit board area occupied by the inductor, increases the power density of the circuit board, and reduces the resistance on the current path, improving the performance of the inductor.
Smart Images
Figure CN119108197A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to an inductor and a manufacturing method thereof, and in particular to an inductor and a manufacturing method thereof in which a coil is erected to reduce the circuit board area occupied by the inductor and to increase the height and performance of the inductor. Background Art
[0002] In the era of advanced technology, everyone cannot live without electronic devices, and each electronic device cannot do without inductors. Among them, the molded inductor formed in one piece has a low magnetic leakage rate and is suitable for use in precision electronic devices where components need to be closely adjacent and have a high power density. However, the molded inductor of the prior art, as shown in FIG. 3 of the patent application No. 110124491 in Taiwan, China, has a central coil portion lying horizontally. Since the area of the coil portion affects the inductance performance, it is difficult to reduce the coil. The molded inductor of the prior art cannot reduce the area of the circuit board occupied. In the situation where various electronic devices are pursuing miniaturization and extreme circuit board power density, there is room for further improvement.
[0003] In view of this, the inventor has devoted himself to research and design, hoping to provide an inductor and a method for manufacturing the inductor that can reduce the occupied area while maintaining the performance, which is the motivation for the invention of the present invention. Summary of the invention
[0004] The main purpose of the present invention is to provide an inductor and a method for manufacturing the same, which changes the placement direction of the internal spiral coil, occupies less circuit board area than the inductor of the prior art, and can also increase the power density of the circuit board.
[0005] The inductor of the present invention comprises an inductor body; a toroidal coil comprising a spiral coil portion and two lead portions, each lead portion being connected to opposite ends of the spiral coil portion, the toroidal coil being arranged inside the inductor body, the central axis of the spiral coil portion being parallel to the bottom surface of the inductor body, each lead portion being perpendicular to the bottom surface of the inductor body; and two electrode portions being arranged at the bottom of the inductor body and being electrically connected to each lead portion respectively.
[0006] Furthermore, each electrode portion is a plating electrode portion.
[0007] Furthermore, each electrode portion is a straight-insertion pin.
[0008] Since the diameter of the coil inside the molded inductor of the prior art is larger than its height when lying horizontally (the diameter is difficult to reduce for efficiency), the present invention changes the annular coil into an upright form, so that the central axis of the spiral coil part is parallel to the bottom surface of the inductor body, and the area of the bottom surface of the inductor body can be reduced, and the area of the circuit board occupied can also be reduced, and the power density of the circuit board can also be increased. The electrode parts of the present invention can be made into electroplated electrode parts or direct plug pins according to the required packaging form.
[0009] Moreover, the two leads of the coil in the molded inductor in the prior art face in opposite directions, while the two leads of the spiral coil of the present invention face in the same direction, so that the length of the spiral coil of the present invention can be slightly longer than the coil in the molded inductor in the prior art, thereby increasing efficiency. The current path length of the electroplated electrode portion of the present invention can be shorter than that of the molded inductor in the prior art. The shorter current path length means that the resistance on the current path is reduced, thereby reducing unnecessary energy consumption.
[0010] The manufacturing method of the inductor of the present invention can be implemented in a variety of ways according to the packaging form of the product, one of which includes: connecting two lead parts of a ring coil to each pin part of a connecting terminal piece, and each lead part extends in the same direction; placing the ring coil in the inductor body material and die-casting it into an inductor body, with the central axis of the ring coil parallel to the bottom surface of the inductor body, and each lead part extends toward the bottom surface of the inductor body; separating each lead part from each pin part; and making two electroplated electrode parts on the bottom surface of the inductor body, and each electroplated electrode part is electrically connected to each lead part. The product of this embodiment is in the form used for surface mount technology (SMT). Since each lead part extends in the same direction, the connecting terminal piece only needs to have protruding pin parts on one side.
[0011] Another embodiment of the method for manufacturing an inductor of the present invention includes: connecting two lead portions of a ring coil to each pin portion of a connection terminal piece, each lead portion extending in the same direction; placing the ring coil in the inductor body material to die-cast into an inductor body, the central axis of the ring coil is parallel to the bottom surface of the inductor body, each lead portion extends toward the bottom surface of the inductor body; and separating each pin portion from the connection terminal piece. This embodiment retains each pin portion as a pin header used for direct insertion.
[0012] Another embodiment of the method for making an inductor of the present invention includes: extending two lead portions of a toroidal coil in the same direction; and placing the toroidal coil in an inductor body material and die-casting it into an inductor body, wherein the central axis of the toroidal coil is parallel to the bottom surface of the inductor body. In this embodiment, the toroidal coil is not connected to the connecting terminal piece, but is directly fed into a mold and die-casted into the inductor body. Each lead portion of the toroidal coil can be connected to a row of pins for making electrodes and then die-casted, or the electrode portion can be made after die-casting.
[0013] In order to further understand the characteristics, features and technical contents of the present invention, please refer to the following detailed description of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Figure 1 is a three-dimensional diagram of embodiment (I) of the present invention; Figure 2 for Figure 1 Schematic diagram of the internal structure; Figure 3A The annular coil of embodiment (1) of the present invention; Figure 3B A schematic diagram of a coil of the prior art; Figure 4 It is a three-dimensional diagram of embodiment (II) of the present invention; Figure 5 It is a flow chart of embodiment (I) of the manufacturing method of the present invention; Figure 6 Schematic diagram of embodiment (I) of the manufacturing method of the present invention; Figure 7 It is a flow chart of embodiment (II) of the manufacturing method of the present invention; Figure 8 It is a schematic diagram of embodiment (II) of the manufacturing method of the present invention; Fig. 9 This is a flow chart of Embodiment 3 of the manufacturing method of the present invention.
[0015] Description of Reference Numerals 1 Inductor body 2 Toroidal coil 21 Helical coil section 211 Central Axis 22 Lead wire 23 Electrode 23A Electroplating Electrode Department 23B straight pin 3 Connecting end piece 31 pins A Coil in the prior art A1 Lead part in the prior art Steps S1 to S4 Steps S11 to S13 Steps S21~S22. DETAILED DESCRIPTION
[0016] See also Figure 1 to Figure 2 In the illustrations disclosing the embodiments of the present invention, the above-mentioned drawings illustrate an embodiment (I) of an inductor of the present invention, which includes an inductor body 1; a ring-shaped coil 2, which includes a spiral coil portion 21 and two lead portions 22, each lead portion 22 is respectively connected to the opposite ends of the spiral coil portion 21, the ring-shaped coil 2 is arranged inside the inductor body 1, the central axis 211 of the spiral coil portion 21 is parallel to the bottom surface of the inductor body 1, and each lead portion 22 is respectively perpendicular to the bottom surface of the inductor body 1; and two electrode portions 23, which are arranged at the bottom of the inductor body 1 and are respectively electrically connected to each lead portion 22. The present embodiment (one) is a product for surface mount welding, so each electrode portion 23 is a plated electrode portion 23A. Since the surface mount inductors in the prior art are often made by bending the electrode plates on both sides downward to the bottom of the body and then welding them to the circuit board, the current needs to pass through the entire length of the electrode plates. The plated electrode portions 23A of the present invention are directly arranged on the bottom surface of the inductor body 1. The path length of the current from the lead portion 22 to the circuit board will be shorter than that of the surface mount inductors in the prior art. The shortened current path length means that the resistance on the current path is reduced. The present invention can reduce unnecessary energy consumption.
[0017] Figure 3A , Figure 3B It can be seen that, since the diameter of the coil A in the molded inductor of the prior art is larger than its height when lying horizontally (the diameter is difficult to reduce for efficiency), the present invention changes the annular coil 2 into an upright form so that the central axis 211 of the spiral coil portion 21 is parallel to the bottom surface of the inductor body 1, and the area of the bottom surface of the inductor body 1 can be reduced. Naturally, the circuit board area occupied by the present invention can also be reduced, and the power density of the circuit board can be increased; and when there is a need to increase the number of turns of the spiral coil portion 21, the width of the present invention can be increased. Moreover, the two lead portions A1 of the coil A in the prior art are facing opposite directions, while the two lead portions 22 of the present invention are facing the same direction, so that the length of the spiral coil portion 21 of the present invention can be slightly larger than the coil A in the prior art, so as to increase the power density of the circuit board. Figure 3B Taking the coil A in the prior art as an example, the length of the annular portion of the coil A in the prior art is approximately 2.5 circumferences, while the length of the spiral coil portion 21 of the present invention is approximately 2.75 circumferences. By changing the direction of the lead portion 22, the coil length can be increased by approximately 0.25 circumferences, thereby increasing the efficiency of the inductor.
[0018] exist Figure 4The electrode portion 23 of the inductor of the second embodiment of the present invention is in the form of a direct-insertion pin 23B, so the present invention can be matched with various product design requirements.
[0019] exist Figure 5 and Figure 6 In the embodiment (I) of the method for manufacturing an inductor of the present invention, the method comprises: connecting two lead portions 22 of a ring coil 2 to each pin portion 31 of a connecting terminal piece 3, and each lead portion 22 extends in the same direction (S1); placing the ring coil 2 in an inductor body material and die-casting it into an inductor body 1, with the central axis 211 of the ring coil 2 parallel to the bottom surface of the inductor body 1, and each lead portion 22 extends toward the bottom surface of the inductor body 1 (S2); separating each lead portion 22 from each pin portion 31 (S3); and manufacturing two electroplating electrode portions 23A on the bottom surface of the inductor body 1, and each electroplating electrode portion 23A is electrically connected to each lead portion 22 respectively (S4).
[0020] The product of the embodiment (I) of this manufacturing method is in the form of surface mount technology (SMT), so it is provided with a plated electrode portion 23A. Please note that Figure 6 Step S3 is skipped for simplicity. Since the lead portions 22 extend in the same direction, the connecting terminal piece 3 only needs to have protruding pin portions 31 on one side.
[0021] exist Figure 7 and Figure 8 In the second embodiment of the method for manufacturing an inductor of the present invention, the method comprises: connecting two lead portions 22 of a ring coil 2 to each pin portion 31 of a connecting terminal piece 3, and each lead portion 22 extends in the same direction (S11); placing the ring coil 2 in the inductor body material to die-cast into an inductor body 1, the central axis 211 of the ring coil 2 is parallel to the bottom surface of the inductor body 1, and each lead portion 22 extends toward the bottom surface of the inductor body 1 (S12); separating each pin portion 31 from the connecting terminal piece 3 (S13). This second embodiment retains each pin portion 31 as a pin header used for direct insertion.
[0022] exist Fig. 9 In the third embodiment of the method for manufacturing an inductor of the present invention, the method comprises: extending two lead portions 22 of a toroidal coil 2 in the same direction (S21); and placing the toroidal coil 2 in the inductor body material to die-cast into an inductor body 1, with the central axis of the toroidal coil 2 being parallel to the bottom surface of the inductor body 1 (S22). In this embodiment, the toroidal coil 2 is not connected to the connecting terminal 3, but directly puts the toroidal coil 2 into the mold to die-cast into the inductor body 1, and each lead portion 22 can face the side, such as the left or right side. Each lead portion 22 of the toroidal coil 2 can be connected to the electrode pins first and then die-cast, or the electrode portion 23 can be made after die-casting.
[0023] The above description is only a preferred embodiment of the present invention and cannot be used to limit the scope of the present invention. Any changes and modifications that can be obviously made by those skilled in the art should be regarded as not departing from the essential content of the present invention.
Claims
1. An inductor, It is characterized in that include: an inductor body; a toroidal coil, comprising a spiral coil portion and two lead portions, each lead portion being connected to two opposite ends of the spiral coil portion, the toroidal coil being arranged inside the inductor body, the central axis of the spiral coil portion being parallel to the bottom surface of the inductor body, and each lead portion being perpendicular to the bottom surface of the inductor body; and Two electrode parts are arranged at the bottom of the inductor body and are electrically connected to each lead part respectively.
2. The inductor according to claim 1, It is characterized in that Each electrode portion is a plating electrode portion.
3. The inductor according to claim 1, It is characterized in that Each electrode portion is a straight-insertion pin.
4. A method for manufacturing an inductor, It is characterized in that include: Connecting two lead wires of a toroidal coil to the pins of a connecting terminal piece, with the lead wires extending in the same direction; The annular coil is placed in an inductor body material and die-casted into an inductor body, wherein the central axis of the annular coil is parallel to the bottom surface of the inductor body, and each lead portion extends toward the bottom surface of the inductor body; Separating each lead portion from each pin portion; and Two electroplating electrode parts are made on the bottom surface of the inductor body, and each electroplating electrode part is electrically connected to each lead part respectively.
5. A method for manufacturing an inductor, It is characterized in that include: Connecting two lead wires of a toroidal coil to the pins of a connecting terminal piece, with the lead wires extending in the same direction; The annular coil is placed in an inductor body material and die-casted into an inductor body, wherein the central axis of the annular coil is parallel to the bottom surface of the inductor body, and each lead portion extends toward the bottom surface of the inductor body; and Each pin portion is separated from the connecting terminal piece.
6. A method for manufacturing an inductor, It is characterized in that include: Extending two lead portions of a toroidal coil in the same direction; and The annular coil is placed in an inductor body material and die-casted into an inductor body, and the central axis of the annular coil is parallel to the bottom surface of the inductor body.