Vertical winding type inductor and manufacturing method thereof

Abstract

The invention discloses a vertical winding type inductor and a manufacturing method thereof. The vertical winding type inductor comprises an inductor body, a coil body, a first outer electrode, a second outer electrode and a middle layer. The inductor body is made of a first magnetic material. The coil body comprises a first coil part and a second coil part which are oppositely arranged, and a first gap is formed between the first coil part and the second coil part. The first external electrode and the second external electrode are arranged on the outer surface of the inductor body, the first external electrode is connected to the first coil part, and the second external electrode is connected to the second coil part. The middle layer is arranged in the inductor body and located in the first gap, and a through hole is formed in the middle layer. Wherein the first coil part is connected to the second coil part through a connecting part penetrating through the through hole, and the direction of a central magnetic line of force generated by the coil body is parallel to the arrangement direction of the first outer electrode and the second outer electrode. The outer electrode is led out in a linear mode, the structural strength is large, and therefore the quality risk problems such as deformation or displacement and even internal crack damage in the hot pressing process can be avoided.

Description

Technical Field

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

[0002] In existing vertically wound inductors, due to the limitations of their structure and the way the electrodes are set, a curved structure is used when leading from the coil to the electrode. In other words, a connecting portion extending from the coil body is usually designed along the radial direction of the coil ring body for connection with the electrode. However, this curved structure makes the connecting portion concave relative to the electrode or the inductor surface, so under the action of internal stress, it is inevitable that the overall structure will have a more fragile part. In this case, the use of a press forming process is prone to quality risks, such as internal crack damage to the electrode.

[0003] Therefore, how to improve the structural design so that the vertically wound inductor can be applied to the pressing process to overcome the above-mentioned defects has become one of the important issues that this business wants to solve. Summary of the invention

[0004] The technical problem to be solved by the present invention is to provide a vertically wound inductor and a manufacturing method thereof in view of the deficiencies in the prior art, which can not only improve the structural strength but also be applied to a hot pressing process.

[0005] In order to solve the above-mentioned technical problems, one of the technical solutions adopted by the present invention is to provide a vertically wound inductor, comprising: an inductor body, made of a first magnetic material; a coil body, comprising a first coil portion and a second coil portion, which are relatively arranged in the inductor body, and a first gap is provided between the first coil portion and the second coil portion; a first external electrode and a second external electrode, which are arranged on an outer surface of the inductor body, the first external electrode is connected to the first coil portion, and the second external electrode is connected to the second coil portion; an intermediate layer, which is arranged in the inductor body and located in the first gap, and a through hole is provided in the intermediate layer; and wherein the first coil portion is connected to the second coil portion through a connecting portion passing through the through hole, and the direction of the central magnetic field line generated by the coil body is parallel to a setting direction of the first external electrode and the second external electrode.

[0006] Optionally, the first coil portion includes a first coil pattern and a first connection pattern, and the first coil pattern is electrically connected to the first external electrode through the first connection pattern, wherein the second coil portion includes a second coil pattern and a second connection pattern, and the second coil pattern is electrically connected to the second external electrode through a second connection pattern.

[0007] Optionally, the first coil pattern is a first spiral coil, and the first connection pattern extends along a first tangent direction formed by a first end of the first spiral coil to connect the first end of the first spiral coil to the first external electrode; wherein the second coil pattern is a second spiral coil, and the second connection pattern extends along a second tangent direction formed by a first end of the second spiral coil to connect the first end of the second spiral coil to the second external electrode, and a second end of the first spiral coil is connected to a second end of the second spiral coil through the connecting portion.

[0008] Optionally, the first connection pattern has a first gradient structure, a first connection surface at the connection between the first gradient structure and the first coil pattern, a second connection surface at the connection between the first gradient structure and the first external electrode, and an area of ​​the first connection surface is smaller than that of the second connection surface, wherein the second connection pattern has a second gradient structure, a third connection surface at the connection between the second gradient structure and the second coil pattern, a fourth connection surface at the connection between the second gradient structure and the second external electrode, and an area of ​​the third connection surface is smaller than that of the fourth connection surface.

[0009] Optionally, the first coil portion also includes a first dummy connection pattern connected to the second external electrode, and the second coil portion also includes a second dummy connection pattern connected to the first external electrode, a first vertical projection of the first dummy connection pattern formed on the intermediate layer overlaps with a second vertical projection of the second connection pattern formed on the intermediate layer, and a third vertical projection of the second dummy connection pattern on the intermediate layer overlaps with a fourth vertical projection of the first connection pattern on the intermediate layer.

[0010] Optionally, the first tangent direction is parallel to the second tangent direction, and the first tangent direction and the second tangent direction are perpendicular to the outer surface of the inductor body.

[0011] Optionally, the middle layer has a closed ring body that completely covers the first spiral coil and the second spiral coil.

[0012] Optionally, the first spiral coil has a first hollow portion, the second spiral coil has a second hollow portion, and the middle layer has a hollow portion corresponding to the first hollow portion and the second hollow portion.

[0013] Optionally, the intermediate layer is made of a non-conductive material, and the non-conductive material includes at least one of an organic material containing oxygen and silicon functional groups, an epoxy resin, a polyimide (PI), a glass fiber material, and a ceramic material.

[0014] Optionally, the end of the first coil pattern connected to the first external electrode has a first outer edge, and the first outer edge is separated from a first edge of the outer surface by a first predetermined length; the end of the second coil pattern connected to the second external electrode has a second outer edge, and the second outer edge is separated from a second edge of the outer surface by a second predetermined length; the first external electrode and the second external electrode have a predetermined width, and the first predetermined length and the second predetermined length are in the range of 0% to 50% of the predetermined width.

[0015] In order to solve the above technical problems, another technical solution adopted by the present invention is to provide a method for manufacturing a vertically wound inductor, characterized in that the method for manufacturing the vertically wound inductor includes: providing a substrate, and performing a drilling process on the substrate to form at least one through hole; performing a photolithography process to form a first coil portion and a second coil portion on both sides of the substrate, the connecting portion penetrates the through hole and connects the first coil portion to the second coil portion, and there is a first gap between the first coil portion and the second coil portion; performing a first cutting process on the substrate, the first coil portion and the second coil portion to form a first coil portion and the second coil portion. A coil body of the second coil part and an intermediate layer are formed in the first gap; the coil body and the intermediate layer are placed in a mold and filled with a first magnetic material to form an inductor body by performing a pressing process; a cutting process is performed on the inductor body to expose a portion of the first coil part and the second coil part; a plating process is performed to form a first external electrode and a second external electrode on an outer surface of the inductor body, wherein the first external electrode is connected to the first coil part, and the second external electrode is connected to the second coil part, wherein the direction of the central magnetic field line generated by the coil body is parallel to a setting direction of the first external electrode and the second external electrode.

[0016] Optionally, in the manufacturing method of the vertically wound inductor, the first coil portion includes a first coil pattern and a first connection pattern, and the first coil pattern is electrically connected to the first external electrode through the first connection pattern, wherein the second coil portion includes a second coil pattern and a second connection pattern, and the second coil pattern is electrically connected to the second external electrode through a second connection pattern.

[0017] Optionally, in the manufacturing method of the vertically wound inductor, the first coil pattern is a first spiral coil, and the first connection pattern extends along a first tangent direction formed by a first end of the first spiral coil to connect the first end of the first spiral coil to the first external electrode; wherein the second coil pattern is a second spiral coil, and the second connection pattern extends along a second tangent direction formed by a first end of the second spiral coil to connect the first end of the second spiral coil to the second external electrode, and a second end of the first spiral coil is connected to a second end of the second spiral coil through the connecting portion.

[0018] Optionally, in the manufacturing method of the vertically wound inductor, the first connection pattern has a first gradient structure, the connection between the first gradient structure and the first coil pattern has a first connection surface, the connection between the first gradient structure and the first external electrode has a second connection surface, and the area of ​​the first connection surface is smaller than that of the second connection surface, wherein the second connection pattern has a second gradient structure, the connection between the second gradient structure and the second coil pattern has a third connection surface, the connection between the second gradient structure and the second external electrode has a fourth connection surface, and the area of ​​the third connection surface is smaller than that of the fourth connection surface.

[0019] Optionally, in the manufacturing method of the vertically wound inductor, the first coil portion also includes a first virtual connection pattern connected to the second external electrode, the second coil portion also includes a second virtual connection pattern connected to the first external electrode, a first vertical projection of the first virtual connection pattern formed on the middle layer overlaps with a second vertical projection of the second connection pattern formed on the middle layer, and a third vertical projection of the second virtual connection pattern on the middle layer overlaps with a fourth vertical projection of the first connection pattern on the middle layer.

[0020] Optionally, in the manufacturing method of the vertically wound inductor, the first tangent direction is parallel to the second tangent direction, and the first tangent direction and the second tangent direction are perpendicular to the outer surface of the inductor body.

[0021] Optionally, in the method for manufacturing the vertically wound inductor, the intermediate layer has a closed ring body that completely covers both the first spiral coil and the second spiral coil.

[0022] Optionally, in the manufacturing method of the vertically wound inductor, the first spiral coil has a first hollow portion, the second spiral coil has a second hollow portion, and the middle layer has a hollow portion corresponding to the first hollow portion and the second hollow portion.

[0023] Optionally, in the manufacturing method of the vertically wound inductor, the intermediate layer is made of a non-conductive material, and the non-conductive material includes at least one of an organic material containing oxygen and silicon functional groups, an epoxy resin, a polyimide (PI), a glass fiber material and a ceramic material.

[0024] Optionally, in the manufacturing method of the vertically wound inductor, the step of executing the photolithography process to form the first coil portion and the second coil portion on both sides of the substrate includes: executing a photolithography process on both sides of the substrate to form a first predetermined pattern layer and a second predetermined pattern layer, respectively; forming a first coil portion to be formed on the first predetermined pattern layer through a deposition process, and forming a second coil portion to be formed on the second predetermined pattern layer; and removing the first predetermined pattern layer and the second predetermined pattern layer to form the first coil portion and the second coil portion.

[0025] Optionally, in the manufacturing method of the vertically wound inductor, the pressing process is a hot pressing process, the hot pressing temperature used is in the range of 100 to 200 degrees, and the pressure used is in the range of 10 to 600 MPa.

[0026] Optionally, in the manufacturing method of the vertically wound inductor, the end of the first coil pattern connected to the first external electrode has a first outer edge, the first outer edge is separated from a first edge of the outer surface by a first predetermined length, the end of the second coil pattern connected to the second external electrode has a second outer edge, the second outer edge is separated from a second edge of the outer surface by a second predetermined length, the first external electrode and the second external electrode have a predetermined width, and the first predetermined length and the second predetermined length are in the range of 0% to 50% of the predetermined width.

[0027] To further understand the features and technical contents of the present invention, please refer to the following detailed description and drawings of the present invention. However, the drawings provided are only for reference and description and are not intended to limit the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 FIG. 4 is a three-dimensional schematic diagram of a vertically wound inductor according to an embodiment of the present invention.

[0029] Figure 2 FIG. 4 is a schematic side view of a vertically wound inductor according to an embodiment of the present invention.

[0030] Figure 3 Schematic diagram of a front view of a vertically wound inductor according to an embodiment of the present invention.

[0031] Figure 4Schematic top view of a first coil portion according to an embodiment of the present invention.

[0032] Figure 5 FIG. 4 is a schematic top view of a second coil portion according to an embodiment of the present invention.

[0033] Figure 6 Schematic top view of the intermediate layer of an embodiment of the present invention.

[0034] Figure 7 The figure is a flow chart of a method for manufacturing a vertically wound inductor according to an embodiment of the present invention.

[0035] Figure 8 FIG. 1 is a schematic diagram of forming a through hole in step S10 .

[0036] Fig. 9 FIG. 1 is a schematic diagram of forming a predetermined pattern layer in step S11 .

[0037] Fig.10 FIG. 1 is a schematic diagram of forming a coil portion to be formed in step S11 .

[0038] Fig.11 It is a schematic diagram of the steps of placing the formed coil body and the intermediate layer into a mold and performing a pressing process in step S13.

[0039] Fig.12 FIG. 1 is a schematic diagram of the steps of performing a cutting process in step S14 to form an inductor body.

[0040] Fig.13 FIG. 1 is a schematic diagram of performing an electroplating process in step S15 to form a first external electrode and a second external electrode. DETAILED DESCRIPTION

[0041] The following is an explanation of the implementation methods of the "vertical-wound inductor and its manufacturing method" disclosed in the present invention through specific examples. Those skilled in the art can understand the advantages and effects of the present invention from the contents disclosed in this specification. The present invention 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 invention. In addition, the drawings of the present invention 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 invention in detail, but the disclosed contents are not intended to limit the scope of protection of the present invention. 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.

[0042] See also Figures 1 to 5As shown, an embodiment of the present invention provides a vertically wound inductor, which includes an inductor body 10 , a coil body 12 , a first external electrode 13 , a second external electrode 14 and an intermediate layer 15 .

[0043] The inductor body 10 may be formed as follows Figures 1 to 3 In addition, the inductor body 10 may optionally include a binder material. The inductor body 10 may be formed by filling a magnetic powder made of the first magnetic material and other components of the vertically wound inductor 1 into a mold and then pressing. In order to clearly show the internal structure of the vertically wound inductor 1, the inductor body 10 is Figures 1 to 3 After being made transparent.

[0044] The coil body 12 may include a first coil portion 120 and a second coil portion 122, which may be arranged opposite to each other in the inductor body 10, and a first gap G1 is formed between the first coil portion 120 and the second coil portion 122. The inductor body 10 may be, for example, a hexahedron, which has a first surface 101 and a second surface 102 opposite to each other in a first direction D1, a third surface 103 and a fourth surface 104 opposite to each other in a second direction D2, and a fifth surface 105 and a sixth surface 106 opposite to each other in a third direction D3. When the vertically wound inductor 1 is mounted on a printed circuit board, the sixth surface 106 of the inductor body 10 may be used as a mounting surface.

[0045] The first external electrode 13 and the second external electrode 14 may be, for example, conductive metal plates, and are disposed on an outer surface of the inductor body 10, for example, the sixth surface 106. The first external electrode 13 is connected to the first coil portion 120, and the second external electrode 14 is connected to the second coil portion 122. Both the first external electrode 13 and the second external electrode 14 extend along the first direction D1, so the first direction D1 is hereinafter referred to as the configuration direction of the first external electrode 13 and the second external electrode 14. Figure 1 As shown, although the lengths of the first external electrode 13 and the second external electrode 14 in the first direction D1 are the same as the length of the inductor body 10 in the first direction D1, the present invention is not limited thereto.

[0046] The middle layer 15 is disposed in the inductor body 10 and is located in the first gap G1. Figures 1 to 3As shown, the first coil portion 120, the intermediate layer 15 and the second coil portion 122 can be arranged in sequence along the first direction D1. The intermediate layer 15 can be made of a non-conductive material, for example, and can have a similar morphology to the first coil portion 120 and the second coil portion 122. The non-conductive material can include: at least one of an organic material containing oxygen and silicon functional groups, an epoxy resin, a polyimide (PI), a glass fiber material and a ceramic material. It should be noted that in order to enable the first coil portion 120 and the second coil portion 122 to be connected to each other, the intermediate layer 15 is provided with a through hole 150 to retain a path that allows the first coil portion 120 and the second coil portion 122 to be connected to each other.

[0047] The details of the first coil portion 120 and the second coil portion 122 are described in detail below. Figure 4 This is a top view of the first coil portion of an embodiment of the present invention. Figure 4 The first coil portion 120 may be, for example, a coil formed by winding a conductive metal flat wire in a spiral shape in a counterclockwise direction, but the present invention is not limited thereto, and the first coil portion 120 may also be formed by winding a metal round wire in a spiral shape. The first coil portion 120 includes a first coil pattern 1200 and a first connection pattern 1201, and the first coil pattern 1200 is electrically connected to the first external electrode 13 through the first connection pattern 1201.

[0048] In this embodiment, the first coil pattern 1200 is a first spiral coil formed from the outside to the inside along the counterclockwise direction. The first spiral coil may be composed of two semicircles and a rectangle, and has a first hollow portion H1, and the first connection pattern 1201 extends along the first tangent direction DT1 formed by the first end T11 of the first spiral coil to connect the first end T11 to the first external electrode 13. In addition, the first coil pattern 1200 also has a second end T12 located at the center of the first spiral coil, on which a connection portion 124 of a through hole 150 penetrating the intermediate layer 15 is provided, so that the first coil portion 120 can be connected to the second coil portion 122.

[0049] In some embodiments, the first connection pattern 1201 may have a gradient structure. Specifically, the connection between the gradient structure and the first coil pattern 1200 (i.e., the first end T11) has a first connection surface S1, and the connection between the gradient structure and the first external electrode 13 has a second connection surface S2, and the area of ​​the first connection surface S1 is smaller than that of the second connection surface S2. Figure 4 It seems that the first connection pattern 1201 may have a trapezoidal column structure, and the design of being wider at the bottom and narrower at the top may provide better stability for the first coil portion 120 .

[0050] Figure 5 This is a top view of the second coil portion of an embodiment of the present invention. Figure 5Similar to the first coil portion 120 , the second coil portion 122 may also be a coil formed by winding a metal flat wire in a spiral shape along a clockwise direction, that is, the first coil portion 120 and the second coil portion 122 may be symmetrically arranged with the middle layer 15 as the center plane.

[0051] The second coil portion 122 includes a second coil pattern 1220 and a second connection pattern 1221 , and the second coil pattern 1220 is electrically connected to the second external electrode 14 through the second connection pattern 1221 .

[0052] In this embodiment, the second coil pattern 1200 is a second spiral coil formed from the outside to the inside along the clockwise direction. Similar to the first spiral coil, the second spiral coil also has a second hollow portion H2, and the second connection pattern 1221 extends along the second tangent direction DT2 formed by the first end T21 of the second spiral coil to connect the first end T21 to the second external electrode 14. In addition, the second coil pattern 1220 also has a second end T2 located at the center of the second spiral coil, on which a connection portion 124 of a through hole 150 penetrating the intermediate layer 15 is provided, so that the second coil portion 122 can be connected to the first coil portion 120.

[0053] The second connection pattern 1221 also has a gradient structure. Specifically, the connection between the gradient structure and the second coil pattern 1220 (i.e., the first end T21) has a third connection surface S3, and the connection between the gradient structure and the second external electrode 14 has a fourth connection surface S4, and the area of ​​the third connection surface S3 is smaller than that of the fourth connection surface S4. Figure 5 It seems that the second connection pattern 1221 may have a trapezoidal column structure, and the design of being wider at the bottom and narrower at the top may provide better stability for the second coil portion 122 .

[0054] Since each of the first coil pattern 1200 and the second coil pattern 1220 has an end extending along the first tangent direction DT1 and the second tangent direction DT2 of the outermost circle of the spiral coil, respectively, and the first tangent direction DT1 is parallel to the second tangent direction DT2. In addition, the first tangent direction DT1 and the second tangent direction DT2 are perpendicular to the outer surface of the inductor body 10 used to form the first external electrode 13 and the second external electrode 14 (i.e., the sixth surface 106). In other words, since the first external electrode 13 and the second external electrode 14 can be led out in a straight line through the first connection pattern 1201 and the second connection pattern 1221, the connection between the connection pattern, the coil pattern and the external electrode will have a greater structural strength, thereby avoiding the quality risk problems such as deformation or displacement of the first coil pattern 1200 and the second coil pattern 1220, or even internal crack damage during the hot pressing process.

[0055] In addition, from Figure 3From the perspective of FIG. 1 , although the first connection pattern 1201 and the second connection pattern 1221 are located at the edges of the first external electrode 13 and the second external electrode 14, respectively, the present invention is not limited thereto. Figure 1 The position of the first connection pattern 1201 can be adjusted along the second direction D2 toward the second external electrode 14, from Figure 3 From the perspective of FIG. 1 , the outer edge E1 of the first connection pattern 1201 and the rightmost edge of the sixth surface 106 can be spaced apart by a first predetermined length. Similarly, the position of the second connection pattern 1221 can be adjusted along the second direction D2 toward the direction of the first external electrode 13, from Figure 3 From this perspective, a second predetermined length may be spaced between the outer edge E2 of the second connection pattern 1221 and the leftmost edge of the sixth surface 106. In some embodiments, the first predetermined length and the second predetermined length may be in the range of 10 μm to 500 μm, respectively.

[0056] However, it should be noted that, for inductor bodies 10 of different sizes, the first outer electrode 13 and the second outer electrode 14 may have different predetermined widths in the second direction D2, and the first predetermined length and the second predetermined length may be adjusted accordingly. In a preferred embodiment, the first predetermined length and the second predetermined length may be within a range of 0% to 50% of the predetermined width, and the inner edge E3 of the first connection pattern 1201 and the inner edge E4 of the second connection pattern 1221 may be adjusted according to the size of the outer diameter of the coils of the first coil pattern 1200 and the second coil pattern 1220, respectively.

[0057] Thus, it can be ensured that the coil body 12 (especially the peripheral areas of the first connection pattern 1201 and the second connection pattern 1221 ) will not be cracked due to internal stress during the manufacturing process (eg, hot pressing process).

[0058] Figure 6 This is a top view of the intermediate layer of an embodiment of the present invention. Figure 6 The intermediate layer 15 is arranged in parallel with the first coil portion 120 and the second coil portion 122 along the first direction D1 and is disposed in the first gap G1. The thickness of the intermediate layer 15 is associated with the first gap G1, so it can be used to adjust the inductance characteristics (e.g., inductance) of the coil body 12. The intermediate layer 15 is a plate body. In terms of morphology, the intermediate layer 15 has a closed ring body 152 similar to the first spiral coil and the second spiral coil. The closed ring body 152 has a hollow portion H3 corresponding to the first hollow portion H1 and the second hollow portion H2, and also has an area that can completely cover the first spiral coil and the second spiral coil.

[0059] In addition, the closed ring body 152 is also connected to the first outer electrode 13 and the second outer electrode 14 respectively through the extensions 154 and 156. The extension 154 extends along the first tangent direction DT1 and fits the first connection pattern 1201, while the extension 156 extends along the second tangent direction DT2 and fits the connection pattern 1121, thereby strengthening the structural strength of the coil body 12 to prevent the coil body 12 from being subjected to external forces during the manufacturing process and causing structural collapse or damage.

[0060] Please refer to Figures 4 to 6 The first coil portion 120 further includes a first dummy connection pattern 1202 connected to the second external electrode 14, and the second coil portion 122 further includes a second dummy connection pattern 1222 connected to the first external electrode 13. The first dummy connection pattern 1202 corresponds to the second connection pattern 1221 in position and shape, and the second dummy connection pattern 1222 corresponds to the first connection pattern 1201 in position and shape.

[0061] The first dummy connection pattern 1202 may be made of the same material and thickness as the first coil pattern 1200, but the present invention is not limited thereto. Figure 6 As shown, the first vertical projection P1 formed by the first dummy connection pattern 1202 on the intermediate layer 15 overlaps with the second vertical projection P2 formed by the second connection pattern 1221 on the intermediate layer 15, and the third vertical projection P3 formed by the second dummy connection pattern 1222 on the intermediate layer 15 overlaps with the fourth vertical projection P4 formed by the first connection pattern 1201 on the intermediate layer 15.

[0062] It should be noted that the first virtual connection pattern 1202 is not directly connected to the first coil pattern 1200, and is arranged on the side where the first spiral coil is not connected to the first connection pattern 1201, so as to contact the second external electrode 14 and the extension portion 156 at the same time, thereby providing support force for the intermediate layer 15 in the first direction D1 to strengthen the structural strength of the intermediate layer 15 at the extension portion 156.

[0063] Similarly, the second dummy connection pattern 1222 is not directly connected to the second coil pattern 1220, and is arranged on the side where the second spiral coil is not connected to the second connection pattern 1221, so as to contact the first external electrode 13 and the extension portion 154 at the same time, thereby providing support force for the intermediate layer 15 in the first direction D1 to strengthen the structural strength of the intermediate layer 15 at the extension portion 154.

[0064] Please refer to Figure 1When the vertically wound inductor 1 is energized, the first coil portion 120 and the second coil portion 122 generate magnetic force lines (called central magnetic force lines) in the center of the coil body 12, and the direction DM of the central magnetic force lines is parallel to the arrangement direction of the first outer electrode 13 and the second outer electrode 14 (i.e., the first direction D1). Compared with the situation in which the magnetic force lines are perpendicular to the arrangement direction of the electrodes in the traditional inductor, since the magnetic force lines are parallel to the arrangement direction of the electrodes, the magnetic force lines generated by the current along the third direction D3 at the electrodes can improve the situation in which the vertically wound inductor will be interfered in application.

[0065] It should be further explained that, although in the above embodiment, the first external electrode 13 and the second external electrode 14 are two plates and are only disposed on the sixth surface 106 of the inductor body 10 (i.e., the bottom of the inductor body 10), the present invention is not limited thereto. The first external electrode 13 and the second external electrode 14 may also be led out from the side of the inductor body 10. For example, the inductor body 10 may be designed as an L-shaped plate. Thus, the first external electrode 13 and the second external electrode 14 may be further led out on one or more of the first surface 101, the second surface 102, the third surface 103, and the fourth surface 104 as required, and provide electrical contacts connected to an external circuit.

[0066] Please refer to Figure 7 , which is a flow chart of a method for manufacturing a vertically wound inductor according to an embodiment of the present invention. In an embodiment of the present invention, a method for manufacturing a vertically wound inductor is also provided, which can be used to manufacture Figure 1 The vertically wound inductor 1 shown comprises the following steps:

[0067] Step S10: providing a substrate, and performing a drilling process on the substrate to form at least one through hole.

[0068] Figure 8 FIG. 1 is a schematic diagram of the step of forming through holes in step S10. In this step, the drilling process is performed on the substrate 20 according to the number of vertically wound inductors 1 to be formed, and the substrate 20 will be used to form the intermediate layer 15 mentioned above in the subsequent steps. Figure 8 As shown in the pattern on the substrate 20, this pattern is only for illustration. Therefore, the setting position of the through hole 200 can correspond to the through hole 150 in the middle layer 15, and this through hole 200 can be used to form the connecting portion 124 in the middle of the coil body 12 in the subsequent process. It should be noted that in order to ensure that a certain support force and structural strength can be provided in the subsequent pressing process, the substrate 20 can be, for example, a non-conductive material, including at least one of an organic material containing oxygen and silicon functional groups, epoxy resin, polyimide (PI), a glass fiber material and a ceramic material, and can have a thickness greater than 20μm, which also corresponds to the thickness of the intermediate layer 15 formed subsequently.

[0069] Step S11 : performing a photolithography process to form a first coil portion and a second coil portion on two sides of the substrate.

[0070] For example, see Fig. 9 , which is a schematic diagram of the step of forming a predetermined pattern layer in step S11. In this step, a photolithography process can be performed separately on both sides of the substrate 20 to form a first predetermined pattern layer 21 and a second predetermined pattern layer 22, respectively. Then, a coil portion 23 to be formed is formed on the first predetermined pattern layer 21 through a deposition process. Similarly, another coil portion to be formed (not shown) having a morphology similar to the coil portion 23 to be formed can be formed on the second predetermined pattern layer 22. Finally, the first predetermined pattern layer 21 and the second predetermined pattern layer 22 can be removed by an etching process, leaving only the coil portion 23 to be formed on the substrate 20, as shown in FIG. Fig.10 As shown, Fig.10 FIG. 2 is a schematic diagram of forming the coil portion to be formed in step S11 . The coil portion to be formed 23 can be used to form the first coil portion 120 and the second coil portion 122 mentioned in the above embodiment.

[0071] During the deposition process, a connection portion 124 is deposited in the through hole 200 to connect the first coil portion 120 to the second coil portion 122. Supported by the substrate 10, a first gap G1 (see Figure 2 ).

[0072] Step S12: performing a first cutting process on the substrate, the first coil portion and the second coil portion.

[0073] Step S13: placing the coil body and the middle layer into a mold, and filling the mold with a first magnetic material, so as to form an inductor body by performing a pressing process.

[0074] Fig.11 This is a schematic diagram of the steps of placing the formed coil body and the intermediate layer into the mold for the pressing process in step S13. Figure 1 , Figure 6 and Fig.11 In step S12, according to Figure 6 The intermediate layer 15 to be formed is cut into the substrate 20, so as to Figure 1 As shown, the coil body 12 including the first coil portion 120 and the second coil portion 122 is formed, and the intermediate layer 15 is formed in the first gap G1.

[0075] Then, you can Fig.11As shown, the corresponding magnetic powder 25 is filled in the mold 24, which may be, for example, an alloy material with a particle size distribution D50 (the particle size corresponding to the cumulative particle size distribution percentage reaching 50%) less than 10 μm, such as iron, silicon, chromium, nickel, aluminum, Fe, Si, Cr, Ni, Al), an amorphous conductor material, nanocrystals, etc., or a carbon-based iron powder or an alloy material with a particle size distribution D50 of more than 10 μm, and is formed by pressing to form an intermediate layer 15 for being arranged in the first gap G1.

[0076] It is worth mentioning that the pressing process can be a hot pressing process, and the hot pressing temperature used is in the range of 100 to 200 degrees, and the pressure used is in the range of 10 to 600 MPa. Outside this temperature range and pressure range, the component may not be formed.

[0077] In addition, since the first external electrode 13 and the second external electrode 14 can be led out in a straight line manner through the first connecting pattern 1201 and the second connecting pattern 1221, the connection between the connecting pattern, the coil pattern and the external electrode will have a greater structural strength, thereby avoiding quality risks such as deformation or displacement of the first coil pattern 1200 and the second coil pattern 1220, or even internal crack damage during the hot pressing process.

[0078] Step S14: performing a cutting process on the inductor body to expose a portion of the first coil portion and the second coil portion. Fig.12 FIG. 1 is a schematic diagram of the steps of performing the cutting process in step S14 to form the inductor body. Fig.12 As shown, the pressed inductor body 10 can be cut along the cutting line 26, while exposing the portion intended for connecting the external electrode, that is, the portion of the first connection pattern 1201 and the second connection pattern 1221 and the first dummy connection pattern 1202 and the second dummy connection pattern 1222 facing the sixth surface 106.

[0079] Step S15: performing an electroplating process to form a first external electrode and a second external electrode on the outer surface of the inductor body.

[0080] Fig.13 FIG. 2 is a schematic diagram of the steps of performing an electroplating process in step S15 to form a first external electrode and a second external electrode. Fig.13 As shown, the first external electrode 13 and the second external electrode 14 may be formed on the sixth surface 106 to form a vertically wound inductor 1 .

[0081] [Beneficial Effects of Embodiments]

[0082] One of the beneficial effects of the present invention is that the vertically wound inductor and the manufacturing method thereof provided by the present invention, because the first external electrode and the second external electrode are led out in a straight line manner through the first connection pattern and the second connection pattern, the connection between the connection pattern, the coil pattern and the external electrode will have a greater structural strength, thereby avoiding the quality risk problems such as deformation or displacement of the first coil pattern and the second coil pattern, or even internal crack damage during the hot pressing process.

[0083] Furthermore, in the vertically wound inductor and the manufacturing method thereof provided by the present invention, the direction of the central magnetic flux generated in the center of the coil body after the first coil portion and the second coil portion are energized is parallel to the arrangement direction of the first outer electrode and the second outer electrode. Compared with the magnetic flux generated along the current in the traditional inductor, the vertically wound inductor can be improved from being disturbed in application.

[0084] The contents disclosed above are only preferred feasible embodiments of the present invention, and are not intended to limit the protection scope of the claims of the present invention. Therefore, all equivalent technical changes made using the contents of the present invention description and drawings are included in the protection scope of the claims of the present invention.

Claims

1. A vertically wound inductor, characterized in that: The vertically wound inductor comprises: An inductor body, made of a first magnetic material; A coil body, comprising a first coil portion and a second coil portion, disposed opposite to each other in the inductor body, and having a first gap between the first coil portion and the second coil portion; a first external electrode and a second external electrode, disposed on an outer surface of the inductor body, the first external electrode connected to the first coil portion, and the second external electrode connected to the second coil portion; and an intermediate layer, disposed in the inductor body and located in the first gap, wherein the intermediate layer has a through hole; The first coil portion is connected to the second coil portion via a connecting portion penetrating the through hole, and a direction of a central magnetic field line generated by the coil body is parallel to a setting direction of the first outer electrode and the second outer electrode.

2. The vertically wound inductor according to claim 1, characterized in that: The first coil portion includes a first coil pattern and a first connection pattern, and the first coil pattern is electrically connected to the first external electrode through the first connection pattern. The second coil portion includes a second coil pattern and a second connection pattern, and the second coil pattern is electrically connected to the second external electrode through a second connection pattern.

3. The vertically wound inductor according to claim 2, characterized in that: The first coil pattern is a first spiral coil, and the first connection pattern extends along a first tangent direction formed by a first end of the first spiral coil to connect the first end of the first spiral coil to the first external electrode; Wherein, the second coil pattern is a second spiral coil, and the second connection pattern extends along a second tangent direction formed by a first end of the second spiral coil to connect the first end of the second spiral coil to the second external electrode, and a second end of the first spiral coil is connected to a second end of the second spiral coil through the connecting portion.

4. The vertically wound inductor according to claim 3, characterized in that: The first connection pattern has a first gradient structure, a first connection surface is formed at the connection between the first gradient structure and the first coil pattern, a second connection surface is formed at the connection between the first gradient structure and the first external electrode, and an area of ​​the first connection surface is smaller than that of the second connection surface. Among them, the second connection pattern has a second gradient structure, the connection between the second gradient structure and the second coil pattern has a third connection surface, the connection between the second gradient structure and the second external electrode has a fourth connection surface, and the area of ​​the third connection surface is smaller than that of the fourth connection surface.

5. The vertically wound inductor according to claim 4, characterized in that: The first coil portion also includes a first dummy connection pattern connected to the second external electrode, and the second coil portion also includes a second dummy connection pattern connected to the first external electrode, a first vertical projection of the first dummy connection pattern formed on the intermediate layer overlaps with a second vertical projection of the second connection pattern formed on the intermediate layer, and a third vertical projection of the second dummy connection pattern formed on the intermediate layer overlaps with a fourth vertical projection of the first connection pattern formed on the intermediate layer.

6. The vertically wound inductor according to claim 3, characterized in that: The first tangent direction is parallel to the second tangent direction, and the first tangent direction and the second tangent direction are perpendicular to the outer surface of the inductor body.

7. The vertically wound inductor according to claim 6, characterized in that: The middle layer has a closed ring body which completely covers the first spiral coil and the second spiral coil.

8. The vertically wound inductor according to claim 7, characterized in that: The first spiral coil has a first hollow portion, the second spiral coil has a second hollow portion, and the middle layer has a hollow portion corresponding to the first hollow portion and the second hollow portion.

9. The vertically wound inductor according to claim 1, characterized in that: The intermediate layer is made of a non-conductive material, and the non-conductive material includes at least one of an organic material containing oxygen and silicon functional groups, epoxy resin, polyimide, a glass fiber material, and a ceramic material.

10. The vertically wound inductor according to claim 2, characterized in that: One end of the first coil pattern connected to the first external electrode has a first outer edge, and the first outer edge is separated from a first edge of the outer surface by a first predetermined length. One end of the second coil pattern connected to the second external electrode has a second outer edge, and the second outer edge is separated from a second edge of the outer surface by a second predetermined length. The first external electrode and the second external electrode have a predetermined width, and the first predetermined length and the second predetermined length are in the range of 0% to 50% of the predetermined width.

11. A method for manufacturing a vertically wound inductor, characterized in that: The manufacturing method of the vertically wound inductor comprises: Providing a substrate, and performing a drilling process on the substrate to form at least one through hole; Performing a photolithography process to form a first coil portion and a second coil portion on both sides of the substrate, wherein the connecting portion passes through the through hole and connects the first coil portion to the second coil portion, and a first gap is formed between the first coil portion and the second coil portion; Performing a first cutting process on the substrate, the first coil portion, and the second coil portion to form a coil body including the first coil portion and the second coil portion, and forming an intermediate layer in the first gap; Placing the coil body and the intermediate layer into a mold, and filling the mold with a first magnetic material, so as to form an inductor body by performing a pressing process; Performing a cutting process on the inductor body to expose a portion of the first coil portion and the second coil portion; performing an electroplating process to form a first external electrode and a second external electrode on an outer surface of the inductor body, wherein the first external electrode is connected to the first coil portion, and the second external electrode is connected to the second coil portion, The direction of the central magnetic field line generated by the coil body is parallel to a setting direction of the first outer electrode and the second outer electrode.

12. The method for manufacturing a vertically wound inductor according to claim 11, characterized in that: The first coil portion includes a first coil pattern and a first connection pattern, and the first coil pattern is electrically connected to the first external electrode through the first connection pattern. The second coil portion includes a second coil pattern and a second connection pattern, and the second coil pattern is electrically connected to the second external electrode through a second connection pattern.

13. The method for manufacturing a vertically wound inductor according to claim 12, characterized in that: The first coil pattern is a first spiral coil, and the first connection pattern extends along a first tangent direction formed by a first end of the first spiral coil to connect the first end of the first spiral coil to the first external electrode; Wherein, the second coil pattern is a second spiral coil, and the second connection pattern extends along a second tangent direction formed by a first end of the second spiral coil to connect the first end of the second spiral coil to the second external electrode, and a second end of the first spiral coil is connected to a second end of the second spiral coil through the connecting portion.

14. The method for manufacturing a vertically wound inductor according to claim 13, characterized in that: The first connection pattern has a first gradient structure, a first connection surface is formed at the connection between the first gradient structure and the first coil pattern, a second connection surface is formed at the connection between the first gradient structure and the first external electrode, and an area of ​​the first connection surface is smaller than that of the second connection surface. Among them, the second connection pattern has a second gradient structure, the connection between the second gradient structure and the second coil pattern has a third connection surface, the connection between the second gradient structure and the second external electrode has a fourth connection surface, and the area of ​​the third connection surface is smaller than that of the fourth connection surface.

15. The method for manufacturing a vertically wound inductor according to claim 14, characterized in that: The first coil portion also includes a first dummy connection pattern connected to the second external electrode, and the second coil portion also includes a second dummy connection pattern connected to the first external electrode, a first vertical projection of the first dummy connection pattern formed on the intermediate layer overlaps with a second vertical projection of the second connection pattern formed on the intermediate layer, and a third vertical projection of the second dummy connection pattern formed on the intermediate layer overlaps with a fourth vertical projection of the first connection pattern formed on the intermediate layer.

16. The method for manufacturing a vertically wound inductor according to claim 13, characterized in that: The first tangent direction is parallel to the second tangent direction, and the first tangent direction and the second tangent direction are perpendicular to the outer surface of the inductor body.

17. The method for manufacturing a vertically wound inductor according to claim 16, characterized in that: The middle layer has a closed ring body which completely covers the first spiral coil and the second spiral coil.

18. The method for manufacturing a vertically wound inductor according to claim 17, characterized in that: The first spiral coil has a first hollow portion, the second spiral coil has a second hollow portion, and the middle layer has a hollow portion corresponding to the first hollow portion and the second hollow portion.

19. The method for manufacturing a vertically wound inductor according to claim 11, characterized in that: The intermediate layer is made of a non-conductive material, and the non-conductive material includes at least one of an organic material containing oxygen and silicon functional groups, epoxy resin, polyimide, a glass fiber material, and a ceramic material.

20. The method for manufacturing a vertically wound inductor according to claim 11, characterized in that: The step of performing the photolithography process to form the first coil portion and the second coil portion on both sides of the substrate includes: Performing a photolithography process on both sides of the substrate to form a first predetermined pattern layer and a second predetermined pattern layer respectively; forming a first coil portion to be formed on the first predetermined pattern layer through a deposition process, and forming a second coil portion to be formed on the second predetermined pattern layer; and The first predetermined pattern layer and the second predetermined pattern layer are removed to form the first coil portion and the second coil portion.

21. The method for manufacturing a vertically wound inductor according to claim 11, characterized in that: The pressing process is a hot pressing process, the hot pressing temperature used is in the range of 100 to 200 degrees, and the pressure used is in the range of 10 to 600 MPa.

22. The method for manufacturing a vertically wound inductor according to claim 12, characterized in that: One end of the first coil pattern connected to the first external electrode has a first outer edge, and the first outer edge is separated from a first edge of the outer surface by a first predetermined length. One end of the second coil pattern connected to the second external electrode has a second outer edge, and the second outer edge is separated from a second edge of the outer surface by a second predetermined length. The first external electrode and the second external electrode have a predetermined width, and the first predetermined length and the second predetermined length are in the range of 0% to 50% of the predetermined width.

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