An AI / PC-specific integrated inductor and its preparation method

Abstract

An integrated inductor dedicated to AI / PC and a preparation method thereof, the inductor includes a first magnetic support body, a second magnetic support body and a coil, the first magnetic support body and the second magnetic support body are fixed and hot-pressed together, the coil is arranged in the main body of the magnetic support body, the coil includes a coil main rod, a coil side rod and a pin connection end, there are two coil side rods, the two coil ends are respectively connected to the two ends of the coil main rod, preferably, the coil side rod is arranged perpendicular to the coil main rod to form a "U"-shaped coil body, and each coil side rod end is connected to a pin connection end. The present invention adopts an inductor coil with a special structural design, which can greatly reduce the size of the inductor, thereby reducing the space it occupies and reducing the production cost. The present invention can perform well in high-frequency applications, can effectively smooth current, and reduce ripple.

Description

Technical Field

[0001] The present invention discloses an inductor, in particular an integrated inductor dedicated to AI / PC and a preparation method thereof, belonging to the technical field of electronic components. Background Art

[0002] A PC inductor (Power Choke Inductor) is a type of inductor widely used in power management and power electronics, primarily for filtering and energy storage. Like conventional inductors, PC inductors are energy storage components that utilize the magnetic field generated by current changes to store energy. PC inductors are commonly used in applications such as switching power supplies and DC-DC converters to smooth output current and reduce ripple and noise.

[0003] AI inductors are mainly used in artificial intelligence hardware platforms. AI processors (such as GPUs and TPUs) have high power requirements. Using AI inductors can help smooth the power supply, reduce ripple and noise, and improve system stability.

[0004] Whether it is a PC inductor or an AI inductor, ferrite core inductor is one of the most common choices. It uses ferrite material as the core, which can provide higher inductance value and better energy storage capacity. On the one hand, it can be used to smooth the output voltage and current and reduce power supply noise. On the other hand, it can be used as part of a low-pass filter to remove high-frequency interference.

[0005] Although they can effectively smooth current, reduce ripple, and perform well in high-frequency applications, conventional ferrite core inductors generally have the disadvantages of being large in size, requiring more space, and having high manufacturing costs. Summary of the Invention

[0006] In response to the above-mentioned disadvantage of the large size of the ferrite core inductor in the prior art, the present invention provides an AI / PC-specific integrated inductor and a preparation method thereof, which adopts an inductor coil with a special structural design to greatly reduce the size of the inductor.

[0007] The technical solution adopted by the present invention to solve its technical problems is: an integrated inductor dedicated to AI / PC, the inductor includes a first magnetic support body, a second magnetic support body and a coil, the first magnetic support body and the second magnetic support body are fixed and hot-pressed together, the coil is arranged in the main body of the magnetic support body, the coil includes a coil main rod, a coil side rod and a pin connection end, there are two coil side rods, and the two coil ends are respectively connected to the two ends of the coil main rod. Preferably, the coil side rod is arranged perpendicular to the coil main rod to form a "U"-shaped coil body, and each coil side rod end is connected to a pin connection end.

[0008] A method for preparing the above-mentioned AI / PC dedicated integrated inductor, the method comprising the following steps:

[0009] Step S1, coil processing: processing the coil according to the set shape. The coil processing includes the following sub-steps:

[0010] Step S1-1, stamping: first, cut a square copper bar of corresponding length according to the set shape of the coil, and then stamp the square copper bar into a coil main rod, a coil side rod and a pin connection end;

[0011] Step S1-2, spray painting: spray painting on the surface of the stamped coil;

[0012] Step S1-3, paint stripping: stripping the paint on the soldering surface of the coil corresponding to the pin connection end;

[0013] Step S2, battery core processing: processing the first and second magnet supports according to the set shape. The first and second magnet supports are formed by hot pressing magnetic powder. The magnetic powder includes a mixture of metal soft magnetic powder and alloy powder. During hot pressing, the hot pressing temperature is controlled between 120 and 180 degrees Celsius, the pressure is 4 to 7 t per square centimeter, and the hot pressing time is 40 to 200 seconds.

[0014] Step S3, assembling: installing the coil in the second magnetic support, and then installing the first magnetic support cover on the second magnetic support;

[0015] Step S4, hot pressing forming: pressing the first magnetic support body and the second magnetic support body together through a hot pressing process to form an inductor;

[0016] Step S5, spray painting: spray painting on the surface of the hot-pressed inductor;

[0017] Step S6, paint stripping: stripping the paint on the soldering surface of the inductor corresponding to the soldering pins to expose the soldering pins;

[0018] Step S7, electroplating tin: forming a solder layer at the soldering surface position corresponding to the soldering pin on the inductor through an electroplating process.

[0019] The technical solution adopted by the present invention to solve the technical problem further includes:

[0020] The cross section of the coil main rod portion is rectangular, the longest length L1 of the coil main rod is 5.90±0.05mm, the width W1 of the copper bar at the coil main rod position is 0.80±0.05mm, and the thickness T1 of the copper bar at the coil main rod position is 1.20±0.05mm.

[0021] The cross section of the coil side rod portion is rectangular, the longest length L2 of the coil side rod is 4.0±0.05mm, the width W2 of the copper bar at the coil side rod position is 0.80±0.05mm, and the thickness T2 of the copper bar at the coil side rod position is 1.20±0.05mm.

[0022] The cross-section of the pin connection end portion is rectangular, the longest length L3 of the pin connection end is 2.00±0.05mm, the width W3 of the copper strip at the pin connection end position is 0.80±0.05mm, and the thickness T3 of the copper strip at the pin connection end position is 0.90±0.05mm.

[0023] The pin connection end and the coil side rod are partially overlapped together, and the overlapping portion of the pin connection end and the coil side rod is a connecting rod, and the length L4 of the connecting rod is 1.20±0.05mm.

[0024] The connection portion between the coil side rod and the coil main rod is arc-shaped, the radius R1 of the inner arc is 0.30±0.05mm, and the radius R2 of the outer arc is 0.30±0.05mm.

[0025] The first magnet support body is in a rectangular parallelepiped shape. An accommodating notch for accommodating the pin connecting end is provided on the main body of the first magnet support body at a position corresponding to the pin connecting end. The pin connecting end is provided in the accommodating notch.

[0026] The second magnet support body is in the shape of a rectangular parallelepiped, and a receiving groove is provided in the main body of the second magnet support body. A protrusion is provided in the receiving groove, and the shape of the protrusion is consistent with the internal shape of the coil "U" shape. The coil main rod and coil side rod of the coil are embedded in the receiving groove.

[0027] The inductor further includes a spray paint layer arranged on the outside, the spray paint layer forms the inductor shell, and the shell is provided with welding pins. There are two welding pins, which are respectively connected to the pin connection ends.

[0028] The invention has the following beneficial effects: the inductor coil adopts a special structural design, which can significantly reduce the size of the inductor, thereby reducing the space it occupies and reducing production costs. The invention can perform well in high-frequency applications, effectively smoothing current and reducing ripple.

[0029] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 It is a schematic diagram of the three-dimensional structure of the present invention.

[0031] Figure 2 It is a schematic diagram of the structure of the decomposed state of the present invention.

[0032] Figure 3 This is a schematic diagram of the three-dimensional structure from another perspective of the present invention.

[0033] Figure 4 This is a schematic diagram of the decomposed state structure from another perspective of the present invention.

[0034] Figure 5 This is a schematic diagram of the side view of the coil structure in the present invention.

[0035] Figure 6 This is a schematic diagram of the front view structure of the coil in the present invention.

[0036] In the figure, 1-housing, 2-welding pin, 3-first magnet support, 31-first magnet support body, 32-accommodating notch, 4-second magnet support, 41-second magnet support body, 42-accommodating groove, 43-bump, 5-coil, 51-coil main rod, 52-coil side rod, 53-connecting rod, 54-pin connecting end. DETAILED DESCRIPTION

[0037] This embodiment is a preferred implementation manner of the present invention. Other embodiments whose principles and basic structures are the same or similar to those of this embodiment are within the scope of protection of the present invention.

[0038] Please combine the attached Figure 1 To the attached Figure 6 The present invention mainly protects an integrated inductor dedicated to AI / PC, which mainly includes a first magnetic support body 3, a second magnetic support body 4 and a coil 5. The first magnetic support body 3 and the second magnetic support body 4 are fixed and hot-pressed together to form a magnetic support body main body, and the coil 5 is arranged in the magnetic support body main body. In the present invention, the first magnetic support body 3 and the second magnetic support body 4 are components in the inductor processing process. When the inductor processing is completed, the first magnetic support body 3 and the second magnetic support body 4 are combined into one by a hot pressing process, and there is no physical separation. Instead, they are defined according to the structure in the processing process.

[0039] In this embodiment, the coil 5 includes a coil main rod 51, a coil side rod 52 and a pin connection end 54. There are two coil side rods 52, and the two coil ends are respectively connected to the two ends of the coil main rod 51. Preferably, the coil side rod 52 is arranged perpendicular to the coil main rod 51 to form a "U"-shaped coil body, and each end of the coil side rod 52 is connected to a pin connection end 54.

[0040] In this embodiment, the coil 5 is formed by bending a copper bar, and the cross-section of the coil main rod 51 is preferably rectangular. The longest length L1 of the coil main rod 51 is preferably 5.9 mm, the width W1 of the copper bar at the position of the coil main rod 51 is preferably 0.8 mm, and the thickness T1 of the copper bar at the position of the coil main rod 51 is preferably 1.2 mm, that is, the length and width of the rectangular cross-section of the coil main rod 51 are 1.2 mm and 0.8 mm respectively.

[0041] In this embodiment, the cross-section of the coil side rod 52 is preferably rectangular, the longest length L2 of the coil side rod 52 is preferably 4.0 mm, the width W2 of the copper bar at the position of the coil side rod 52 (W2 is the same as W1, not marked in the figure) is preferably 0.8 mm, and the thickness T2 of the copper bar at the position of the coil side rod 52 (T2 is the same as T1, not marked in the figure) is preferably 1.2 mm, that is, the length and width of the rectangular cross-section of the coil side rod 52 are 1.2 mm and 0.8 mm respectively.

[0042] In this embodiment, the cross-section of the pin connection end 54 is preferably rectangular, the longest length L3 of the pin connection end 54 is preferably 2.0 mm, the width W3 of the copper bar at the pin connection end 54 is preferably 0.8 mm, and the thickness T3 of the copper bar at the pin connection end 54 is preferably 0.9 mm, that is, the length and width of the rectangle in the cross-section of the pin connection end 54 are 0.9 mm and 0.8 mm respectively.

[0043] In this embodiment, the pin connection end 54 and the coil side rod 52 are partially overlapped together, that is, the pin connection end 54 is arranged on the side of the coil side rod 52, and the overlapping part of the pin connection end 54 and the coil side rod 52 is defined as the connecting rod 53, and the length L4 of the connecting rod 53 is preferably 1.2 mm.

[0044] In this embodiment, the connection portion between the coil side rod 52 and the coil main rod 51 is arc-shaped, and the radius R1 of the inner arc is preferably 0.30 mm, and the radius R2 of the outer arc is preferably 0.30 mm.

[0045] The above structural dimensions are preferred standard dimensions of the present invention. During specific implementation, due to limitations in machining accuracy, each structural dimension may have an error of ±0.05 mm.

[0046] In this embodiment, the first magnet support body 3 is in a rectangular parallelepiped shape. An accommodating notch 32 for accommodating the pin connection end 54 is provided on the main body 31 of the first magnet support body at a position corresponding to the pin connection end 54 . The pin connection end 54 is disposed in the accommodating notch 32 .

[0047] In this embodiment, the second magnet support body 4 is in the shape of a rectangular parallelepiped, and a receiving groove 42 is provided in the main body 41 of the second magnet support body for accommodating the coil main rod 51 and the coil side rod 52 of the coil 5. A protrusion 43 is provided in the receiving groove 42, and the shape of the protrusion 43 is consistent with the internal shape of the "U" shape of the coil 5, so that the coil main rod 51 and the coil side rod 52 of the coil 5 can be just embedded in the receiving groove 42.

[0048] In this embodiment, the inductor further includes a spray paint layer disposed on the outside, the spray paint layer forming the inductor housing 1 , and the housing 1 is provided with welding pins 2 . There are two welding pins 2 , each connected to the pin connection end 54 .

[0049] The present invention also protects a method for preparing the aforementioned AI / PC dedicated integrated inductor, which comprises the following steps:

[0050] Step S1, coil processing: processing the coil 5 according to the set shape. In this embodiment, the coil processing includes the following sub-steps:

[0051] Step S1-1, stamping: In this embodiment, the coil 5 is made of a rectangular copper bar. First, a square copper bar of a corresponding length is cut according to the set shape of the coil 5. Then, the square copper bar is stamped to form the coil main rod 51, the coil side rod 52 and the pin connection end 54;

[0052] Step S1-2, painting: spray paint on the surface of the stamped coil 5 to form an "enameled wire" structure. Before painting, the stamped coil 5 needs to be ground. In this embodiment, a pick or polishing aid is used for polishing during grinding. The grinding time is 25 to 35 minutes, preferably 30 minutes. The ratio of the polishing aid to the product mass is preferably 1:1. During specific implementation, it can also be adjusted according to actual needs. The speed of the grinder is preferably set to 500 to 600 revolutions per minute to remove the burrs formed on the surface of the coil 5 during the stamping process. Then The coil 5 is then cleaned. In this embodiment, an ultrasonic cleaning machine is used for cleaning, and pure water is used as a cleaning medium. The ground coil 5 is placed in an ultrasonic cleaning machine with pure water added, and ultrasonic cleaning is performed for more than 5 minutes to remove impurities on the surface. The cleaned coil is then dried. In this embodiment, the drying is performed in an environment of 120° C. for at least 30 minutes to remove surface moisture. After drying, the surface of the coil 5 is sprayed with paint using a roller spraying process. In this embodiment, the surface of the coil 5 is sprayed with insulating paint with a thickness of 10 to 20 μm.

[0053] Step S1-3, paint stripping: stripping the paint on the soldering surface of the coil 5 corresponding to the pin connection end 54 to expose the soldering pin. In this embodiment, laser ablation is used for the stripping.

[0054] Step S2, battery core processing: processing the first magnet support 3 and the second magnet support 4 according to the set shape. In this embodiment, the first magnet support 3 and the second magnet support 4 are processed by hot pressing of magnetic powder. In this embodiment, the magnetic powder includes a mixture of metal soft magnetic powder and alloy powder. The metal soft magnetic powder can be iron powder containing carbonyl, and the alloy powder can be amorphous powder or nanocrystalline powder, and the two can be mixed. During hot pressing, the hot pressing temperature is controlled between 120 and 180°C, the pressure is 4 to 7T per square centimeter, and the hot pressing time is 40 to 200 seconds.

[0055] In this embodiment, the coil 5 processing and the battery core processing can be performed simultaneously or in steps. The coil 5 processing and the battery core processing are not performed at the same station, and the order of the two processing is not necessarily related.

[0056] Step S3, assembly: install the coil 5 in the second magnetic support 4, and then cover the first magnetic support 3 on the second magnetic support 4;

[0057] Step S4, hot pressing: pressing the first magnetic support 3 and the second magnetic support 4 together through a hot pressing process to form an inductor;

[0058] Step S5, painting: spray paint on the surface of the hot-pressed inductor to form a protective layer of a specific color. Before painting, the hot-pressed inductor needs to be ground. In this embodiment, a pick or polishing aid is used for polishing during grinding. The grinding time is 25 to 35 minutes, preferably 30 minutes. The ratio of the polishing aid to the product mass is preferably 1:1. During specific implementation, it can also be adjusted according to actual needs. The speed of the grinder is preferably set to 500 to 600 revolutions per minute to remove the burrs formed on the surface of the inductor. Then, the inductor is ground. Cleaning is performed. In this embodiment, an ultrasonic cleaning machine is used for cleaning, and pure water is used as a cleaning medium. The ground inductor is placed in an ultrasonic cleaning machine with pure water added, and ultrasonic cleaning is performed for more than 5 minutes to remove impurities on the surface. The cleaned inductor is dried. In this embodiment, the inductor is baked in an environment of 120° C. for at least 30 minutes to remove surface moisture. After drying, the surface of the inductor is sprayed with paint using a roller spraying process. In this embodiment, the surface of the coil 5 is sprayed with insulating paint with a thickness of 10 to 20 μm.

[0059] Step S6, paint stripping: stripping the paint on the soldering surface of the inductor corresponding to the soldering pin 2 to expose the soldering pin 2;

[0060] Step S7, electroplating tin: forming a solder layer on the inductor at the soldering surface position corresponding to the soldering pin 2 by electroplating process to facilitate subsequent soldering operations.

[0061] The invention adopts a specially designed inductor coil, which can greatly reduce the size of the inductor, thereby reducing the space it occupies and reducing production costs. The invention can perform well in high-frequency applications, effectively smooth current and reduce ripple.

Claims

1. An integrated inductor for AI / PC, characterized by: The inductor comprises a first magnetic support body (3), a second magnetic support body (4) and a coil (5), wherein the first magnetic support body (3) and the second magnetic support body (4) are fixedly hot-pressed together to form a magnetic support body main body, and the coil (5) is arranged in the magnetic support body main body, and the coil (5) comprises a coil main rod (51), a coil side rod (52) and a pin connection end (54), and two coil side rods (52) are provided, and the two coil side rods (52) are respectively connected to the two ends of the coil main rod (51), and the coil side rods (52) are arranged perpendicular to the coil main rod (51) to form a "U"-shaped coil body, and each coil side rod (52) is connected to a pin connection end (54) at its end; The cross section of the coil main rod (51) is rectangular, the longest length L1 of the coil main rod (51) is 5.90±0.05 mm, the width W1 of the copper strip at the position of the coil main rod (51) is 0.80±0.05 mm, and the thickness T1 of the copper strip at the position of the coil main rod (51) is 1.20±0.05 mm; The cross section of the coil side rod (52) is rectangular, the longest length L2 of the coil side rod (52) is 4.0±0.05 mm, the width W2 of the copper bar at the position of the coil side rod (52) is 0.80±0.05 mm, and the thickness T2 of the copper bar at the position of the coil side rod (52) is 1.20±0.05 mm; The cross section of the pin connection end (54) is rectangular, the longest length L3 of the pin connection end (54) is 2.00±0.05 mm, the width W3 of the copper strip at the position of the pin connection end (54) is 0.80±0.05 mm, and the thickness T3 of the copper strip at the position of the pin connection end (54) is 0.90±0.05 mm; The pin connection end (54) and the coil side rod (52) are partially overlapped together, and the overlapping portion of the pin connection end (54) and the coil side rod (52) is a connecting rod (53), and the length L4 of the connecting rod (53) is 1.20±0.05mm.

2. The AI / PC-specific integrated inductor according to claim 1, characterized in that: The connection portion between the coil side rod (52) and the coil main rod (51) is arc-shaped, the radius R1 of the inner arc is 0.30±0.05 mm, and the radius R2 of the outer arc is 0.30±0.05 mm.

3. The AI / PC-specific integrated inductor according to claim 1, wherein: The first magnetic support body (3) is in the shape of a rectangular parallelepiped, and a receiving notch (32) for receiving the pin connection end (54) is provided on the main body (31) of the first magnetic support body at a position corresponding to the pin connection end (54), and the pin connection end (54) is provided in the receiving notch (32).

4. The AI / PC-specific integrated inductor according to claim 1, wherein: The second magnetic support body (4) is in the shape of a rectangular parallelepiped. A receiving groove (42) is provided in the main body (41) of the second magnetic support body. A protrusion (43) is provided in the receiving groove (42). The shape of the protrusion (43) matches the "U"-shaped internal shape of the coil (5). The coil main rod (51) and the coil side rod (52) of the coil (5) are embedded in the receiving groove (42).

5. The AI / PC-specific integrated inductor according to claim 1, wherein: The inductor further comprises a spray paint layer arranged on the outside, the spray paint layer forming an inductor housing (1), a welding pin (2) being arranged on the inductor housing (1), and two welding pins (2) being respectively connected to the pin connection ends (54).

6. A method for preparing the AI / PC dedicated integrated inductor according to any one of claims 1 to 5, characterized in that: The method comprises the following steps: Step S1, coil processing: processing the coil (5) according to the set shape, the coil processing includes the following sub-steps: Step S1-1, stamping: first, cutting a square copper bar of corresponding length according to the set shape of the coil (5), and then stamping the square copper bar to form a coil main rod (51), a coil side rod (52) and a pin connection end (54); Step S1-2, spray painting: spray painting on the surface of the stamped coil (5); Step S1-3, paint stripping: stripping the paint on the soldering surface of the coil (5) corresponding to the pin connection end (54); Step S2, battery core processing: processing the first magnet support (3) and the second magnet support (4) according to the set shape, the first magnet support (3) and the second magnet support (4) are processed by a hot pressing molding process of magnetic powder, the magnetic powder includes a mixture of metal soft magnetic powder and alloy powder, during hot pressing, the hot pressing temperature is controlled between 120 and 180°C, the pressure is 4 to 7T per square centimeter, and the hot pressing time is 40 to 200 seconds; Step S3, assembly: installing the coil (5) in the second magnetic support (4), and then installing the first magnetic support (3) cover on the second magnetic support (4); Step S4, hot pressing forming: pressing the first magnetic support body (3) and the second magnetic support body (4) together through a hot pressing process to form an inductor; Step S5, spray painting: spray painting on the surface of the hot-pressed inductor; Step S6, paint stripping: stripping the paint on the soldering surface of the inductor corresponding to the soldering pin (2) to expose the soldering pin (2); Step S7, electroplating tin: forming a solder layer at the soldering surface position corresponding to the soldering pin (2) on the inductor by electroplating process.

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