Two-in-one double-coil integrated inductor and manufacturing method

Abstract

The invention discloses a two-in-one double-coil integrated inductor and a manufacturing method.The inductor comprises a first magnetic core, a second magnetic core, a first coil, a second coil, a partition plate and a substrate, the first coil is arranged on the first magnetic core, the second coil is arranged on the second magnetic core, and the first magnetic core and the second magnetic core are arranged side by side; the partition plate is arranged between the first magnetic core and the second magnetic core, and the substrate is arranged at the bottoms of the first magnetic core, the second magnetic core and the partition plate. According to the invention, a two-in-one structure is adopted, the processing is convenient, the processing cost is saved, and the partition plate is arranged inside, so that mutual interference of signals generated in the use process can be prevented.

Description

Technical Field

[0001] The invention discloses an inductor, in particular to a two-in-one dual-coil integrated inductor and a manufacturing method thereof, belonging to the technical field of components of consumer electronic products. Background Art

[0002] An integrated inductor (also called an integrated inductor) is an inductor that integrates the inductor element and its related structures (such as a magnetic core, a coil, a housing, etc.) into a single component. Compared with traditional split inductors, integrated inductors have a more compact design and higher integration. They are widely used in modern electronic products, especially in situations where small size, superior performance, and simple assembly are required, such as mobile phones, computers, LED lighting, and automotive electronics. Integrated inductors are widely used in power management, wireless charging, communication equipment, automotive electronics, LED drive circuits, and other fields due to their small size, high efficiency, stability, and ease of automated production. Integrated inductors provide better performance and smaller size in modern electronic devices through a highly integrated design, and are suitable for high-frequency, precision, and high-efficiency circuit applications. However, when selecting an integrated inductor, in addition to the inductance value and maximum operating current, efficiency, thermal management, and special requirements of the application scenario also need to be considered.

[0003] The integrated inductor in the prior art is usually a single inductor mode. If a two-in-one or multi-in-one structure is adopted, on the one hand, it is not convenient in processing, and on the other hand, signals between the inductors will inevitably interfere with each other, affecting the use effect. Summary of the invention

[0004] In view of the above-mentioned disadvantage that the integrated inductors in the prior art all adopt a single inductor mode, the present invention provides a two-in-one dual-coil integrated inductor and a manufacturing method. The two-in-one structure is not only convenient for processing, but also can prevent mutual signal interference during use.

[0005] The technical solution adopted by the present invention to solve its technical problem is: a two-in-one dual-coil integrated inductor, the inductor includes a first magnetic core, a second magnetic core, a first coil, a second coil, a partition and a substrate, the first coil is arranged on the first magnetic core, the second coil is arranged on the second magnetic core, the first magnetic core and the second magnetic core are arranged side by side, the partition is arranged between the first magnetic core and the second magnetic core, and the substrate is arranged at the bottom of the first magnetic core, the second magnetic core and the partition.

[0006] A method for manufacturing the two-in-one dual-coil integrated inductor as described above comprises the following steps: Step S1, coil processing: processing the first coil and the second coil according to the set shape, the first coil and the second coil are made of round copper bars, and positions for welding pins are reserved at both ends; Step S2, welding pin processing: flatten the welding pins at both ends of the coil to form flat welding pins and pin connecting parts, and cut them into shapes according to set sizes; Step S3, magnetic core processing: processing the first magnetic core, the second magnetic core, the partition and the substrate according to the set shape; Step S4, assembling: installing the first coil and the second coil on the first magnetic core and the second magnetic core respectively, and then installing the first magnetic core, the partition and the second magnetic core side by side between two side edges of the substrate; Step S5, hot pressing: pressing the first magnetic core, the partition, the second magnetic core and the substrate together through a hot pressing process to form an inductor; Step S6, electrode bending: bending the first welding pin, the second welding pin, the third welding pin and the fourth welding pin according to a set shape, and pasting them on the bottom of the substrate; Step S7, appearance inspection: select defective products through appearance inspection machine; Step S8, test packaging: test the product and then put the product into packaging materials.

[0007] The technical solution adopted by the present invention to solve the technical problem further includes: A first accommodating cavity is formed on the inner side surface of the first magnetic core. A first winding post is arranged in the first accommodating cavity. The first magnetic core is wound on the first winding post.

[0008] The first winding rod is cylindrical and is arranged in the middle of the first accommodating cavity.

[0009] A second accommodating cavity is formed on the inner side surface of the second magnetic core. A second winding post is arranged in the second accommodating cavity. The second magnetic core is wound on the second winding post.

[0010] The second winding post is cylindrical and is arranged in the middle of the second accommodating cavity.

[0011] The first coil includes a first coil body, a first welding pin, a second welding pin, a first pin connecting portion and a second pin connecting portion, the first welding pin is connected to one end of the first coil body through the first pin connecting portion, the second welding pin is connected to the other end of the first coil body through the second pin connecting portion, and the first welding pin and the second welding pin are arranged side by side; the second coil includes a second coil body, a third welding pin, a fourth welding pin, a third pin connecting portion and a fourth pin connecting portion, the third welding pin is connected to one end of the second coil body through the third pin connecting portion, the fourth welding pin is connected to the other end of the second coil body through the fourth pin connecting portion, and the third welding pin and the fourth welding pin are arranged side by side.

[0012] A side edge is respectively arranged on both sides of the substrate, so that the cross section of the substrate is "U"-shaped, a first lower limit plate is arranged at the bottom of the first magnetic core, a second lower limit plate is arranged at the bottom of the second magnetic core, and a third lower limit plate is arranged at the bottom of the partition, and the first lower limit plate, the second lower limit plate and the third lower limit plate are clamped between the two side edges.

[0013] A pin notch is respectively arranged on the side of the substrate corresponding to the first pin connection part, the second pin connection part, the third pin connection part and the fourth pin connection part, and the first pin connection part, the second pin connection part, the third pin connection part and the fourth pin connection part are respectively located at the pin notch positions.

[0014] A welding pin groove is respectively arranged at the bottom of the substrate corresponding to the first welding pin, the second welding pin, the third welding pin and the fourth welding pin. The first welding pin, the second welding pin, the third welding pin and the fourth welding pin are respectively located at the welding pin groove positions.

[0015] The beneficial effects of the present invention are as follows: the present invention adopts a two-in-one structure, which is not only convenient to process and saves processing costs, but also has a partition plate arranged inside, which can prevent mutual interference of signals during use.

[0016] The present invention will be further described below in conjunction with the accompanying drawings and specific implementation methods. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a schematic diagram of the three-dimensional structure of the present invention.

[0018] Figure 2 It is a schematic diagram of the structure of the decomposed state of the present invention.

[0019] Figure 3 It is a schematic diagram of the three-dimensional structure from a second viewing angle of the present invention.

[0020] Figure 4 This is a schematic diagram of the structure of the decomposed state from the second viewing angle of the present invention.

[0021] In the figure, 1-first magnetic core, 11-first accommodating cavity, 12-first winding post, 13-first lower limit plate, 2-second magnetic core, 21-second accommodating cavity, 22-second winding post, 23-second lower limit plate, 3-first coil, 31-first coil body, 32-first welding pin, 33-second welding pin, 34-first pin connecting part, 35-second pin connecting part, 4-second coil, 41-second coil body, 42-third welding pin, 43-fourth welding pin, 44-third pin connecting part, 45-fourth pin connecting part, 5-partition, 51-third lower limit plate, 6-substrate, 61-side, 62-pin notch, 63-welding pin groove. DETAILED DESCRIPTION

[0022] This embodiment is a preferred implementation mode of the present invention. Other embodiments whose principles and basic structures are the same or similar to those of this embodiment are within the protection scope of the present invention.

[0023] Please refer to the attached Figure 1 To Attachment Figure 4 The present invention mainly protects a two-in-one dual-coil integrated inductor, which mainly includes a first magnetic core 1, a second magnetic core 2, a first coil 3, a second coil 4, a partition 5 and a substrate 6. The first coil 3 is arranged on the first magnetic core 1, the second coil 4 is arranged on the second magnetic core 2, the first magnetic core 1 and the second magnetic core 2 are arranged side by side, the partition 5 is arranged between the first magnetic core 1 and the second magnetic core 2, and the substrate 6 is arranged at the bottom of the first magnetic core 1, the second magnetic core 2 and the partition 5.

[0024] In this embodiment, a first accommodating cavity 11 is formed on the inner side surface (the side facing the partition 5 ) of the first magnetic core 1 . A first winding post 12 is disposed in the first accommodating cavity 11 , and the first magnetic core 1 is wound on the first winding post 12 .

[0025] In this embodiment, the first winding post 12 is cylindrical and is disposed in the middle of the first accommodating cavity 11 .

[0026] In this embodiment, a second accommodating cavity 21 is formed on the inner side surface of the second magnetic core 2 (the side facing the partition 5 ), a second winding post 22 is disposed in the second accommodating cavity 21 , and the second magnetic core 2 is wound on the second winding post 22 .

[0027] In this embodiment, the second winding post 22 is cylindrical and is disposed in the middle of the second accommodating cavity 21 .

[0028] In this embodiment, the first coil 3 includes a first coil body 31, a first welding pin 32, a second welding pin 33, a first pin connection portion 34 and a second pin connection portion 35. The first coil 3 is arranged as an integral whole, and each part is artificially defined according to its functional distinction. The first welding pin 32 is connected to one end of the first coil body 31 through the first pin connection portion 34, and the second welding pin 33 is connected to the other end of the first coil body 31 through the second pin connection portion 35.

[0029] In this embodiment, the first welding pin 32 and the second welding pin 33 are arranged side by side.

[0030] In this embodiment, the second coil 4 includes a second coil body 41, a third welding pin 42, a fourth welding pin 43, a third pin connecting portion 44 and a fourth pin connecting portion 45. The second coil 4 is arranged as an integral whole, and each part is artificially defined according to its functional distinction. The third welding pin 42 is connected to one end of the second coil body 41 through the third pin connecting portion 44, and the fourth welding pin 43 is connected to the other end of the second coil body 41 through the fourth pin connecting portion 45.

[0031] In this embodiment, the third welding pin 42 and the fourth welding pin 43 are arranged side by side.

[0032] In this embodiment, a side edge 61 is respectively provided on both sides of the substrate 6, so that the cross-section of the substrate 6 is "U"-shaped, a first lower limit plate 13 is provided at the bottom of the first magnetic core 1, a second lower limit plate 23 is provided at the bottom of the second magnetic core 2, and a third lower limit plate 51 is provided at the bottom of the partition 5. The first lower limit plate 13, the second lower limit plate 23 and the third lower limit plate 51 are clamped between the two side edges 61, which can make their installation simpler and more convenient.

[0033] In this embodiment, a pin notch 62 is respectively provided at the position of the first pin connection part 34, the second pin connection part 35, the third pin connection part 44 and the fourth pin connection part 45 on the side surface of the substrate 6, and the first pin connection part 34, the second pin connection part 35, the third pin connection part 44 and the fourth pin connection part 45 are respectively located at the position of the pin notch 62, so that only a part of them is exposed at the side surface of the substrate 6; a welding pin groove 63 is respectively provided at the position of the first welding pin 32, the second welding pin 33, the third welding pin 42 and the fourth welding pin 43 on the bottom surface of the substrate 6, and the first welding pin 32, the second welding pin 33, the third welding pin 42 and the fourth welding pin 43 are respectively located at the position of the welding pin groove 63, so that only a part of them is exposed at the bottom surface of the substrate 6.

[0034] The present invention also protects a method for manufacturing the above-mentioned two-in-one dual-coil integrated inductor, which comprises the following steps: Step S1, coil processing: processing the first coil 3 and the second coil 4 according to the set shape, the first coil 3 and the second coil 4 are made of round copper bars, and positions for welding pins are reserved at both ends; Step S2, welding pin processing: flatten the welding pins at both ends of the coil to form flat welding pins and pin connecting parts, and cut them into shapes according to set sizes; Step S3, magnetic core processing: processing the first magnetic core 1, the second magnetic core 2, the partition 5 and the substrate 6 according to the set shape. In this embodiment, the first magnetic core 1, the second magnetic core 2, the partition 5 and the substrate 6 are processed by hot pressing molding process of magnetic powder. In this embodiment, the magnetic powder includes a mixture of metal soft magnetic powder and alloy powder. The metal soft magnetic powder can be iron powder containing carbonyl, and the alloy powder can be amorphous powder or nanocrystalline powder. The two can be mixed. During hot pressing, the hot pressing temperature is controlled between 120 and 180°C, the pressure is 4 to 7T per square centimeter, and the hot pressing time is 40 to 200S; In this embodiment, the processing of the first coil 3 and the second coil 4 and the processing of the magnetic core can be performed simultaneously or in steps. The processing of the first coil 3 and the second coil 4 and the processing of the magnetic core are not performed at the same station, and the order of the two processing is not necessarily related; Step S4, assembling: installing the first coil 3 and the second coil 4 on the first magnetic core 1 and the second magnetic core 2 respectively, and then installing the first magnetic core 1, the partition 5 and the second magnetic core 2 side by side between the two side edges 61 of the substrate 6; Step S5, hot pressing: pressing the first magnetic core 1, the partition 5, the second magnetic core 2 and the substrate 6 together through a hot pressing process to form an inductor; Step S6, electrode bending: bend the first welding pin 32, the second welding pin 33, the third welding pin 42 and the fourth welding pin 43 according to a set shape, and stick them to the bottom of the substrate 6; Step S7, appearance inspection: select defective products through the appearance machine to ensure product quality; Step S8, test packaging: test the product and then put the product into packaging materials to ensure product quality.

[0035] The present invention adopts a two-in-one structure, which is not only convenient to process and saves processing costs, but also has a partition plate arranged inside to prevent mutual interference of signals during use.

Claims

1. A two-in-one dual-coil integrated inductor, characterized by: The inductor comprises a first magnetic core (1), a second magnetic core (2), a first coil (3), a second coil (4), a partition (5) and a substrate (6); the first coil (3) is arranged on the first magnetic core (1), the second coil (4) is arranged on the second magnetic core (2), the first magnetic core (1) and the second magnetic core (2) are arranged side by side, the partition (5) is arranged between the first magnetic core (1) and the second magnetic core (2), and the substrate (6) is arranged at the bottom of the first magnetic core (1), the second magnetic core (2) and the partition (5).

2. The two-in-one dual-coil integrated inductor according to claim 1 is characterized in that: A first accommodating cavity (11) is provided on the inner side surface of the first magnetic core (1), a first winding post (12) is arranged in the first accommodating cavity (11), and the first magnetic core (1) is wound on the first winding post (12).

3. The two-in-one dual-coil integrated inductor according to claim 2, characterized in that: The first winding pole (12) is cylindrical and is arranged at the middle position of the first accommodating cavity (11).

4. The two-in-one dual-coil integrated inductor according to claim 1 is characterized in that: A second accommodating cavity (21) is provided on the inner side surface of the second magnetic core (2), a second winding post (22) is arranged in the second accommodating cavity (21), and the second magnetic core (2) is wound on the second winding post (22).

5. The two-in-one dual-coil integrated inductor according to claim 4 is characterized in that: The second winding post (22) is cylindrical and is arranged at the middle position of the second accommodating cavity (21).

6. The two-in-one dual-coil integrated inductor according to claim 1, characterized in that: The first coil (3) comprises a first coil body (31), a first welding pin (32), a second welding pin (33), a first pin connection portion (34) and a second pin connection portion (35); the first welding pin (32) is connected to one end of the first coil body (31) through the first pin connection portion (34); the second welding pin (33) is connected to the other end of the first coil body (31) through the second pin connection portion (35); the first welding pin (32) and the second welding pin (33) are arranged side by side; the second coil (4) comprises a second coil body (41), a third welding pin (42), a fourth welding pin (43), a third pin connection portion (44) and a fourth pin connection portion (45); the third welding pin (42) is connected to one end of the second coil body (41) through the third pin connection portion (44); the fourth welding pin (43) is connected to the other end of the second coil body (41) through the fourth pin connection portion (45); the third welding pin (42) and the fourth welding pin (43) are arranged side by side.

7. The two-in-one dual-coil integrated inductor according to claim 6 is characterized in that: The substrate (6) is provided with a side edge (61) on both sides, so that the cross section of the substrate (6) is "U"-shaped, a first lower limit plate (13) is provided at the bottom of the first magnetic core (1), a second lower limit plate (23) is provided at the bottom of the second magnetic core (2), and a third lower limit plate (51) is provided at the bottom of the partition plate (5), and the first lower limit plate (13), the second lower limit plate (23) and the third lower limit plate (51) are clamped between the two side edges (61).

8. The two-in-one dual-coil integrated inductor according to claim 6 is characterized in that: A pin notch (62) is provided on the side surface of the substrate (6) at positions corresponding to the first pin connection portion (34), the second pin connection portion (35), the third pin connection portion (44) and the fourth pin connection portion (45), respectively; the first pin connection portion (34), the second pin connection portion (35), the third pin connection portion (44) and the fourth pin connection portion (45) are respectively located at the positions of the pin notches (62).

9. The two-in-one dual-coil integrated inductor according to claim 6, characterized in that: A welding pin groove (63) is respectively provided at the bottom of the substrate (6) at positions corresponding to the first welding pin (32), the second welding pin (33), the third welding pin (42) and the fourth welding pin (43); the first welding pin (32), the second welding pin (33), the third welding pin (42) and the fourth welding pin (43) are respectively located at the positions of the welding pin grooves (63).

10. A method for manufacturing a two-in-one dual-coil integrated inductor according to any one of claims 1 to 9, characterized in that: The method comprises the following steps: Step S1, coil processing: processing the first coil (3) and the second coil (4) according to a set shape, wherein the first coil (3) and the second coil (4) are made of round copper bars, and positions for welding pins are reserved at both ends; Step S2, welding pin processing: flatten the welding pin positions at both ends of the coil to form flat welding pins and pin connecting parts, and cut and shape them according to the set size; Step S3, magnetic core processing: processing the first magnetic core (1), the second magnetic core (2), the partition (5) and the substrate (6) according to the set shape; Step S4, assembling: installing the first coil (3) and the second coil (4) on the first magnetic core (1) and the second magnetic core (2) respectively, and then installing the first magnetic core (1), the partition (5) and the second magnetic core (2) side by side between two side edges (61) of the substrate (6); Step S5, hot pressing: pressing the first magnetic core (1), the partition (5), the second magnetic core (2) and the substrate (6) together through a hot pressing process to form an inductor; Step S6, electrode bending: bending the first welding pin (32), the second welding pin (33), the third welding pin (42) and the fourth welding pin (43) according to a set shape, and pasting them on the bottom of the substrate (6); Step S7, appearance inspection: select defective products through appearance inspection machine; Step S8, test packaging: test the product and then put the product into packaging materials.

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