Inductor component and manufacturing method thereof

Abstract

The invention discloses an inductor assembly and a manufacturing method thereof. The manufacturing method of the inductor assembly comprises the following steps: filling a mold with first magnetic powder to form a substrate layer; forming a recess in the substrate layer; a coil is placed in the corresponding recess; second magnetic powder is filled in the mold to form a covering layer, and the covering layer fills gaps between the recesses and the corresponding coils and covers the substrate layer and the coils at the same time; executing a pressure forming procedure to form a to-be-cut packaging body and taking out the packaging body; cutting the to-be-cut packaging body to obtain a to-be-packaged body; and forming a protective layer on the surface of the to-be-packaged body and an electrode part electrically connected with the coil.

Description

Technical Field

[0001] The invention relates to a component and a manufacturing method thereof, in particular to an inductor component and a manufacturing method thereof. Background Art

[0002] In the current manufacturing process of small inductors, a single molding process is often used with corresponding molding tools. When mass-producing, it is easy to cause serious tool wear, making it difficult to reduce manufacturing costs. In addition, when multiple molds are used for the molding process, the thickness uniformity of the product will be poor due to uneven heights.

[0003] Therefore, how to improve product characteristics and reliability through the improvement of process and inductor structure, while reducing mold cost and increasing mold life, has become one of the important issues that need to be solved urgently in this field. Summary of the invention

[0004] The technical problem to be solved by the present invention is to provide an inductor component and a manufacturing method thereof which can improve product characteristics and reliability while reducing mold costs and increasing mold life in view of the deficiencies of the prior art.

[0005] In order to solve the above technical problems, one of the technical solutions adopted in the present application is to provide a method for manufacturing an inductor component, which includes: filling a first magnetic powder in a mold to form a base layer; forming at least one recess in the base layer; placing at least one coil corresponding to at least one recess; filling a second magnetic powder in the mold to form a covering layer, wherein the covering layer fills the gap between each recess and the corresponding coil, and simultaneously covers the base layer and at least one coil; performing a pressurization molding procedure to form a package to be cut, and taking the package to be cut out of the mold; cutting the package to be cut to obtain at least one package to be packaged; and forming a protective layer on the surface of each package to be packaged and an electrode portion electrically connected to the coil.

[0006] Optionally, the manufacturing method of the inductor component also includes: preparing at least one of the coils, wherein each of the coils includes: a coil body; a first pin portion connected to a first end of the coil body; and a second pin portion connected to a second end of the coil body.

[0007] Optionally, the coil body has a first height, each of the recesses has a second height, the first height is greater than the second height, and the heights of the first end and the second end are both greater than the second height, so that the first pin portion and the second pin portion are located above the corresponding recesses.

[0008] Optionally, the step of preparing at least one of the coils further includes winding each of the coil bodies around a magnetic core to form the coil.

[0009] Optionally, the steps of forming a protective layer on the surface of each of the bodies to be packaged and electrically connecting the electrode portion of the coil include: performing a spraying process on the surface of each of the bodies to be packaged to form a protective layer to be processed; removing a portion of the protective layer to be processed to expose a portion of the first pin portion and a portion of the second pin portion to form the protective layer; and forming a first electrode electrically connected to the first pin portion and a second electrode electrically connected to the second pin portion as the electrode portion on the surface of each of the bodies to be packaged.

[0010] Optionally, the first magnetic powder and the second magnetic powder are made of the same or different magnetic materials.

[0011] Optionally, the first magnetic powder, the second magnetic powder and the magnetic core are made of the same or two or more different magnetic materials.

[0012] Optionally, each of the recesses is a columnar recess, and the top of the columnar recess has a first width in a horizontal direction, the bottom of the columnar recess has a second width in the horizontal direction, and each of the bodies to be encapsulated has a third width in the horizontal direction, the first width is greater than the second width, and the third width is greater than the first width and the second width.

[0013] Optionally, a first portion of each of the coil bodies is located in the corresponding recess, a second portion of each of the coil bodies is not located in the corresponding recess, and a portion of the first pin portion and a portion of the second pin portion are located above the upper surface of the base layer surrounding the recess.

[0014] Optionally, each of the recesses has a bottom surface and an inner surface surrounding the bottom surface, and a distance between each of the coils and the inner surface of the corresponding recess in the horizontal direction is in the range of 0 mm to 0.5 mm.

[0015] In order to solve the above technical problems, another technical solution adopted in the present application is to provide an inductor component, characterized in that the inductor component includes: a base layer, including a first magnetic powder, and the base layer has at least one recess; at least one coil is correspondingly arranged in at least one recess; a covering layer, including a second magnetic powder, and the covering layer fills the gap between each recess and the corresponding coil, and simultaneously covers the base layer and at least one coil, wherein the base layer, at least one coil and the covering layer together form an inductor body; a protective layer and an electrode portion, which are arranged on the surface of the inductor body, wherein the electrode portion is electrically connected to at least one coil.

[0016] Optionally, in the inductor assembly, each of the coils includes: a coil body; a first pin portion connected to a first end of the coil body; and a second pin portion connected to a second end of the coil body.

[0017] Optionally, in the inductor component, the coil body has a first height, the cavity has a second height, the first height is greater than the second height, and the heights of the first end and the second end are both greater than the second height, so that the first pin portion and the second pin portion are located above the corresponding cavity.

[0018] Optionally, the inductor component further includes a magnetic core, and the coil body is formed around the magnetic core.

[0019] Optionally, in the inductor component, the protective layer exposes a portion of the first pin portion and a portion of the second pin portion, and the electrode portion includes a first electrode electrically connected to the first pin portion and a second electrode electrically connected to the second pin portion.

[0020] Optionally, in the inductor component, the first magnetic powder and the second magnetic powder are made of the same or different magnetic materials.

[0021] Optionally, in the inductor component, the first magnetic powder, the second magnetic powder and the magnetic core are made of the same or two or more different magnetic materials.

[0022] Optionally, in the inductor component, each of the recesses is a columnar recess, and the top of the columnar recess has a first width in a horizontal direction, the bottom of the columnar recess has a second width in the horizontal direction, and each of the inductor bodies has a third width in the horizontal direction, the first width is greater than the second width, and the third width is greater than the first width and the second width.

[0023] Optionally, in the inductor component, a first portion of each coil body is located in the corresponding recess, a second portion of each coil body is not located in the corresponding recess, and a portion of the first pin portion and a portion of the second pin portion of each coil are located above the upper surface of the corresponding recess defined by the base layer.

[0024] Optionally, in the inductor component, each of the recesses has a bottom surface and an inner surface surrounding the bottom surface, and the distance between each of the coils and the inner surface of the corresponding recess in the horizontal direction is in the range of 0 mm to 0.5 mm.

[0025] To further understand the features and technical contents of the present application, please refer to the following detailed description and drawings of the present application. However, the drawings provided are only for reference and illustration and are not intended to limit the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 FIG. 4 is a schematic diagram of an inductor component according to a first embodiment of the present invention.

[0027] Figure 2 for Figure 1 Top view of the inductor.

[0028] Figure 3 For along Figure 2 The cross-sectional view is obtained along line segment III-III.

[0029] Figure 4 FIG. 4 is a cross-sectional view of an inductor component according to a second embodiment of the present invention.

[0030] Figure 5A FIG. 4 is a top view of an inductor component according to a third embodiment of the present invention.

[0031] Figure 5B For along Figure 5A The cross-sectional view obtained by line segment VV.

[0032] Figure 6 FIG. 4 is a flow chart of a method for manufacturing an inductor component according to a fourth embodiment of the present invention.

[0033] Figure 7 It is a process schematic diagram of steps S60 to S61.

[0034] Figure 8 It is a process schematic diagram of steps S61 to S62.

[0035] Fig. 9 It is a process schematic diagram of steps S63 to S64.

[0036] Fig.10 and Fig.11It is a process schematic diagram of steps S65 to S66.

[0037] Fig.12 and Fig.13 FIG. 5 is a schematic diagram of an inductor component according to a fifth embodiment of the present invention. DETAILED DESCRIPTION

[0038] The following is an explanation of the implementation methods of the "inductor component and its manufacturing method" disclosed in the present application through specific examples. Those skilled in the art can understand the advantages and effects of the present application from the contents disclosed in this specification. The present application can be implemented or applied through other different specific embodiments, and the details in this specification can also be modified and changed in various ways based on different viewpoints and applications without departing from the concept of the present application. In addition, the drawings of the present application are only simple schematic illustrations and are not depicted according to actual dimensions. It is stated in advance. The following implementation methods will further explain the relevant technical contents of the present application in detail, but the disclosed contents are not intended to limit the scope of protection of the present application. In addition, the term "or" used in this article may include any one or more combinations of the associated listed items depending on the actual situation.

[0039] Figure 1 is a schematic diagram of an inductor component according to a first embodiment of the present invention, Figure 2 for Figure 1 A top view of the inductor. Figure 3 For along Figure 2 The cross-sectional view obtained along the line segment III-III. Figures 1 to 3 As shown, the first embodiment of the present invention provides an inductor component 1 including a base layer 10 , a coil 12 , a cover layer 14 , a protection layer 16 and an electrode portion 18 .

[0040] The base layer 10 may be formed as follows Figures 1 to 3 The rectangular parallelepiped shown in FIG. 1 includes the first magnetic powder, and a recess 100 is provided at the center of the base layer 10. From the top view ( Figure 2 ), the cavity 100 can be formed by being recessed from one of the surfaces of the base layer 10, and is a columnar cavity (e.g., a cylindrical cavity). The cavity 100 has an inner surface S1 and a bottom surface S2. The inner surface S1 is inclined at a predetermined angle relative to the bottom surface S2, and an opening OP is defined at the edge of the inner surface S1 adjacent to the upper surface of the base layer 10, and its area is larger than that of the bottom surface S2, so as to allow at least a portion of the coil 12 (e.g., the coil body 120) to pass through. The top of the columnar cavity (e.g., the opening OP) has a first width W1 in the horizontal direction (e.g., the first direction D1), and the bottom of the columnar cavity (e.g., the bottom surface S2) has a second width W2 in the horizontal direction (e.g., the first direction D1), and the first width W1 is larger than the second width W2.

[0041] The first magnetic powder can be a powder formed by one of the following materials: iron, iron-nickel alloy, iron-cobalt alloy, iron-silicon alloy, iron-vanadium alloy, iron-silicon-chromium alloy, iron-silicon-aluminum alloy, iron-silicon-aluminum alloy, iron-cobalt-vanadium alloy, iron-based amorphous alloy, iron-based nanocrystalline alloy, nickel-zinc ferrite, nickel-copper-zinc ferrite and manganese-zinc ferrite. It should be noted that in order to shape the first magnetic powder, the base layer 10 may also include an adhesive, and the adhesive material may be epoxy resin, silicone resin, acrylic resin, phenolic resin or polyvinyl alcohol. The weight percentage concentration of the adhesive contained in the first magnetic powder may be between 0.5wt% and 10wt%, so that the first magnetic powder can have a better molding density and magnetic properties.

[0042] The coil 12 is disposed in the cavity 100. The coil 12 may be wound with a metal wire made of a metal conductor (such as copper), and the metal wire may be, for example, a round wire, a flat wire (for example, a cross section having an aspect ratio not equal to 1), or a square wire, and its winding form may be flat winding (also called horizontal winding) or external winding (vertical winding, α winding). Moreover, the present invention does not limit the wire form and winding form of the coil 12.

[0043] The coil 12 may include a coil body 120 , a first pin portion 122 , and a second pin portion 124 . The first pin portion 122 is connected to a first end portion 1201 of the coil body 120 , and the second pin portion 124 is connected to a second end portion 1202 of the coil body 120 .

[0044] like Figure 1 As shown, the coil body 120 includes a plurality of ring bodies stacked on each other, and the first end 1201 is located at the top ring body of the coil body 120 and extends along the tangential direction of the ring body. The first pin portion 122 is formed by bending the metal wire from the tangential direction toward a direction (e.g., the first direction D1) away from the center of the coil body 120 with the first end 1201 as the starting point. Similarly, the second end 1202 is also located at the top ring body of the coil body 120 and extends along the tangential direction of the ring body. The second pin portion 124 is formed by bending the metal wire from the tangential direction toward another direction (i.e., the direction opposite to the first direction D1) away from the center of the coil body 120 with the second end 1202 as the starting point. The first part of the coil body 120 is located in the cavity 100, and the second part of the coil body 120 is not located in the cavity 100, so that a part of the first pin portion and a part of the second pin portion can be located above the upper surface of the base layer 10.

[0045] For example, one or more ring bodies in the coil body 120 located at the same height as the first end 1201 and the second end 1202 may not be set in the cavity 100, while the remaining ring bodies in the coil body 120 are set in the cavity 100, so that the corresponding first pin portion 122 and the second pin portion 124 can be directly extended to a position close to the surface of the inductor component 1 without being blocked by the cavity 100.

[0046] However, in other embodiments, considering that the electrode portion 18 may be arranged in other ways, the first pin portion 122 and the second pin portion 124 may be formed by bending the metal wire from the tangential direction toward the top of the coil body 120 (for example, the second direction D2) with the first end portion 1201 and the second end portion 1202 as the starting points, respectively. In other words, by adjusting the directions of the first pin portion 122 and the second pin portion 124, the electrode portion 18 may be led out from any surface of the inductor component 1.

[0047] In addition, the coil body has a first height H1, the cavity has a second height H2, the first height H1 is greater than the second height H2, and the heights of the first end 1201 and the second end 1202 are both greater than the second height H2, so that the first pin portion 122 and the second pin portion 124 are located above the corresponding cavity 100.

[0048] The size of the coil body 120 can be determined by the outer diameter of the ring body, for example, in the range of 0.5 mm to 5 mm, preferably in the range of 1.0 mm to 3.0 mm. The size of the cavity 100 is slightly larger than the size of the coil body 120. For a cylindrical cavity 100, its diameter can be in the range of 0.6 to 5.1 mm, preferably in the range of 1.01 mm to 3.01 mm. The above-mentioned size ranges of the coil body 120 and the cavity 100 are also applicable to the inductor component 1 with a specific product size. For example, the length and width of the cross section of the specific product size can be in the range of 1 mm*1 mm to 5 mm*5 mm.

[0049] Furthermore, the cover layer 14 is formed on the base layer 10 and may be formed into a cuboid similar to the base layer 10, and the cover layer 14 has a morphology complementary to that of the base layer 10. Specifically, relative to the base layer 10 having the cavity 100, the cover layer 14 may have a protrusion 140 corresponding to the cavity 100, which fills the gap between the cavity 100 and the coil 12, so that the cover layer 14 may cover both the base layer 10 and the coil 12.

[0050] The cover layer 14 may include a second magnetic powder and an adhesive. The second magnetic powder may be a powder formed by one of the following materials: iron, iron-nickel alloy, iron-cobalt alloy, iron-silicon alloy, iron-vanadium alloy, iron-silicon-chromium alloy, iron-silicon-aluminum alloy, iron-silicon-aluminum alloy, iron-cobalt-vanadium alloy, iron-based amorphous alloy, iron-based nanocrystalline alloy, nickel-zinc ferrite, nickel-copper-zinc ferrite and manganese-zinc ferrite, and the adhesive material may be epoxy resin, silicone resin, acrylic resin, phenolic resin or polyvinyl alcohol. The weight percentage concentration of the adhesive contained in the second magnetic powder may be between 0.5wt% and 10wt%, so that the second magnetic powder can have a better molding density and magnetic properties. It should be noted that the first magnetic powder and the second magnetic powder are made of the same or different magnetic materials. For example, the characteristics of the inductor component 1, such as the inductance, can be improved by using a combination of different magnetic materials on the upper (cover layer 14) and the lower (base layer 10).

[0051] In this embodiment, the base layer 10, the coil 12 and the cover layer 14 together form the inductor body 11 without the protective layer 16 and the electrode portion 18, and the surface of the inductor body 11 is another cuboid formed by overlapping the base layer 10 and the cover layer 14, and the inductor body 11 can be integrally formed. In detail, the so-called integrally formed means that when the base layer 10 and the cover layer 14 are made of the same or similar materials, that is, when the composition of the first magnetic powder and the second magnetic powder is the same or similar, the junction of the base layer 10 and the cover layer 14 will not present an obvious interface, and compared with the traditional assembled inductor component, the integrally formed inductor component 1 of the present invention can have a better component durability and life.

[0052] In addition, if Figure 3 As shown, the inductor body 11 has a third width W3 in the horizontal direction (first direction D1), and the third width W3 is greater than the first width W1 and the second width W2. Figure 3 ), the protective layer 16 and the electrode portion 18 are disposed on the surface of the inductor body 11. The protective layer 16 has a first opening 160 and a second opening 162 that expose the surface of the inductor body 11, and the first opening 160 exposes a portion of the first pin portion 122, and the second opening 162 exposes a portion of the second pin portion 124. The first opening 160 and the second opening 162 are areas reserved for the electrode portion 18, and may be, for example, Figure 3 The protective layer 16 may be made of one of the following materials: epoxy resin, silicone resin, acrylic resin, phenolic resin.

[0053] In addition, the electrode portion 18 includes a first electrode 180 and a second electrode 181 electrically connected to the coil 12. More specifically, the first electrode 180 is electrically connected to the first pin portion 122, and the second electrode 181 is electrically connected to the second pin portion 124. The first electrode 180 and the second electrode 181 can fill the first opening portion 160 and the second opening portion 162 respectively, so as to form an outer layer that completely covers all surfaces of the inductor body 11 together with the protective layer 16. The first electrode 180 and the second electrode 181 can be made of conductive metal, such as copper, nickel, tin or conductive silver paste. The first electrode 180 and the second electrode 181 can be, for example, a material having Figure 3 The L-shape shown in the figure is L-shaped, but the arrangement is not limited thereto. The bending directions of the first pin portion 122 and the second pin portion 124 can be adjusted according to design requirements to lead out the first electrode 180 and the second electrode 181 from any surface of the inductor body 11 to form external electrodes, thereby improving the flexibility of using the inductor component 1. In addition, the first electrode 180 and the second electrode 181 have the same width as the inductor body, but the present invention is not limited thereto.

[0054] Please refer to Figure 4 , which is a cross-sectional view of an inductor component according to a second embodiment of the present invention. Figure 4 As shown, the inductor component 1A of the second embodiment of the present invention is similar to Figures 1 to 3 The inductor component 1A is different from the first embodiment in that the inductor component 1A further includes a magnetic core 15, and the coil body 120 is formed around the magnetic core 15, and the base layer 10, the coil 12, the cover layer 14 and the magnetic core 15 together form the inductor body 11A on which the protective layer 16 and the electrode portion 18 are not yet provided.

[0055] The magnetic core 15 may include a third magnetic powder and an adhesive. The third magnetic powder may be a powder formed by one of the following materials: iron, iron-nickel alloy, iron-cobalt alloy, iron-silicon alloy, iron-vanadium alloy, iron-silicon-chromium alloy, iron-silicon-aluminum alloy, iron-silicon-aluminum alloy, iron-cobalt-vanadium alloy, iron-based amorphous alloy, iron-based nanocrystalline alloy, nickel-zinc ferrite, nickel-copper-zinc ferrite and manganese-zinc ferrite, and the adhesive material may be epoxy resin, silicone resin, acrylic resin, phenolic resin or polyvinyl alcohol. The weight percentage concentration of the adhesive contained in the third magnetic powder may be between 0.5wt% and 10wt%, so that the third magnetic powder can have a better molding density and magnetic properties. It should be noted that the first magnetic powder, the second magnetic powder and the magnetic core are made of the same or two or more different magnetic materials. Similarly, the characteristics of the inductor component 1 can be improved by using a combination of different magnetic materials in the cover layer 14, the base layer 10 and the magnetic core 15.

[0056] The magnetic core 15 may have a columnar structure, for example, a cylindrical structure or a square columnar structure, but the present invention is not limited thereto. The magnetic core 15 may have a first surface 150 and a second surface 152 opposite to each other, and a side surface 154 between the first surface 150 and the second surface 152, and the coil body 120 may be formed around the magnetic core 15. The height of the first surface 150 may be equal to or greater than the height of the highest point of the uppermost ring of the coil body 120, and the second surface 152 may be in contact with the bottom surface S2.

[0057] In some embodiments, the base layer 10, the cover layer 14 and the magnetic core 15 can be integrally formed. Specifically, the so-called integral forming means that the base layer 10, the cover layer 14 and the magnetic core 15 are made of the same or similar materials, that is, when the composition of the first magnetic powder, the second magnetic powder and the third magnetic powder is the same or similar, there will be no obvious interface at the junction between any two of the base layer 10, the cover layer 14 and the magnetic core 15, and compared with the traditional assembled inductor component, the integrally formed inductor component 1 of the present invention can have a better component durability and lifespan.

[0058] Please refer to Figure 5A and Figure 5B , Figure 5A is a top view of an inductor component according to a third embodiment of the present invention, Figure 5B For along Figure 5A The cross-sectional view is obtained by the line segment VV. Figure 5A and Figure 5B As shown, the inductor assembly 1B of the third embodiment of the present invention can be regarded as comprising a plurality of (for example, three) Figure 4 Specifically, the base layer 10A is provided with recesses 100, 100A, 100B, the coil body 120 is provided corresponding to the recess 100, the coil body 120A is provided corresponding to the recess 100A, and the coil body 120B is provided corresponding to the recess 100B. In addition, the magnetic cores 15, 15A, 15B are provided in the recesses 100, 100A, and 100B, respectively, the coil body 120 is wound around the magnetic core 15, the coil body 120A is wound around the magnetic core 15A, and the coil body 120B is wound around the magnetic core 15B.

[0059] In addition, since the inductor assembly 1B includes a plurality of inductor bodies 11A, the coil bodies 120, 120A, and 120B may be electrically independent of each other. For example, the coil body 120 may be connected to the first electrode 180 and the second electrode 181 through the first pin portion 122 and the second pin portion 124, respectively, the coil body 120A may be connected to the first electrode 180A and the second electrode 181A through the first pin portion 122A and the second pin portion 124A, respectively, and the coil body 120B may be connected to the first electrode 180B and the second electrode 181B through the first pin portion 122B and the second pin portion 124B, respectively. Furthermore, the arrangement direction of the first electrode 180 and the second electrode 181 is parallel to the arrangement direction of the first electrode 180A and the second electrode 181A, and the arrangement direction of the first electrode 180A and the second electrode 181A is parallel to the arrangement direction of the first electrode 180B and the second electrode 181B. However, the present invention is not limited to this connection and arrangement method.

[0060] The following instructions Figures 1 to 5B A method for manufacturing an inductor component. Figure 6 The fourth embodiment of the present invention provides a method for manufacturing an inductor component, which can mass-produce inductor components through array-type acupuncture points, and the simple mold structure can greatly increase the mold life.

[0061] like Figure 6 As shown, the method for manufacturing the inductor assembly includes the following steps:

[0062] Step S60: Filling the mold with the first magnetic powder to form a base layer.

[0063] Step S61: forming at least one recess in the base layer.

[0064] Step S62: inserting at least one coil into the at least one cavity.

[0065] Please refer to Figure 7 and Figure 8 , Figure 7 is a process schematic diagram of steps S60 to S61, Figure 8 Schematic diagram of the process of steps S61 to S62. As shown in the figure, after the first magnetic powder (and adhesive) are filled in the mold M1 to form the base layer 10, the first pressurization process can be performed to press the first magnetic powder with the mold M2. It should be noted that the mold M2 is provided with a protrusion structure, and its morphology corresponds to Figure 1 5 , so as to press out the corresponding cavity 100 on the base layer 10. The cavity 100 is not limited to Figure 8 Two are shown, and can be arranged in an array in the base layer 10 in a top view.

[0066] After obtaining a plurality of recesses 100, a corresponding number of coils 12 can be obtained corresponding to the number of recesses 100, and the obtained coils 12 can be placed in the recesses 100. It should be noted that the coils 12 can be pre-wound. The coils 12 can be pre-wound with a metal wire made of a metal conductor (such as copper), and the metal wire can be, for example, a round wire, a flat wire (for example, a cross-section having an aspect ratio not equal to 1) or a square wire, and the winding form can be flat winding (also called horizontal winding) or external winding (vertical winding, α winding). In addition, the present invention does not limit the wire form and winding form of the coil 12.

[0067] In addition, if the inductor component to be manufactured belongs to Figure 4 In the type shown in FIG. 1 , the magnetic core 15 can be preformed with the third magnetic powder, and then the coil body 120 is wound around the magnetic core 15 to form the coil 12 (eg, Figure 8 As shown on the right side, after winding is completed, it is implanted into the cavity 100.

[0068] Step S63: filling the mold with second magnetic powder to form a covering layer.

[0069] Step S64: performing a pressurizing process to form a package to be cut, and taking the package to be cut out from the mold.

[0070] Please refer to Fig. 9 , Fig. 9 FIG. 4 is a process diagram of steps S63 to S64. Fig. 9 As shown, the base layer 10 provided with the coil 12 and pressurized and cured can be placed in a mold M3, and then filled with the second magnetic powder. The formed covering layer 14 will fill the gap between each cavity 100 and the corresponding coil 12, and cover the base layer 10 and the coil 12 at the same time.

[0071] In the presence of the magnetic core 15, as Fig. 9 As shown on the right side, the covering layer 14 formed by the second magnetic powder (and adhesive) fills the gaps between each cavity 100 and the corresponding coil 12 and magnetic core 15 , and covers the base layer 10 , the coil 12 and the magnetic core 15 at the same time.

[0072] Then, the second pressurizing process can be performed to pressurize the covering layer 14 with the mold M4 to mold the final covering layer 14. Here, the package to be cut is formed. It should be noted that during the first and second pressurizing processes, the molds M1 to M4 used can be preheated in advance to allow part of the adhesive in the first magnetic powder and the second magnetic powder to dissipate and improve the overall hardness of the finished product after pressing.

[0073] Step S65: cutting the package body to be cut to obtain at least one package body to be cut.

[0074] Step S66: forming a protective layer and an electrode portion electrically connected to the coil on the surface of each to-be-packaged body.

[0075] Please refer to Fig.10 and Fig.11 , Fig.10 and Fig.11 FIG. 4 is a process schematic diagram of steps S65 to S66. Fig.10 As shown, after the package X1 to be cut is cut into a single or multiple inductor bodies 11, a spraying process (or immersion in glue) is performed on the outer surface of the inductor body 11 to form a protective layer 16X to be processed that completely covers the inductor body 11. As described in the previous embodiment, the inductor body 11 can be formed by the base layer 10, the coil 12 and the cover layer 14, or by the base layer 10, the coil 12, the magnetic core 15 and the cover layer 14, which will not be repeated here. In addition, when cutting, it can be formed according to the needs. Figures 1 to 4 The single inductor component 11, 11A may be formed, or the inductor component 11B including a plurality of inductor bodies as shown in FIG. 5 may be formed.

[0076] Next, a portion of the protective layer 18X to be processed may be removed, for example, by removing the corresponding adhesive material on the electrode area to be fabricated by laser, grinding, etc., to form Figure 3 The first opening 160 and the second opening 162 are shown to expose a portion of the first lead portion 122 and a portion of the second lead portion 124 to form the protection layer 16. Then, an electroplating process may be performed to form a first electrode 180 electrically connected to the first lead portion 122 and a second electrode 181 electrically connected to the second lead portion 124 in the first opening 160 and the second opening 162, respectively. Figure 1 As shown in Figure 5.

[0077] In this way, the inductor components of the present invention can be mass-produced at one time, and the mold structure is simple, the manufacturing cost is low, and the batch-produced inductor components have a high degree of uniformity in product thickness and quality. The characteristics of the inductor components can also be improved by using a combination of different magnetic materials in the covering layer, the base layer (and the magnetic core).

[0078] In addition, it should be noted that although Figures 1 to 11 The coils depicted in the drawings are mainly round wires, however, the present invention is not limited thereto. Fig.12 and Fig.13 , which is a schematic diagram of an inductor component according to a fifth embodiment of the present invention. In the fifth embodiment, Figure 1 Similar component symbols refer to similar components and are not described in detail here. Fig.12As shown, in the inductor assembly 1B, the coil is wound with a flat wire having a rectangular cross section. Specifically, the flat wire is wound and stacked with a plurality of ring bodies of the same diameter, so that the height of the coil body 120 is higher than or equal to the depth of the cavity 100, and then the flat wire is bent to extend to both sides of the coil body 120 to form a first pin portion 122 and a second pin portion 124, and finally the coil 12 is formed. It should be noted that the contact surface between the ring bodies is the long side of the flat wire.

[0079] On the other hand, Fig.13 As shown, in the inductor component 1C, the flat wire is firstly wound from the inside to the outside to form a tape body, and then the tape bodies are stacked so that the height of the coil body 120 is higher than or equal to the depth of the cavity 100, and then the flat wire is bent to extend to both sides of the coil body 120 to form a first pin portion 122 and a second pin portion 124, and finally the coil 12 is formed. It should be noted that in each layer of the tape body, the contact surface between the flat wires is the long side of the flat wire. The contact surface between the tape bodies of different layers is the short side of the flat wire.

[0080] [Beneficial Effects of Embodiments]

[0081] One of the beneficial effects of the present invention is that the inductor component and the manufacturing method thereof provided by the present invention can form hundreds or thousands of inductor components through one-time molding. In addition to greatly improving the thickness and quality uniformity of the product, the characteristics of the inductor component can also be improved by using a combination of different magnetic materials in the covering layer, the base layer (and the magnetic core).

[0082] The contents disclosed above are only preferred feasible embodiments of the present application, and are not intended to limit the protection scope of the claims of the present application. Therefore, all equivalent technical changes made using the contents of the present application specification and drawings are included in the protection scope of the claims of the present application.

Claims

1. A method for manufacturing an inductor component, characterized in that: The manufacturing method of the inductor assembly comprises: Filling a mold with first magnetic powder to form a base layer; forming at least one recess in the base layer; At least one coil is placed corresponding to at least one of the recesses; Filling the mold with a second magnetic powder to form a covering layer, wherein the covering layer fills the gap between each of the recesses and the corresponding coil and covers the base layer and at least one of the coils at the same time; Performing a press molding process to form a package to be cut, and taking the package to be cut out from the mold; Cutting the package to be cut to obtain at least one package to be cut; and A protective layer and an electrode portion electrically connected to the coil are formed on the surface of each of the bodies to be packaged.

2. The manufacturing method according to claim 1, characterized in that: The manufacturing method of the inductor assembly further includes: Prepare at least one of the coils, wherein each of the coils comprises: a coil body; a first pin portion connected to a first end portion of the coil body; and A second pin portion is connected to a second end portion of the coil body.

3. The manufacturing method according to claim 2, characterized in that: The coil body has a first height, each of the recesses has a second height, the first height is greater than the second height, and the heights of the first end and the second end are both greater than the second height, so that the first pin portion and the second pin portion are located above the corresponding recesses.

4. The manufacturing method according to claim 3, characterized in that: The step of preparing at least one of the coils further includes winding each of the coil bodies around a magnetic core to form the coil.

5. The manufacturing method according to claim 2, characterized in that: The steps of forming a protective layer on the surface of each of the bodies to be packaged and electrically connecting the electrode portion of the coil include: Performing a spraying process on the surface of each of the bodies to be packaged to form a protective layer to be processed; removing a portion of the to-be-processed protection layer to expose a portion of the first lead portion and a portion of the second lead portion to form the protection layer; and A first electrode electrically connected to the first lead portion and a second electrode electrically connected to the second lead portion are formed on the surface of each of the bodies to be packaged as the electrode portion.

6. The manufacturing method according to claim 1, characterized in that: The first magnetic powder and the second magnetic powder are made of the same or different magnetic materials.

7. The manufacturing method according to claim 4, characterized in that: The first magnetic powder, the second magnetic powder and the magnetic core are made of the same or two or more different magnetic materials.

8. The manufacturing method according to claim 2, characterized in that: Each of the recesses is a columnar recess, and the top of the columnar recess has a first width in a horizontal direction, the bottom of the columnar recess has a second width in the horizontal direction, and each of the bodies to be packaged has a third width in the horizontal direction, the first width is greater than the second width, and the third width is greater than the first width and the second width.

9. The manufacturing method according to claim 8, characterized in that: A first portion of each coil body is located in the corresponding cavity, a second portion of each coil body is not located in the corresponding cavity, and a portion of the first pin portion and a portion of the second pin portion are located above the upper surface of the base layer surrounding the cavity.

10. The manufacturing method according to claim 9, characterized in that: Each of the recesses has a bottom surface and an inner surface surrounding the bottom surface, and a distance between each of the coils and the inner surface of the corresponding recess in the horizontal direction is in a range of 0 mm to 0.5 mm.

11. An inductor component, characterized in that: The inductor assembly comprises: A base layer, comprising a first magnetic powder, wherein the base layer has at least one recess; At least one coil is correspondingly arranged in at least one of the recesses; a covering layer, comprising a second magnetic powder, the covering layer filling the gap between each of the recesses and the corresponding coil, and simultaneously covering the base layer and at least one of the coils, wherein the base layer, at least one of the coils and the covering layer together form an inductor body; A protection layer and an electrode portion are disposed on the surface of the inductor body, wherein the electrode portion is electrically connected to at least one of the coils.

12. The inductor assembly according to claim 11, characterized in that: Each of the coils comprises: a coil body; a first pin portion connected to a first end portion of the coil body; and A second pin portion is connected to a second end portion of the coil body.

13. The inductor assembly according to claim 12, characterized in that: The coil body has a first height, the cavity has a second height, the first height is greater than the second height, and the heights of the first end and the second end are both greater than the second height, so that the first pin portion and the second pin portion are located above the corresponding cavity.

14. The inductor assembly according to claim 13, characterized in that: The inductor assembly further includes a magnetic core, and the coil body is formed around the magnetic core.

15. The inductor assembly according to claim 12, characterized in that: The protection layer exposes a portion of the first lead portion and a portion of the second lead portion, and the electrode portion includes a first electrode electrically connected to the first lead portion and a second electrode electrically connected to the second lead portion.

16. The inductor assembly according to claim 11, characterized in that: The first magnetic powder and the second magnetic powder are made of the same or different magnetic materials.

17. The inductor assembly according to claim 14, characterized in that: The first magnetic powder, the second magnetic powder and the magnetic core are made of the same or two or more different magnetic materials.

18. The inductor assembly according to claim 12, characterized in that: Each of the recesses is a columnar recess, and the top of the columnar recess has a first width in a horizontal direction, the bottom of the columnar recess has a second width in the horizontal direction, and each of the inductor bodies has a third width in the horizontal direction, the first width is greater than the second width, and the third width is greater than the first width and the second width.

19. The inductor assembly according to claim 18, characterized in that: A first portion of each coil body is located in the corresponding recess, a second portion of each coil body is not located in the corresponding recess, and a portion of the first pin portion and a portion of the second pin portion of each coil are located above the upper surface of the corresponding recess defined by the base layer.

20. The inductor assembly according to claim 19, characterized in that: Each of the recesses has a bottom surface and an inner surface surrounding the bottom surface, and a distance between each of the coils and the inner surface of the corresponding recess in the horizontal direction is in a range of 0 mm to 0.5 mm.

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