A series-connected high-sensitivity molded inductor and its forming method

Abstract

The present application relates to a series-connected high-sensitivity molded inductor and a molding method thereof. The molded inductor includes a metal wire and a plurality of soft magnetic metal blocks. The soft magnetic metal blocks are arranged at intervals on the metal wire. By bending the metal wire, the plurality of soft magnetic metal blocks are attached and arranged in parallel. The side surfaces of adjacent soft magnetic metal blocks are fixedly connected by an adhesive. The two ends of the metal wire are located at the bottom of the soft magnetic metal blocks and are used as pins or are welded with pins; or are located on the side surfaces of the soft magnetic metal blocks and are bent to the bottom of the soft magnetic metal blocks to be used as pins; or are located on the side surfaces of the soft magnetic metal blocks and are welded with pins, and the pins are bent to the bottom of the soft magnetic metal blocks. The present application uses the same metal wire to connect multiple inductor units in series, doubling the magnetic flux density, thereby achieving the purpose of increasing the inductance value. At the same time, since there is only one metal wire inside each soft magnetic metal block, high-temperature heat treatment can be adopted to produce an integrally formed co-fired molded inductor with a high inductance value and low loss.

Description

Technical Field

[0001] This application relates to the technical field of inductor processing, and particularly relates to a series high-inductance molded inductor and a forming method thereof. Background Art

[0002] The inductance value of an integrally formed molded inductor can be greatly improved through high-temperature heat treatment. From a microscopic analysis, on the one hand, the internal atomic activity of the metal soft magnetic material is enhanced at high temperatures, accelerating the release of internal stress, reducing the coercive force, and increasing the density and magnetic permeability; on the other hand, high-temperature heat treatment promotes the growth and recrystallization of grains, improves the organizational structure of the material, and thus enhances its magnetic and mechanical properties.

[0003] The above is to improve the inductance value from the perspective of metal soft magnetic powder. Another way is to start from the internal coil of the product. Increasing the number of winding turns is one of the main methods to improve the inductance value of an integrally formed molded inductor at present. However, the temperature resistance of the paint coating film is limited, and carbonization will occur in a high-temperature environment above 300°C, causing short circuits between the coil windings and resulting in inductor failure. Therefore, the winding coil is not suitable for the high-temperature heat treatment process. How to ensure the effectiveness of the inductor while maintaining high inductance value and low loss has become a difficult problem in the industry.

[0004] The Chinese patent application with the publication number CN111243814A discloses a copper sheet embedded soft magnetic powder core inductor and a preparation method thereof. The specific method is to embed a layer of copper sheet inside the soft magnetic powder core inductor. The surface of the copper sheet is covered with a soft magnetic material, and an insulating resin material is contained at the interface between the soft magnetic material and the copper sheet. The soft material is symmetrically distributed on both side surfaces of the copper sheet, and it is pressed and formed and annealed in an inert atmosphere. The regions of the two ends of the copper sheet that are not covered by the soft magnetic material are bent to obtain the copper sheet embedded soft magnetic powder core inductor. The copper sheet embedded soft magnetic powder core inductor has the characteristics of high density, high magnetic core permeability, high inductance, high saturation magnetic flux density, small volume, and less magnetic leakage. When it is used to replace a ferrite inductor with the same inductance in a low-voltage DC / DC converter circuit, it can obtain the same or higher efficiency, and at the same time, the inductor volume can be reduced by more than half.

[0005] The Chinese patent application with the publication number CN112435844A discloses an integrally co-fired inductor and a preparation method thereof. The preparation method includes: filling magnetic powder into a mold cavity, burying at least one wire in the magnetic powder, with both ends of the wire extending out of the mold cavity, and then successively performing molding and heat treatment to obtain a magnetic core, and bending and tinning the wire extending outside the magnetic core to obtain the co-fired inductor. The inductor obtained by this solution avoids the assembly process of too many components. After integrally forming, heat treatment is carried out to fully release stress and reduce the magnetic hysteresis loss of the material.

[0006] The Chinese patent application with publication number CN115938718A discloses a plug-in integrated co-fired inductor and a preparation method thereof. The inductor consists of two parts: a soft magnetic metal powder and an inverted U-shaped copper conductor. The two ends of the copper conductor extend out of the powder, and the rest is buried in the powder. The steps of the inductor preparation method are: (1) pretreatment of the soft magnetic metal powder; (2) burying the copper conductor in the treated metal powder and pressing it under a high pressure of 1700-2100MPa; (3) gradient annealing the product obtained in step (2) using a reducing atmosphere; (4) impregnating the annealed product in a resin solution, washing and baking to obtain a plug-in integrated co-fired inductor. The inductor not only has the advantages of high magnetic shielding performance, high mechanization of production, and high performance uniformity of an integrated inductor, but also has the advantages of high density and low loss of magnetic powder core materials.

[0007] The above three methods all use high temperature technology to maximize the inductance value from the powder, but the product uses a single copper wire or a single copper sheet as a conductor. Although it effectively avoids the problem of carbonization short circuit of the enamel film, the induced magnetic flux density is limited. This patent invents a structural design and production method of a series high-inductance molded inductor, which can maximize the magnetic flux density by connecting n inductors in series, thereby achieving the purpose of increasing the inductance. Summary of the invention

[0008] In order to solve the technical problem of how to maintain the effectiveness of the inductor in a high-temperature heat treatment process while ensuring high inductance and low loss, the present invention provides a series high-inductance molded inductor and a molding method thereof.

[0009] On the one hand, the technical solution provided by the present application is as follows: a series high-inductance molded inductor, comprising a metal conductor and a plurality of soft magnetic metal blocks, wherein the soft magnetic metal blocks are arranged at intervals on the metal conductor, and the plurality of soft magnetic metal blocks are attached and arranged in a row by bending the metal conductor, and the sides of adjacent soft magnetic metal blocks are fixedly connected by adhesive, and the two ends of the metal conductor are located at the bottom of the soft magnetic metal block and serve as pins or are welded with pins; or the two ends of the metal conductor are located at the side of the soft magnetic metal block and are bent to the bottom of the soft magnetic metal block and serve as pins; or the two ends of the metal conductor are located at the side of the soft magnetic metal block and are welded with pins, and the pins are bent to the bottom of the soft magnetic metal block.

[0010] By adopting the above technical solution, the present application uses the structure of an integrally formed co-fired inductor in the prior art, but adopts a series structure. A plurality of inductor units are connected in series by using the same metal wire, which increases the magnetic flux density by N times, thereby achieving the purpose of increasing the inductance value. At the same time, since there is only one metal wire inside each soft magnetic metal block, high-temperature heat treatment can be adopted to produce an integrally formed co-fired molded inductor with a high inductance value and low loss, without worrying about the technical problem that the paint coating film will be carbonized in a high-temperature environment, resulting in a short circuit between the coil windings and causing the inductor to fail. The adjacent soft magnetic metal blocks are fixedly connected by adhesive on the side surfaces to avoid vibration and noise problems. The length, width and height dimensions of the molded inductor product of the present application can be flexibly selected and adjusted to meet the complex and diverse needs of customers.

[0011] Preferably, a plurality of the soft magnetic metal blocks are arranged side by side in a straight line. The metal wire enters from the bottom surface of the first soft magnetic metal block, passes through the top surface of the first soft magnetic metal block, then bends and enters from the top surface of the second soft magnetic metal block, passes through the bottom surface of the second soft magnetic metal block, and so on, and finally passes through the bottom surface of the Nth soft magnetic metal block. The two ends of the metal wire are used as pins or welded with pins.

[0012] Preferably, a plurality of the soft magnetic metal blocks are arranged side by side in a straight line. The metal wire enters from the side surface of the first soft magnetic metal block, passes through the opposite side surface of the first soft magnetic metal block, then bends and enters from the side surface of the second soft magnetic metal block, passes through the opposite side surface of the second soft magnetic metal block, and so on, and finally passes through the side surface of the Nth soft magnetic metal block. The two ends of the metal wire are bent to the bottom of the soft magnetic metal block and used as pins or welded with pins.

[0013] Preferably, the molded inductor further includes an insulating top cover, and the insulating top cover and the top of the soft magnetic metal block are fixedly connected by adhesive; or the top of the soft magnetic metal block is coated with glue to make the common top of the plurality of soft magnetic metal blocks flat and gapless.

[0014] Preferably, the metal wire is copper foil, copper sheet, flat copper wire, round copper wire, enameled flat copper wire or enameled round copper wire.

[0015] Preferably, the shape of the soft magnetic metal block is a cuboid, and the metal wire is arranged in the middle of the soft magnetic metal block.

[0016] Preferably, the two ends of the metal wire are flattened to form pins; or pins are connected by spot welding.

[0017] Preferably, the bent metal wire between a plurality of soft magnetic metal blocks is fixed on the soft magnetic metal block by adhesive.

[0018] On the other hand, the present application also provides the following technical solution: A forming method of the above-mentioned series-connected high-sensitivity molded inductor, comprising the following steps:

[0019] S1. Place a metal wire in a forming mold, and the forming mold has at least two cavities;

[0020] S2. Fill the soft magnetic metal powder into the cavities and press it into shape;

[0021] S3. Perform high-temperature heat treatment;

[0022] S4. Bend the metal wire so that multiple soft magnetic metal blocks are attached and arranged in parallel, and the sides of adjacent soft magnetic metal blocks are fixedly connected by glue;

[0023] S5. Form the two ends of the metal wire into pins, or shape the pins welded to the two ends of the metal wire.

[0024] Preferably, in step S3, the temperature of the high-temperature heat treatment is 650 °C to 850 °C.

[0025] In summary, the present application includes at least one of the following beneficial technical effects:

[0026] 1. The present application adopts a series structure, using the same metal wire to connect multiple inductor units in series, doubling the magnetic flux density, thereby achieving the purpose of increasing the inductance value;

[0027] 2. Since there is only one metal wire inside each soft magnetic metal block, high-temperature heat treatment can be used to produce an integrally formed co-fired molded inductor with a high inductance value and low loss, without worrying about the technical problem that the paint coating film will carbonize in a high-temperature environment, causing a short circuit between the coil windings and resulting in the failure of the inductor;

[0028] 3. The sides of adjacent soft magnetic metal blocks are fixedly connected by glue to avoid vibration and noise problems;

[0029] 4. The length, width and height dimensions of the molded inductor product of the present application can be flexibly selected and adjusted to meet the complex and diverse needs of customers. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 is a perspective view of the molded inductor according to Embodiment 1 of the present application;

[0031] Figure 2 is a perspective view of the molded inductor according to Embodiment 1 of the present application;

[0032] Figure 3 is a schematic semi-sectional structure view of the molded inductor according to Embodiment 1 of the present application;

[0033] Figure 4It is an exploded perspective view of the molded inductor described in Embodiment 1 of the present application;

[0034] Figure 5 It is a schematic diagram of forming a soft magnetic metal block on a metal wire in the forming method of the molded inductor described in Embodiment 1 of the present application;

[0035] Figure 6 It is a schematic diagram after the soft magnetic metal blocks are bonded and arranged side by side in the forming method of the molded inductor described in Embodiment 1 of the present application;

[0036] Figure 7 It is a schematic diagram of bending the end of the metal wire into a lead and assembling an insulating top cover in the forming method of the molded inductor described in Embodiment 1 of the present application;

[0037] Figure 8 It is a perspective view of the molded inductor described in Embodiment 2 of the present application;

[0038] Figure 9 It is a front perspective view of the molded inductor described in Embodiment 3 of the present application;

[0039] Figure 10 It is a rear perspective view of the molded inductor described in Embodiment 3 of the present application;

[0040] Figure 11 It is a schematic diagram of forming a soft magnetic metal block on a metal wire in the forming method of the molded inductor described in Embodiment 3 of the present application;

[0041] Figure 12 It is a perspective view of the molded inductor described in Embodiment 4 of the present application;

[0042] Figure 13 It is a rear perspective view of the molded inductor described in Embodiment 5 of the present application;

[0043] Figure 14 It is a schematic diagram of forming a soft magnetic metal block on a metal wire in the forming method of the molded inductor described in Embodiment 5 of the present application.

[0044] Explanation of reference numerals: 1, metal wire; 11, end; 2, soft magnetic metal block; 3, adhesive; 4, lead; 5, insulating top cover. Detailed Description of the Embodiments

[0045] The following further describes the present application in detail with reference to the accompanying Figures 1 to 14 drawings. Embodiment 1:

[0046] Refer to Figures 1 to 4The embodiment of the present application discloses a series high-inductance molded inductor, including a metal wire 1 and a plurality of soft magnetic metal blocks 2, wherein the soft magnetic metal blocks 2 are arranged on the metal wire 1 at intervals, and the metal wire 1 is bent so that the plurality of soft magnetic metal blocks 2 are attached to each other and arranged in a row, and the sides of adjacent soft magnetic metal blocks 2 are fixedly connected by adhesive 3, and the two ends of the metal wire 1 are located at the bottom of the soft magnetic metal block 2 and are bent outward to fit the bottom of the soft magnetic metal block 2, and serve as SMD pins 4 of the molded inductor.

[0047] In this embodiment, the plurality of soft magnetic metal blocks 2 are attached and arranged in a straight line, the metal wire 1 enters from the bottom surface of the first soft magnetic metal block 2, passes through the top surface of the first soft magnetic metal block 2, enters from the top surface of the second soft magnetic metal block 2 after bending, and passes through the bottom surface of the second soft magnetic metal block 2, and the two ends of the metal wire 1 are used as pins 4. (If the two ends are not bent, they can be used as the pins of the direct plug-in (DIP) inductor, and if the two ends are bent, the pins 4 of the surface mount (SMD) inductor are formed).

[0048] If there are more than two soft magnetic metal blocks, the above method can be used to pierce through the bottom surface of the Nth soft magnetic metal block. In this way, the inductance of the molded inductor will increase by three times, four times, or N times.

[0049] In this embodiment, the metal wire 1 is a copper sheet, but it can also be in other forms, such as copper foil, flat copper wire, round copper wire, enameled flat copper wire or enameled round copper wire, etc., and the material is not limited to copper.

[0050] In this embodiment, the soft magnetic metal block 2 is in the shape of a cuboid, and the metal wire 1 is centrally arranged in the soft magnetic metal block 2 , so as to facilitate the soft magnetic metal blocks 2 to be attached and arranged in parallel and fixed with the adhesive 3 .

[0051] In this embodiment, the molded inductor further includes an insulating top cover 5, and the insulating top cover 5 and the top of the soft magnetic metal block 2 are fixedly connected by adhesive 3. Since the metal wires 1 between adjacent soft magnetic metal blocks 2 are located outside the soft magnetic metal blocks 2, the top of the soft magnetic metal blocks 2 will be uneven. In this embodiment, the insulating top cover 5 is added because the top surface of the insulating top cover 5 is flat, and the main purpose is to facilitate the SMT suction operation of the client.

[0052] In addition, in the present application, the top of the soft magnetic metal block can also be coated with glue to make the common top of the multiple soft magnetic metal blocks flat and gap-free, which can also facilitate the client's SMT suction operation. This application is not limited to the above form, as long as the central position of the top can be guaranteed to be flat and can be sucked by the suction nozzle.

[0053] In this application, the bent metal wire 1 between multiple soft magnetic metal blocks 2 can also be fixed to the soft magnetic metal blocks 2 by an adhesive 3, for the same reason of avoiding vibration noise problems.

[0054] This application adopts the structure of an integrally molded co-fired inductor in the prior art, but uses a series structure. Using the same metal wire 1 to connect multiple inductor units in series, the magnetic flux density is increased by N times, thereby achieving the purpose of increasing the inductance value. At the same time, since there is only one metal wire 1 inside each soft magnetic metal block 2, high-temperature heat treatment can be used to produce an integrally molded co-fired molded inductor with a high inductance value and low loss, without worrying about the carbonization of the paint coating film in a high-temperature environment, resulting in a short circuit between the coil windings and causing the inductor to fail. The adjacent sides of the soft magnetic metal blocks 2 are fixedly connected by an adhesive 3 to avoid vibration noise problems. The length, width, and height dimensions of the molded inductor product of this application can be flexibly selected and adjusted to meet the complex and diverse needs of customers.

[0055] The forming method of the above-mentioned series-connected high-inductance molded inductor includes the following steps:

[0056] S1. Place the metal wire 1 in a forming mold. When the metal wire 1 is relatively soft, both ends should be straightened and tightened. The forming mold has at least two cavities, that is, at least two soft magnetic metal blocks 2 are made on the metal wire 1.

[0057] S2. Refer to Figure 5 , fill the soft magnetic metal powder into the cavity and press it into shape. High pressure can be used for molding here to obtain a compact and dense soft magnetic metal block 2. Since the metal wire 1 does not need to be wound into a winding and does not form a multi-turn coil structure, the high-pressure molding will not have a great impact on the shape of the metal wire 1.

[0058] S3. Perform high-temperature heat treatment. The temperature of the high-temperature heat treatment is preferably 650°C to 850°C. The specific temperature selection factor also needs to refer to the specific composition of the soft magnetic metal powder actually used. The high-temperature heat treatment can greatly increase the inductance value. On the one hand, the internal atomic activity of the metal soft magnetic material is enhanced at high temperatures, accelerating the release of internal stress, reducing the coercive force, and increasing the density and magnetic permeability. On the other hand, the high-temperature heat treatment promotes the growth and recrystallization of grains, improves the microstructure of the material, and thus improves its magnetic properties and mechanical properties.

[0059] S4. Refer to Figure 6, Bend the metal wire 1 so that multiple soft magnetic metal blocks 2 are attached and arranged side by side. The sides of adjacent soft magnetic metal blocks 2 are fixedly connected by an adhesive 3. Here, the adhesive 3 is preferably an insulating adhesive to avoid adjacent soft magnetic metal blocks 2 contacting and conducting electricity, which may affect the inductance unit. In this embodiment, multiple said soft magnetic metal blocks 2 are attached and arranged side by side in a straight line. Of course, other arrangement methods can also be used, such as a multi-row and multi-column form like a square grid. The shape of the metal wire 1 should also be adaptively modified to match the folding direction of the soft magnetic metal blocks 2 (for round copper wires, this problem is basically not considered).

[0060] S5, Refer to Figure 7 , Shape the two ends 11 of the metal wire 1 into pins 4. In this embodiment, the two ends 11 are bent outwards so that the two ends 11 fit against the bottom surface of the soft magnetic metal block 2 to form SMD pins 4; when the sizes of the two ends 11 are too large or too small and not suitable for directly forming into pins 4, pins 4 with appropriate sizes can also be welded to the two ends 11 of the metal wire 1. Since the molded inductor in this embodiment also includes an insulating top cover 5, the step of pasting the insulating top cover 5 to the top of the soft magnetic metal block 2 is also required.

[0061] If in the actual usage scenario of the client, there are restrictions on the length and width of the inductor, but no restrictions on the height, then the structure of this embodiment can be selected. By increasing the height of the soft magnetic metal block 2 and increasing the length of the metal wire 1, the inductance can be increased. In fact, the width of the soft magnetic metal block 2 can be made very small, down to the millimeter level. For example, if the total width of the inductor product is required to be 5 mm and the height is not restricted, then five inductor units can be connected in series, and the width of each inductor unit (mainly referring to the soft magnetic metal block 2) is limited to about 0.9 mm, and the thickness of the glue bonding is about 0.1 mm. Without being restricted by the customer's required dimensions, the length, width, and height dimensions of the inductor product can be flexibly selected and adjusted. Embodiment Two:

[0062] Refer to Figure 5 , The difference from Embodiment One is that the metal wire 1 is a round copper wire, and copper sheets are welded to the two ends of the round copper wire. Half of the copper sheet is inside the soft magnetic metal block 2 and half is exposed outside the soft magnetic metal block 2, and then it is bent outwards to fit against the bottom of the soft magnetic metal block 2 to form the pin 4. Because the diameter of the round copper wire is too small and its size is not suitable for directly serving as the pin 4 of the SMD product, a copper sheet is welded to each end to form the pin 4. In addition, half of the copper sheet is inside the soft magnetic metal block 2, which is equivalent to being embedded in the soft magnetic metal block 2. The fixing effect of the copper sheet is good, and the force is no longer limited to the solder joints. The strength and stability of the pin 4 are better, and the solder joints are generally not damaged when the copper sheet is bent outwards.

[0063] In the forming method of the molded inductor of this embodiment, first, the copper sheet is welded to the two ends of the round copper wire, then the soft magnetic metal block 2 is formed. After high-temperature heat treatment, the copper sheet is bent and shaped.

[0064] In this embodiment, it is also feasible to first flatten the two ends of the metal wire 1 so that the ends become copper sheets, and then bend them into the pins 4. However, this requires a relatively large diameter of the metal wire 1. Other structures and beneficial effects are the same as those in Embodiment 1 and will not be elaborated here. Embodiment Three:

[0065] Refer to Figure 9 and Figure 10 In this embodiment, the difference from Embodiment 1 is that the direction of the metal wire 1 passing through and out is different, and the way of forming the two ends of the metal wire 1 into the pins 4 is also different. Specifically as follows: A plurality of the soft magnetic metal blocks 2 are arranged side by side in a straight line. The metal wire 1 enters from the side of the first soft magnetic metal block 2 and exits from the opposite side of the first soft magnetic metal block 2. After bending, it then enters from the side of the second soft magnetic metal block 2 and exits from the opposite side of the second soft magnetic metal block 2. For the developed view of the molded inductor of this embodiment, please refer to Figure 11 .

[0066] If the number of soft magnetic metal blocks is more than two, it can be analogized according to the above penetration method. Finally, it exits from the side of the Nth soft magnetic metal block. The two ends of the metal wire are bent to the bottom of the soft magnetic metal block and used as pins or welded with pins.

[0067] This embodiment does not require an insulating top cover because the top surface of the soft magnetic metal block 2 is flat itself and will not affect the SMT suction operation of the client. The application of this embodiment is also very flexible because the metal wire 1 between adjacent soft magnetic metal blocks 2 is located on the side of the soft magnetic metal block 2, and the number of soft magnetic metal blocks 2 can be expanded arbitrarily.

[0068] If in the actual use scenario of the client, there is a limit on the height of the inductor, but no limit on the length and width, then the structure of this embodiment can be selected. By increasing the number of soft magnetic metal blocks 2 arranged in parallel, the length of the metal wire 1 can be increased to increase the inductance. For example, if the inductor product requires a height of 8 mm and the length and width are not limited, then two or more inductor units can be connected in series. Then the height limit of each inductor unit is about 7.9 mm, and the thickness of the bottom pin 4 is about 0.1 mm. Other structures and beneficial effects are the same as those in Embodiment 1 and will not be elaborated here. Embodiment Four:

[0069] Refer to Figure 12, different from Embodiment 3 in that the metal wire 1 is a round copper wire, and copper sheets are welded to both ends of the round copper wire. A small half of the copper sheet is inside the soft magnetic metal block 2, and a large half is exposed outside the soft magnetic metal block 2 and then bent outward to fit against the bottom of the soft magnetic metal block 2 to form the pin 4. The advantages of welding copper sheets to both ends of the metal wire 1 have been described in Embodiment 2 and will not be elaborated here. Embodiment 5:

[0070] Refer to Figure 13 and Figure 14 , different from Embodiment 3 in that the number of soft magnetic metal blocks 2 is different. In this embodiment, there are three soft magnetic metal blocks 2. When the number of soft magnetic metal blocks 2 is odd or even, the directions of the two ends 11 of the metal wire 1 are different and need to be adjusted. In this embodiment, relative to the middle part, one of the two ends 11 is offset to the left and the other is offset to the right. After being formed into the pin 4, they are basically close to the two diagonal positions of the molded inductor to balance the support of the molded inductor. Other structures and beneficial effects are the same as those in Embodiment 3 and will not be elaborated here.

[0071] The above are all the preferred embodiments of this application, and the protection scope of this application is not limited accordingly. Therefore, all equivalent changes made according to the structure, shape, and principle of this application should be covered within the protection scope of this application.

Claims

1. A series high-inductance molded inductor, characterized in that: It comprises a metal wire and a plurality of soft magnetic metal blocks, wherein the soft magnetic metal blocks are arranged on the metal wire at intervals, and the metal wire is bent so that the plurality of soft magnetic metal blocks are attached and arranged in a row, and the sides of adjacent soft magnetic metal blocks are fixedly connected by adhesive, and the two ends of the metal wire are located at the bottom of the soft magnetic metal block and are used as pins or are welded with pins, and the molded inductor also comprises an insulating top cover, and the insulating top cover and the top of the soft magnetic metal block are fixedly connected by adhesive; the metal wire between adjacent soft magnetic metal blocks is located outside the soft magnetic metal block, the top of the soft magnetic metal block is uneven, and the top surface of the insulating top cover is flat to facilitate SMT absorption; or the two ends of the metal wire are located at the side of the soft magnetic metal block, bent to the bottom of the soft magnetic metal block, and used as pins; or the two ends of the metal wire are located at the side of the soft magnetic metal block and are welded with pins, and the pins are bent to the bottom of the soft magnetic metal block; Each soft magnetic metal block has only one straight metal wire segment inside, and high-temperature heat treatment is used to produce a high-inductance, low-loss one-piece co-fired molded inductor. The molding method of the series high-inductance molded inductor comprises the following steps: S1, placing a metal wire in a molding die, wherein the molding die has at least two cavities for producing at least two soft magnetic metal blocks, and the two ends of the metal wire are straightened and tightened outside the two cavities, and the middle section of the metal wire extends between the two cavities; S2, filling the two cavities with soft magnetic metal powder and pressing them into shape; S3, performing high temperature heat treatment; in step S3, the temperature of the high temperature heat treatment is 650°C to 850°C; S4, bending the metal wire so that the multiple soft magnetic metal blocks are attached to each other and arranged in a row, and the sides of adjacent soft magnetic metal blocks are fixedly connected by adhesive; S5, forming the two ends of the metal wire into pins, or shaping the pins welded to the two ends of the metal wire.

2. The series high-inductance molded inductor according to claim 1, characterized in that: The multiple soft magnetic metal blocks are attached and arranged in a straight line. The metal wire enters from the bottom surface of the first soft magnetic metal block, passes through the top surface of the first soft magnetic metal block, enters from the top surface of the second soft magnetic metal block after bending, passes through the bottom surface of the second soft magnetic metal block, and so on, and finally passes through the bottom surface of the Nth soft magnetic metal block. The two ends of the metal wire are used as pins or are welded with pins.

3. The series high-inductance molded inductor according to claim 1, characterized in that: The multiple soft magnetic metal blocks are arranged in a straight line and in a row. The metal wire enters from the side of the first soft magnetic metal block, passes through the other side opposite to the first soft magnetic metal block, enters from the side of the second soft magnetic metal block after bending, passes through the other side opposite to the second soft magnetic metal block, and so on, and finally passes through the side of the Nth soft magnetic metal block. The two ends of the metal wire are bent to the bottom of the soft magnetic metal block and used as pins or welded with pins.

4. The series high-inductance molded inductor according to claim 1, characterized in that: The soft magnetic metal block is in the shape of a cuboid, and the metal wire is centrally arranged in the soft magnetic metal block.

5. The series high-inductance molded inductor according to claim 1, characterized in that: The two ends of the metal wire are flattened to form pins; or the pins are connected by spot welding.

6. The series high-inductance molded inductor according to claim 1, characterized in that: The bent metal wires between the multiple soft magnetic metal blocks are fixed on the soft magnetic metal blocks by adhesive.

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