Matrix inductor manufacturing method and matrix inductor

Abstract

The invention belongs to the technical field of inductor manufacturing, and discloses a matrix inductor manufacturing method and a matrix inductor, and the matrix inductor manufacturing method comprises the following steps: winding a coil on a soft magnetic substrate to form an inductor monomer, and preparing a plurality of inductor monomers; a plurality of inductor monomers are arranged in a cavity of a mold, the inductor monomers are arranged in the cavity in multiple rows in the X direction, and a plurality of inductor monomers are arranged in each row in the Y direction at intervals; soft magnetic metal powder is added into a cavity of the mold; the soft magnetic metal powder and the inductor monomers are pressed together to form an integrated inductor integration; demolding the integrated inductor integration, and segmenting the integrated inductor integration to obtain a matrix inductor with a required number of inductor monomers; the matrix inductor comprises a magnetic conductive connecting part and inductor monomers. According to the manufacturing method of the matrix type inductor, the manufacturing efficiency is high, the chip mounting space of the finished matrix type inductor can be effectively saved, and meanwhile the voltage resistance requirement of the single-phase inductor is lowered.

Description

Technical Field

[0001] The present invention relates to the technical field of inductor manufacturing, and in particular to a matrix inductor manufacturing method and a matrix inductor. Background Art

[0002] At present, some electronic products use multiple unidirectional inductors during the assembly process. Multiple unidirectional inductors will involve multiple assembly processes and multiple patching operations. The installation operation is relatively complicated. During the patching process, sufficient gaps need to be reserved between the internal components of the electronic product. This will cause the overall size of the electronic product to be correspondingly larger, occupying space and increasing costs. In addition, after multiple unidirectional inductors are installed, there is a concentrated air gap between two adjacent inductors. The existence of the air gap affects the inductance value on the one hand, and the induced electromotive force is divided into different paths, and the inductance value will decrease, otherwise the inductance value will increase; on the other hand, it affects the magnetic flux distribution, and the uneven magnetic flux distribution will cause the inductance to be unstable or incomplete, affecting the use effect of the inductor. Summary of the invention

[0003] The object of the present invention is to provide a method for manufacturing a matrix inductor and a matrix inductor, which have high manufacturing efficiency, and the finished matrix inductor can effectively save patch space and reduce the withstand voltage requirement of a single-phase inductor.

[0004] To achieve this object, the present invention adopts the following technical solutions:

[0005] A method for manufacturing a matrix inductor comprises the following steps:

[0006] S100, winding a coil on a soft magnetic substrate to form an inductor monomer, and preparing a plurality of the inductor monomers;

[0007] S200, placing a plurality of the inductor monomers in a mold cavity, wherein the plurality of the inductor monomers are arranged in a plurality of rows along the X direction in the mold cavity, and each row is provided with a plurality of inductor monomers at intervals along the Y direction;

[0008] S300, adding soft magnetic metal powder into the cavity of the mold;

[0009] S400, pressing the soft magnetic metal powder and the plurality of inductor monomers together to form an integrated inductor assembly;

[0010] S500, demoulding the integrated inductor assembly and dividing it to obtain a matrix inductor having a required number of inductor monomers.

[0011] As an optional implementation, in step S100, two ends of the coil extend out of the soft magnetic substrate to serve as electrode terminals.

[0012] As an optional implementation, in step S200, in each row of the inductor monomers, a plurality of the coils are wound around the Y direction on the corresponding soft magnetic substrate.

[0013] As an optional implementation, in step S300, the material of the soft magnetic metal powder is selected from one or more of metal soft magnetic, ferrite soft magnetic, amorphous nano alloy, and nanocrystalline alloy.

[0014] As an optional implementation, in step S400, the temperature during the pressing process is set to 150°C-200°C, and the pressing time is set to 1min-30min.

[0015] As an optional implementation, in step S400, the packaging pressure during the pressing process is set to 300T-500T.

[0016] As an optional implementation, in step S500, after the integrated inductor is segmented, the following step is further included: performing terminal processing on both ends of the coil extending out of the soft magnetic substrate to form an alloy plating layer.

[0017] As an optional implementation, the inductor monomers in the matrix inductor are arranged in M ​​rows along the X direction, and each row is arranged with N inductors at intervals along the Y direction;

[0018] The voltage difference of a single coil in the matrix inductor is V1, the voltage difference of the matrix inductor as a whole is V, and the relationship between V1 and V satisfies: V1=V / (M×N).

[0019] As an optional implementation, the inductor monomers in the matrix inductor are arranged in M ​​rows along the X direction, and each row is arranged with N inductors at intervals along the Y direction;

[0020] The inductance of a single coil in the matrix inductor is L1, the inductance of a single inductor monomer is L, and the relationship between L1 and L satisfies: L1=k×L; wherein K>1.

[0021] A matrix inductor, comprising:

[0022] The magnetic connection part is formed by pressing the soft magnetic metal powder;

[0023] An inductor monomer is fixedly connected to the magnetic conductive connecting portion. The inductor monomer is arranged in M ​​rows along the X direction, and each row is arranged with N inductors at intervals along the Y direction. The inductor monomer includes a soft magnetic substrate and a coil wound on the soft magnetic substrate. The two ends of the coil extending from the soft magnetic substrate are arranged as electrode terminals, and the electrode terminals are coated with an alloy plating layer.

[0024] Beneficial effects:

[0025] The matrix inductor manufacturing method provided by the present invention firstly winds a coil on a soft magnetic substrate to form an inductor monomer, and prepares a plurality of inductor monomers by the above operation. A plurality of inductor monomers are placed in the mold cavity of a mold, and a plurality of inductor monomers are arranged in a plurality of rows along the X direction in the mold cavity, and a plurality of inductor monomers are arranged in each row along the Y direction, that is, an X×Y number of inductor monomers are placed in the mold cavity. Then, soft magnetic metal powder is added to the mold cavity, and the metal powder is evenly distributed on the surrounding sides of the plurality of inductor monomers. When the soft magnetic metal powder is heated, the mold is closed and a pressing device is used to press the inductor monomer and the soft magnetic metal powder under certain temperature, pressure and time conditions, and finally an integrated inductor integration is formed. The integrated inductor integration is demolded and divided as needed, and finally a matrix inductor with the required number of inductor monomers is obtained. The matrix inductor obtained by the above method can be divided into a matrix inductor that meets the number of inductor monomers according to the use requirements, and the production efficiency is high.

[0026] The matrix inductor provided by the present invention is manufactured by the above-mentioned matrix inductor manufacturing method, and can avoid multiple single-unit patching during the assembly process with electronic products, effectively improve the installation efficiency, save space, and reduce the unidirectional inductor withstand voltage requirement. In addition, there is no air gap between two adjacent inductor monomers of the matrix inductor, so that the inductance value and magnetic flux of the inductor remain stable, ensuring that the use effect of the inductor itself is stable and reliable. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 is a schematic flow chart of a method for manufacturing a matrix inductor provided by an embodiment of the present invention;

[0028] Figure 2 is a simplified structural diagram of preparing a plurality of inductor monomers provided by an embodiment of the present invention;

[0029] Figure 3 is a simplified structural diagram of a plurality of inductor monomers placed in a mold according to an embodiment of the present invention;

[0030] Figure 4 is a simplified structural diagram of an integrated inductor provided by an embodiment of the present invention;

[0031] Figure 5 is a schematic diagram of segmenting an integrated inductor assembly provided by an embodiment of the present invention;

[0032] Figure 6 1 is a simplified structural diagram of a matrix inductor provided in one embodiment of the present invention.

[0033] In the figure:

[0034] 1. coil; 11. alloy plating; 121. separation groove; 122. through hole;

[0035] 2. Soft magnetic substrate;

[0036] 3. Inductor monomer;

[0037] 4. Soft magnetic metal powder;

[0038] 5. Mould. DETAILED DESCRIPTION

[0039] The present invention will be further described in detail below in conjunction with the accompanying drawings and embodiments. It is to be understood that the specific embodiments described herein are only used to explain the present invention, rather than to limit the present invention. It should also be noted that, for ease of description, only parts related to the present invention, rather than all structures, are shown in the accompanying drawings.

[0040] In the description of the present invention, unless otherwise clearly specified and limited, the terms "connected", "connected", and "fixed" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0041] In the present invention, unless otherwise clearly specified and limited, a first feature being "above" or "below" a second feature may include that the first and second features are in direct contact, or may include that the first and second features are not in direct contact but are in contact through another feature between them. Moreover, a first feature being "above", "above" and "above" a second feature includes that the first feature is directly above and obliquely above the second feature, or simply indicates that the first feature is higher in level than the second feature. A first feature being "below", "below" and "below" a second feature includes that the first feature is directly below and obliquely below the second feature, or simply indicates that the first feature is lower in level than the second feature.

[0042] In the description of this embodiment, the terms "upper", "lower", "right", etc., directions or positional relationships are based on the directions or positional relationships shown in the drawings, and are only for the convenience of description and simplification of operation, rather than indicating or implying that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore cannot be understood as limiting the present invention. In addition, the terms "first" and "second" are only used to distinguish in the description and have no special meaning.

[0043] This embodiment provides a method for manufacturing a matrix inductor. Figures 1 to 6 As shown, the method for manufacturing a matrix inductor includes the following steps:

[0044] S100, winding the coil 1 on the soft magnetic substrate 2 to form an inductor monomer 3, and preparing a plurality of inductor monomers 3;

[0045] S200, placing a plurality of inductor monomers 3 in the cavity of the mold 5, wherein the plurality of inductor monomers 3 are arranged in a plurality of rows along the X direction in the cavity, and each row is provided with a plurality of inductor monomers 3 at intervals along the Y direction;

[0046] S300, adding soft magnetic metal powder 4 into the cavity of the mold 5;

[0047] S400, pressing the soft magnetic metal powder 4 and the plurality of inductor monomers 3 together to form an integrated inductor assembly;

[0048] S500 , demoulding the integrated inductor and dividing it to obtain a matrix inductor with a required number of inductor monomers 3 .

[0049] The X and Y directions are shown in the attached Figures 2 to 6 As shown, the X direction is perpendicular to the Y direction.

[0050] For example, Figures 3 to 6 In the structure shown, a total of 6 inductor monomers 3 are prepared, and the 6 inductor monomers 3 are arranged in 2 rows along the X direction in the cavity, and each row is arranged with 3 inductor monomers 3 at intervals along the Y direction. After segmentation, 2 matrix inductors can be formed, and each matrix inductor has 1 row of inductor monomers 3, and the number of inductor monomers 3 in each row is set to 3.

[0051] In this embodiment, the matrix inductor manufacturing method firstly winds the coil 1 on the soft magnetic substrate 2 to form an inductor monomer 3, and prepares a plurality of inductor monomers 3 by the above operation. The plurality of inductor monomers 3 are placed in the cavity of the mold 5, and the plurality of inductor monomers 3 are arranged in multiple rows along the X direction in the cavity, and each row is arranged with multiple intervals along the Y direction, that is, the cavity of the mold 5 is filled with X×Y number of inductor monomers 3. Then, the soft magnetic metal powder 4 is added to the cavity of the mold 5, and the metal powder is evenly distributed on the surrounding side of the plurality of inductor monomers 3. When the soft magnetic metal powder 4 is heated, the mold 5 is closed and a pressing device is used to press the inductor monomer 3 and the soft magnetic metal powder 4 under certain temperature, pressure and time conditions, and finally an integrated inductor integration is formed. The integrated inductor integration is demolded and divided as needed, and finally a matrix inductor with the required number of inductor monomers 3 is obtained. The matrix inductor obtained by the above method can be divided into a matrix inductor that meets the number of inductor monomers 3 according to the use requirements, and the production efficiency is high. In addition, the final matrix inductor can avoid multiple single-cell patching during the assembly process with electronic products, effectively improve the installation efficiency, save space, and reduce the unidirectional inductor withstand voltage requirements. In addition, there is no air gap between two adjacent inductor monomers 3 of the matrix inductor, so that the inductance value and magnetic flux of the inductor remain stable, ensuring that the inductor itself is stable and reliable.

[0052] In this embodiment, the integrated inductor assembly can be divided by cutting using a cutting device to obtain a matrix inductor having a required number of inductor monomers 3 .

[0053] In this embodiment, in step S100, two ends of the coil 1 extend out of the soft magnetic substrate 2 to serve as electrode terminals. The electrode terminals are used to connect to electrode terminals of adjacent inductors or to be welded to pads.

[0054] As an optional implementation, the coil 1 can be made of copper.

[0055] As an optional embodiment, the soft magnetic substrate 2 is made of a soft magnetic material, which can be selected from one or more of metal soft magnetic, ferrite soft magnetic, amorphous nano alloy, and nanocrystalline alloy. This configuration enables the soft magnetic substrate 2 to have good magnetic conductivity.

[0056] In this embodiment, in step S200, in each row of inductor monomers 3, multiple coils 1 are wound around the Y direction on the corresponding soft magnetic substrate 2. This arrangement ensures that the orientation of multiple inductor monomers 3 on the final matrix inductor remains consistent.

[0057] In this embodiment, in step S300, the material of the soft magnetic metal powder 4 is selected from one or more of iron silicon, iron silicon aluminum, iron silicon chromium, and iron nickel. This configuration enables the soft magnetic metal powder 4 to have good magnetic conductivity.

[0058] In this embodiment, in step S300, after adding the soft magnetic metal powder 4 into the mold 5, a scraper or other tool is used to remove the soft magnetic metal powder 4 overflowing from the mold 5 to ensure the reliability and effectiveness of the subsequent mold closing and pressing work.

[0059] In this embodiment, in step S400, the temperature during the pressing process is set to 150°C-200°C, and the pressing time is set to 1min-30min. Exemplarily, the temperature during the pressing process can be set to 150°C, 160°C, 170°C, 180°C, 190°C, 200°C. The pressing time can be set to 1min, 5min, 10min, 15min, 30min.

[0060] In this embodiment, in step S400, the packaging pressure during the pressing process is set to 300T-500T. Exemplarily, the packaging pressure during the pressing process can be optionally set to 300T, 350T, 400T, 450T, 500T.

[0061] In this embodiment, in step S500, after the integrated inductor is segmented, the following steps are also included: terminal treatment is performed on both ends of the coil 1 extending from the soft magnetic substrate 2 to form an alloy plating layer 11. Exemplarily, the terminal treatment can be specifically electroplating, and the alloy plating layer 11 can be specifically set as a tin-silver-copper alloy layer. By setting the plating layer, the corrosion resistance, hardness, and wear resistance of the electrode terminal part at the end of the coil 1 can be increased, and the mechanical properties can be enhanced, which also plays a role in aesthetics and decoration.

[0062] Optionally, in the integrated inductor, a through hole 122 is provided between two adjacent rows of inductor monomers 3 along the X direction; and a through hole 122 is provided between two adjacent inductor monomers 3 along the Y direction. Specifically, the provision of the through hole 122 facilitates the subsequent rapid and effective segmentation of the integrated inductor, and facilitates the final formation of the matrix inductor.

[0063] Optionally, on the integrated inductor, along the Y direction, a separation groove 121 is provided between two adjacent rows of inductor monomers 3, and the through holes 122 between two adjacent rows of inductor monomers 3 are provided on the corresponding separation groove 121. The provision of the separation groove 121 is also convenient for rapid positioning when the integrated inductor is divided, ensuring accurate position division of the integrated inductor.

[0064] Optionally, the separation groove 121 and the through hole 122 are both provided with corresponding modeling structures in the cavity of the mold 5, and the separation groove 121 and the through hole 122 can be directly formed after the mold is closed and pressed, without the need for subsequent special opening.

[0065] It is worth mentioning that the demoulding method is an existing mature process and will not be elaborated on here.

[0066] In this embodiment, the inductor monomers 3 in the matrix inductor are arranged in M ​​rows along the X direction, and each row is arranged with N inductors at intervals along the Y direction; the voltage difference of a single coil 1 in the matrix inductor is V1, and the voltage difference of the matrix inductor as a whole is V, and the relationship between V1 and V satisfies: V1 = V / (M×N). With such an arrangement, the matrix inductor provided in this embodiment can perform voltage division compared to the traditional unidirectional inductor, and distribute the same voltage to multiple inductor monomers 3 in the matrix inductor.

[0067] In this embodiment, the inductance of a single coil 1 in the matrix inductor is L1, and the inductance of a single inductor monomer 3 is L. The relationship between L1 and L satisfies: L1 = k × L; wherein K> 1. Since the inductor monomer 3 in the matrix inductor is affected by the surrounding soft magnetic metal powder 4, the inductance is increased. K is the increase coefficient, and its specific value is positively correlated with the amount of soft magnetic metal powder 4 around the inductor monomer 3.

[0068] This embodiment also provides a matrix inductor, which is made using the above-mentioned matrix inductor manufacturing method. The matrix inductor includes a magnetic connection part and an inductor monomer 3, the magnetic connection part is pressed by soft magnetic metal powder 4, the inductor monomer 3 is fixedly connected to the magnetic connection part, the inductor monomer 3 is provided with M rows along the X direction, and each row is provided with N intervals along the Y direction, the inductor monomer 3 includes a soft magnetic substrate 2 and a coil 1 wound on the soft magnetic substrate 2, the coil 1 extends out of the two ends of the soft magnetic substrate 2 and is set as an electrode terminal, and the electrode terminal is coated with an alloy coating 11. The matrix inductor provided in this embodiment can avoid multiple monomer patches during the assembly process with electronic products, effectively improve the installation efficiency, save space, and reduce the unidirectional inductor withstand voltage requirements. In addition, there is no air gap between two adjacent inductor monomers 3 of the matrix inductor, so that the inductance value and magnetic flux of the inductor remain stable, ensuring that the use effect of the inductor itself is stable and reliable.

[0069] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the embodiments of the present invention. For those skilled in the art, various obvious changes, readjustments and substitutions can be made without departing from the protection scope of the present invention. It is not necessary and impossible to list all the embodiments here. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the claims of the present invention.

Claims

1. A method for manufacturing a matrix inductor, characterized in that: The following steps are involved: S100, winding a coil (1) on a soft magnetic substrate (2) to form an inductor monomer (3), and preparing a plurality of the inductor monomers (3); S200, placing a plurality of the inductor monomers (3) in a mold cavity of a mold (4), wherein the plurality of the inductor monomers (3) are arranged in a plurality of rows along the X direction in the mold cavity, and each row is provided with a plurality of inductor monomers (3) at intervals along the Y direction; S300, adding soft magnetic metal powder (4) into the cavity of the mold (5); S400, pressing the soft magnetic metal powder (4) and a plurality of the inductor monomers (3) together to form an integrated inductor assembly; S500, demoulding the integrated inductor assembly and dividing it to obtain a matrix inductor having a required number of the inductor monomers (3).

2. The method for manufacturing a matrix inductor according to claim 1, wherein: In step S100, two ends of the coil (1) extend out of the soft magnetic substrate (2) to serve as electrode terminals.

3. The method for manufacturing a matrix inductor according to claim 1, wherein: In step S200, in each row of the inductor monomers (3), a plurality of the coils (1) are wound around the Y direction on the corresponding soft magnetic substrate (2).

4. The method for manufacturing a matrix inductor according to claim 1, wherein: In step S300, the material of the soft magnetic metal powder (4) is selected from one or more of metal soft magnetic, ferrite soft magnetic, amorphous nano alloy, and nanocrystalline alloy.

5. The method for manufacturing a matrix inductor according to claim 1, wherein: In step S400, the temperature during the pressing process is set to 150°C-200°C, and the pressing time is set to 1min-30min.

6. The method for manufacturing a matrix inductor according to claim 1, wherein: In step S400, the packaging pressure during the pressing process is set to 300T-500T.

7. The method for manufacturing a matrix inductor according to claim 1, wherein: In step S500, after the integrated inductor is divided, the following steps are also included: terminal processing is performed on the two ends of the coil (1) extending out of the soft magnetic substrate (2) to form an alloy coating (11).

8. The method for manufacturing a matrix inductor according to claim 1, wherein: The inductor monomers (3) in the matrix inductor are arranged in M ​​rows along the X direction, and each row is arranged with N inductor monomers at intervals along the Y direction; The voltage difference of a single coil (1) in the matrix inductor is V1, the voltage difference of the matrix inductor as a whole is V, and the relationship between V1 and V satisfies: V1=V / (M×N).

9. The method for manufacturing a matrix inductor according to claim 1, characterized in that: The inductor monomers (3) in the matrix inductor are arranged in M ​​rows along the X direction, and each row is arranged with N inductor monomers at intervals along the Y direction; The inductance of a single coil (1) in the matrix inductor is L1, the inductance of a single inductor monomer (3) is L, and the relationship between L1 and L satisfies: L1=k×L; wherein K>1.

10. A matrix inductor, characterized in that: include: The magnetic conductive connecting part is formed by pressing the soft magnetic metal powder (4); An inductor monomer (3) is fixedly connected to the magnetic conductive connecting portion. The inductor monomer (3) is provided with M rows along the X direction, and each row is provided with N inductors at intervals along the Y direction. The inductor monomer (3) comprises a soft magnetic substrate (2) and a coil (1) wound on the soft magnetic substrate (2). The two ends of the coil (1) extending from the soft magnetic substrate (2) are arranged as electrode terminals, and the electrode terminals are coated with an alloy plating layer (11).

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