Laminated inductor and preparation method thereof

Abstract

The invention belongs to the technical field of inductors, and discloses a laminated inductor and a preparation method of the laminated inductor, the laminated inductor comprises at least one first inner electrode and at least one second inner electrode, the first inner electrode comprises a first conductive part, the second inner electrode comprises a second conductive part, the first conductive part and the second conductive part are spiral, and the first conductive part and the second conductive part are spiral. The at least one first inner electrode and the at least one second inner electrode are arranged in a stacked mode, the at least one first conductive piece and the at least one second conductive piece are arranged in series, and on the premise that the number of the first inner electrodes and the number of the second inner electrodes are limited, the overall inductance strength of the laminated inductor is high.

Description

Technical Field

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

[0002] With the rapid development of electronic communication technologies, as well as the continuous upgrading of mobile communication technologies and digital communication networks, the miniaturization and high performance of electronic components are the general trend. Compared with wire-wound inductors, stacked inductors have advantages such as small size, no mutual interference, and no directionality, and have a broader application prospect.

[0003] A stacked inductor is usually formed by laminating multiple inner electrodes. The more the number of inner electrodes, the higher the inductance intensity of the stacked inductor. Due to the limitation of the height of the stacked inductor itself, the number of inner electrodes cannot be increased indefinitely. Therefore, the height dimension of the stacked inductor itself limits the upper limit of its inductance intensity.

[0004] Therefore, it is urgent to propose a stacked inductor and a method for manufacturing the stacked inductor to solve the above technical problems. Summary of the Invention

[0005] The first object of the present invention is to provide a stacked inductor with a relatively high overall inductance intensity.

[0006] To achieve this purpose, the present invention adopts the following technical solutions:

[0007] A stacked inductor, comprising:

[0008] At least one first inner electrode, the first inner electrode comprising a first conductive member, the first conductive member being spiral;

[0009] At least one second inner electrode, the second inner electrode comprising a second conductive member, the second conductive member being spiral, at least one first inner electrode and at least one second inner electrode being stacked, and at least one first conductive member and at least one second conductive member being connected in series.

[0010] Optionally, at least one first inner electrode and at least one second inner electrode are stacked alternately, the spiral direction of the first conductive member being opposite to the spiral direction of the second conductive member, the inner end of the first conductive member being the electrical input end of the first conductive member, the outer end of the first conductive member being the electrical output end of the first conductive member, the outer end of the second conductive member being the electrical input end of the second conductive member, and the inner end of the second conductive member being the electrical output end of the second conductive member.

[0011] Optionally, the first inner electrode further includes a first conductive column, the first conductive column is connected to the outer end of the first conductive member, the second inner electrode further includes a second conductive column, the second conductive column is connected to the inner end of the second conductive member, along the stacking direction of at least one first inner electrode and at least one second inner electrode, the first conductive column of one first inner electrode is connected to the outer end of the next second conductive member, and the second conductive column of one second inner electrode is connected to the inner end of the next first conductive member.

[0012] Optionally, the stacked inductor further includes a lead-out electrode and an outer electrode, at least one first inner electrode and at least one second inner electrode are stacked to form an intermediate inner electrode, and the intermediate inner electrode is electrically connected to the outer electrode through the lead-out electrode.

[0013] Optionally, the lead-out electrode includes a first lead-out electrode and a second lead-out electrode, the outer electrode includes a first outer electrode and a second outer electrode, the first lead-out electrode includes a first lead-out conductive member and a third conductive column, one end of the first lead-out conductive member is connected to the first outer electrode, the other end of the first lead-out conductive member is connected to the third conductive column, and the third conductive column is connected to the electrical input end of the intermediate inner electrode. The second lead-out electrode includes a second lead-out conductive member, one end of the second lead-out conductive member is connected to the second outer electrode, and the other end of the second lead-out conductive member is connected to the electrical output end of the intermediate inner electrode.

[0014] Optionally, the lead-out electrode includes a lead-out conductive member, the lead-out conductive member includes a first end and a second end, the first end is electrically connected to the outer electrode, and the second end is electrically connected to one of the electrical input end and the electrical output end of the intermediate inner electrode.

[0015] Optionally, the first end includes a first surface, the first surface is in contact with the outer electrode, the connecting direction of the first end and the second end is the first direction, the first surface extends along the second direction, and the second direction is perpendicular to the first direction.

[0016] Optionally, the first end includes a second surface and a third surface, both the second surface and the third surface are in contact with the outer electrode, the second surface and the third surface are oppositely arranged with respect to the connection line of the first end and the second end, the connecting direction of the first end and the second end is the first direction, and both the second surface and the third surface extend along the first direction.

[0017] Optionally, the first inner electrode further includes a first substrate, a spiral first groove is provided on the first substrate, the first conductive member is embedded in the first groove, the second inner electrode further includes a second substrate, a spiral second groove is provided on the second substrate, and the second conductive member is embedded in the second groove.

[0018] The second object of the present invention is to provide a method for manufacturing a stacked inductor, which can not only improve the inductance strength of the stacked inductor, but also reduce the production cost of the stacked inductor.

[0019] To achieve this purpose, the present invention adopts the following technical solutions:

[0020] A method for preparing a stacked inductor, comprising:

[0021] 1) Fabricating a first internal electrode: Printing a spiral first conductive member on a first substrate, and printing a first conductive column at the outer end of the first conductive member;

[0022] Fabricating a second internal electrode: Printing a spiral second conductive member on a second substrate, the spiral direction of the second conductive member being opposite to that of the first conductive member, and printing a second conductive column at the inner end of the second conductive member;

[0023] Fabricating a first lead electrode: Printing a first lead conductive member on a third substrate, and printing a third conductive column at one end of the first lead conductive member;

[0024] Fabricating a second lead electrode: Printing a second lead conductive member on a fourth substrate;

[0025] 2) Glue spraying: Spraying an adhesive on the first internal electrode, the second internal electrode, the first lead electrode, and the second lead electrode, and drying the first internal electrode, the second internal electrode, the first lead electrode, and the second lead electrode to cure the paste printed on the first internal electrode, the second internal electrode, the first lead electrode, and the second lead electrode;

[0026] 3) Laminating: Stacking at least one first internal electrode and at least one second internal electrode alternately to form an intermediate internal electrode, and stacking a first lead electrode and a second lead electrode on the starting end and the ending end of the intermediate internal electrode respectively to form a stacked component. Along the stacking direction, the first conductive column of a first internal electrode is connected to the outer end of the next second conductive member, the second conductive column of a second internal electrode is connected to the inner end of the next first conductive member, the third conductive column is connected to the electrical input end of the intermediate internal electrode, one end of the second lead conductive member is connected to the electrical output end of the intermediate internal electrode, and the other end of the first lead conductive member and the other end of the second lead conductive member extend in a direction away from each other;

[0027] 4) Pressing: Pressing the stacked component to form a laminated component;

[0028] 5) Cutting: Cutting the laminated component to form a plurality of stacked inductor bodies, exposing the other end of the first lead conductive member and the other end of the second lead conductive member on each stacked inductor body, and the other end of the first lead conductive member and the other end of the second lead conductive member are respectively located on opposite sides of the stacked inductor body;

[0029] 6) Debinding and sintering: Heating the stacked inductor body, keeping the heated stacked inductor body warm to complete debinding, and performing sintering after debinding to completely cure the stacked inductor body;

[0030] 7) Electroplating the outer electrodes: On one side of the laminated inductor body where the first lead conductive member is exposed, metal is electroplated to form the first outer electrode, making the first outer electrode contact the other end of the first lead conductive member. On the side of the laminated inductor body where the second lead conductive member is exposed, metal is electroplated to form the second outer electrode, making the second outer electrode contact the other end of the second lead conductive member.

[0031] Beneficial effects:

[0032] For the laminated inductor provided by the present invention, both the first conductive member and the second conductive member are spiral, thereby increasing the number of turns of the first conductive member and the number of turns of the second conductive member, and further increasing the inductance intensity of the first inner electrode and the inductance intensity of the second inner electrode. On the premise that the height dimension of the laminated inductor is limited, that is, on the premise that the number of the first inner electrodes and the number of the second inner electrodes are both limited, the overall inductance intensity of the laminated inductor can be greatly improved.

[0033] For the preparation method of the laminated inductor provided by the present invention, the first inner electrode, the second inner electrode, the first lead electrode and the second lead electrode are respectively manufactured, such that the spiral directions of the first conductive member and the second conductive member are opposite. At least one first inner electrode and at least one second inner electrode are alternately laminated to form an intermediate inner electrode, and a first lead electrode and a second lead electrode are respectively laminated at the starting end and the ending end of the intermediate electrode. Along the lamination direction, the first conductive column of a first inner electrode is connected to the outer end of the next second conductive member, the second conductive column of a second inner electrode is connected to the inner end of the next first conductive member, the third conductive column of the first lead electrode is connected to the input end of the core of the intermediate inner electrode, and the second conductive member of the second lead electrode is connected to the electrical output end of the intermediate inner electrode. This preparation method increases the number of turns of each first conductive member and the number of turns of each second conductive member, and further increases the inductance intensity of each first inner electrode and the inductance intensity of each second inner electrode, and finally can greatly improve the overall inductance intensity of the laminated inductor. In addition, when preparing the intermediate inner electrode, only two electrode patterns with opposite spiral directions need to be printed, so that the overall spiral direction of the laminated intermediate inner electrode is consistent, and finally it is ensured that the overall current spiral direction of the laminated inductor is consistent, effectively reducing the number of screen plates used when preparing the intermediate inner electrode, and having the effect of greatly reducing the production cost. Description of the drawings

[0034] Figure 1 is a schematic exploded sectional structure view of the laminated inductor body provided by the embodiment of the present invention;

[0035] Figure 2 is a schematic structure view of the laminated inductor body (the first substrate, the second substrate, the third substrate and the fourth substrate are not shown) provided by the embodiment of the present invention;

[0036] Figure 3 It is an exploded schematic view of the stacked inductor body (the first substrate, the second substrate, the third substrate, and the fourth substrate are not shown) provided by an embodiment of the present invention;

[0037] Figure 4 It is a schematic view of the stacked inductor (the first substrate, the second substrate, the third substrate, and the fourth substrate are not shown) provided by an embodiment of the present invention;

[0038] Figure 5 It is an exploded schematic view of the stacked inductor (the first substrate, the second substrate, the third substrate, and the fourth substrate are not shown) provided by an embodiment of the present invention;

[0039] Figure 6 It is a schematic view of the second lead conductive member provided by an embodiment of the present invention;

[0040] Figure 7 It is an inductance performance curve graph of the stacked inductor provided by an embodiment of the present invention.

[0041] In the figure:

[0042] 100, the first inner electrode; 110, the first conductive member; 120, the first conductive column; 130, the first substrate; 200, the second inner electrode; 210, the second conductive member; 220, the second conductive column; 230, the second substrate; 310, the first lead electrode; 311, the first lead conductive member; 312, the third conductive column; 313, the third substrate; 320, the second lead electrode; 321, the second lead conductive member; 322, the fourth substrate; 330, the first end; 331, the first surface; 332, the second surface; 333, the third surface; 340, the second end; 410, the first outer electrode; 420, the second outer electrode; 500, the fifth substrate; 600, the intermediate inner electrode. Detailed implementation manners

[0043] The present invention will be further described in detail below with reference to the drawings and embodiments. It can be understood that the specific embodiments described herein are only used to explain the present invention, rather than limiting the present invention. In addition, it should be noted that for the convenience of description, only parts related to the present invention are shown in the drawings, rather than all the structures.

[0044] In the description of the present invention, unless otherwise clearly defined and limited, the terms "connected", "connected to", and "fixed" shall be understood in a broad sense. For example, it may be a fixed connection, a detachable connection, or integrated; it may be a mechanical connection or an electrical connection; it may be directly connected or indirectly connected through an intermediate medium, and it may be the communication inside two components or the interaction relationship between two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention may be understood according to specific circumstances.

[0045] In the present invention, unless otherwise clearly defined and limited, the first feature being "above" or "below" the second feature may include the direct contact between the first and second features, or may include the situation where the first and second features are not in direct contact but in contact through other features between them. Moreover, the first feature being "above", "over", and "on top of" the second feature includes that the first feature is directly above and obliquely above the second feature, or merely means that the horizontal height of the first feature is higher than that of the second feature. The first feature being "below", "beneath", and "underneath" the second feature includes that the first feature is directly below and obliquely below the second feature, or merely means that the horizontal height of the first feature is lower than that of the second feature.

[0046] In the description of this embodiment, the orientation or positional relationships such as "above", "below", "right", etc. are based on the orientation or positional relationship shown in the drawings, and are only for the convenience of description and simplifying the operation, rather than indicating or implying that the device or component referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation to the present invention. In addition, the terms "first" and "second" are only used for distinction in description and have no special meaning.

[0047] This embodiment provides a stacked inductor, and the overall inductance intensity of the stacked inductor is relatively high.

[0048] Specifically, as Figures 1 to 3 shown, the stacked inductor includes at least one first internal electrode 100 and at least one second internal electrode 200. Among them, the first internal electrode 100 includes a first conductive member 110, the first conductive member 110 is spiral, the second internal electrode 200 includes a second conductive member 210, the second conductive member 210 is spiral, at least one first internal electrode 100 and at least one second internal electrode 200 are stacked, and at least one first conductive member 110 and at least one second conductive member 210 are connected in series.

[0049] Based on the above design, both the first conductive member 110 and the second conductive member 210 are spiral, thereby increasing the number of turns of the first conductive member 110 and the number of turns of the second conductive member 210, and further increasing the inductance intensity of the first inner electrode 100 and the inductance intensity of the second inner electrode 200. On the premise that the height dimension of the stacked inductor is limited, that is, on the premise that the number of the first inner electrodes 100 and the number of the second inner electrodes 200 are both limited, the inductance intensity of the overall stacked inductor can be greatly increased.

[0050] It should be noted that the number of turns of the spiral first conductive member 110 and the spiral second conductive member 210 can be determined according to the inductance intensity requirements, and no specific limitation is made here. In addition, as Figures 1 to 3 shown, both the first conductive member 110 and the second conductive member 210 in this embodiment are elliptical spiral structures. Of course, in other embodiments, the first conductive member 110 and the second conductive member 210 can also be circular spiral structures or square spiral structures, etc., which can be determined according to the actual production application situation.

[0051] In the prior art, after laminating multiple inner electrodes, in order to maintain the consistency of the overall current direction of the stacked inductor, electrode patterns of different shapes need to be printed on the multiple inner electrodes respectively. After the electrode patterns are cured, conductive members are formed, and the shapes of the conductive members on the multiple inner electrodes are different. After laminating the multiple inner electrodes, along the lamination direction, the multiple conductive members are connected in series in turn to form a stacked inductor with a consistent current direction. It can be seen that the stacked inductor in the prior art needs to use multiple different types of screen printing to print multiple electrode patterns of different shapes. In order to increase the inductance intensity of the stacked inductor, often a dozen or more layers of inner electrodes are required, and the types of screen printing corresponding to each layer of inner electrodes are different, which greatly increases the production cost of the stacked inductor.

[0052] To solve the above technical problems, as Figures 1 to 3As shown, in the stacked inductor provided in this embodiment, at least one first inner electrode 100 and at least one second inner electrode 200 are stacked alternately. The spiral direction of the first conductive member 110 is opposite to the spiral direction of the second conductive member 210. The inner end of the first conductive member 110 is the electrical input end of the first conductive member 110, and the outer end of the first conductive member 110 is the electrical output end of the first conductive member 110. The outer end of the second conductive member 210 is the electrical input end of the second conductive member 210, and the inner end of the second conductive member 210 is the electrical output end of the second conductive member 210. It can be seen that this structural arrangement only requires two first conductive members 110 and second conductive members 210 with opposite spiral directions. Regardless of the number of the first conductive members 110 and the second conductive members 210 respectively, when printing the patterns of the first conductive member 110 and the second conductive member 210, only two stencils with opposite spiral shapes are needed; when stacking the first inner electrode 100 and the second inner electrode 200, at least one first inner electrode 100 and at least one second inner electrode 200 are stacked alternately to form an intermediate inner electrode 600. Along the stacking direction, the outer end of one first conductive member 110 is connected in series with the outer end of the next second conductive member 210, and the inner end of one second conductive member 210 is connected in series with the inner end of the next first conductive member 110. That is to say, the inner end of the first conductive member 110 is used as the electrical input end of the first conductive member 110, the outer end of the first conductive member 110 is used as the electrical output end of the first conductive member 110, the outer end of the second conductive member 210 is used as the electrical input end of the second conductive member 210, and the inner end of the second conductive member 210 is used as the electrical output end of the second conductive member 210. In this way, the overall current direction of the intermediate inner electrode 600 can be made consistent (that is, the current directions of the intermediate inner electrode 600 are all in the same spiral direction), and further the overall current direction of the stacked inductor can be made consistent (that is, the current directions of the entire stacked inductor are all in the same spiral direction). This structural arrangement effectively reduces the number of stencils used to manufacture the stacked inductor, and the number of stencils is not limited by the number of the first inner electrodes 100 and the second inner electrodes 200, which has the effect of reducing production costs. Especially when the number of the first inner electrodes 100 and the second inner electrodes 200 is large, the cost reduction due to the reduction in the number of stencils is particularly significant.

[0053] Exemplarily, as Figures 1 to 3As shown in the figure, there are two first conductive members 110 and two second conductive members 210 in this embodiment. After the two first conductive members 110 and the two second conductive members 210 are stacked in an interleaved manner and the adjacent first conductive member 110 and second conductive member 210 are connected in series in the above manner, the overall current direction of the stacked inductor is in a counterclockwise spiral direction. Of course, in other implementation schemes, the number of the first conductive members 110 can also be one, three, four, etc., and the number of the second conductive members 210 can also be one, three, four, etc. The number of the first conductive members 110 and the second conductive members 210 can be the same or different, which can be determined according to the actual production and application conditions, and will not be listed one by one here.

[0054] Further, as Figures 1 to 3 shown, the first inner electrode 100 further includes a first conductive post 120, the first conductive post 120 is connected to the outer end of the first conductive member 110, the second inner electrode 200 further includes a second conductive post 220, the second conductive post 220 is connected to the inner end of the second conductive member 210, along the stacking direction of at least one first inner electrode 100 and at least one second inner electrode 200, the first conductive post 120 of one first inner electrode 100 is connected to the outer end of the next second conductive member 210 to realize the series connection between this first conductive member 110 and the next second conductive member 210, and the second conductive post 220 of one second inner electrode 200 is connected to the inner end of the next first conductive member 110 to realize the series connection between this second conductive member 210 and the next first conductive member 110.

[0055] Optionally, as Figures 1 to 3 shown, the first inner electrode 100 further includes a first substrate 130, a spiral first groove is provided on the first substrate 130, the first conductive member 110 is embedded in the first groove, the second inner electrode 200 further includes a second substrate 230, a spiral second groove is provided on the second substrate 230, the spiral direction of the second groove is opposite to that of the first groove, and the second conductive member 210 is embedded in the second groove. Compared with the structure of directly printing the first conductive member 110 on the surface of the first substrate 130 and directly printing the second conductive member 210 on the surface of the second substrate 230, the structure provided in this embodiment of embedding the first conductive member 110 in the first groove of the first substrate 130 and embedding the second conductive member 210 in the second groove of the second substrate 230 is beneficial to reducing the thickness of the first inner electrode 100 and reducing the thickness of the second inner electrode 200, and finally achieving the effect of reducing the overall thickness of the stacked inductor. When the overall thickness dimension of the stacked inductor is a fixed value, this structural setting can increase the number of the first inner electrode 100 and / or the second inner electrode 200. That is to say, this structural setting improves the upper limit of the number of the first inner electrode 100 and / or the second inner electrode 200, and achieves the effect of improving the overall inductance strength of the stacked inductor.

[0056] On the other hand, when at least one first inner electrode 100 and at least one second inner electrode 200 are laminated, since the first conductive member 110 is embedded in the first groove and the second conductive member 210 is embedded in the second groove, the problems of deformation and being crushed of the first conductive member 110 and the second conductive member 210 can be avoided. After lamination, the first conductive member 110 and the second conductive member 210 can still maintain the shapes before lamination, so that the stacked inductors produced in the same batch can ensure consistent dimensional parameters and improve the overall performance of the stacked inductors.

[0057] Furthermore, a first through hole is provided at the bottom of the first groove. The first through hole is located at the outer end of the spiral first groove. The first conductive post 120 is embedded in the first through hole. A second through hole is provided at the bottom of the second groove. The second through hole is located at the inner end of the spiral second groove. The second conductive post 220 is embedded in the second through hole, so that the first conductive post 120 can be connected to the outer end of the next second conductive member 210, and the second conductive post 220 can be connected to the inner end of the next first conductive member 110.

[0058] Optionally, as Figures 1 to 5 shown, the stacked inductor further includes a lead-out electrode and an outer electrode. At least one first inner electrode 100 and at least one second inner electrode 200 are laminated to form an intermediate inner electrode 600. The intermediate inner electrode 600 is electrically connected to the outer electrode through the lead-out electrode.

[0059] Furthermore, as Figures 1 to 6 shown, the lead-out electrode includes a lead-out conductive member. The lead-out conductive member includes a first end 330 and a second end 340 which are oppositely arranged. The first end 330 is electrically connected to the outer electrode. The second end 340 is electrically connected to one of the electrical input end and the electrical output end of the intermediate inner electrode 600.

[0060] In the prior art, only one surface of the end (i.e., the first end 330) of the lead conductive member facing away from the middle inner electrode 600 is in contact with the outer electrode. This results in the need for a high cutting accuracy in the cutting process (cutting a plurality of integrated stacked inductor bodies into a plurality of separate stacked inductor bodies) to ensure that the one surface where the first end 330 is in contact with the outer electrode is exposed, so that the outer electrode can be electroplated at the position of the above one surface. It can be seen that the structural design of the prior art has a low tolerance for the cutting process; alternatively, in order to enable the first end 330 of the lead conductive member to have a plurality of surfaces in contact with the outer electrode, the prior art usually uses multiple screen printing for multiple lead electrodes, and then stacks the multiple lead electrodes to form a lead electrode assembly, so that the lead electrode assembly has a plurality of surfaces in contact with the outer electrode. This structural setting increases the number of screens on the one hand, thereby increasing the production cost, and increases the thickness of the stacked inductor on the other hand, thereby reducing the upper limit of the number of layers of the middle inner electrode 600.

[0061] To address the above technical problems, as Figures 1 to 6 shown, in this embodiment, the first end 330 of the lead conductive member includes a second surface 332 and a third surface 333. Both the second surface 332 and the third surface 333 are in contact with the outer electrode. The second surface 332 and the third surface 333 are oppositely arranged with respect to the connection line between the first end 330 and the second end 340. The connection direction of the first end 330 and the second end 340 is the first direction ( Figure 6 the D1 direction in Figure 6 ). Both the second surface 332 and the third surface 333 extend along the first direction. This structural setting enables, in the cutting process, even if the actual cutting line has an angle with the second direction ( Figure 6 the D2 direction in Figure 6 ), that is, there is a problem of cutting skew, the second surface 332 and the third surface 333 can still be exposed, so that the outer electrode can be electroplated at the positions of the exposed second surface 332 and the third surface 333. It can be seen that this structural setting improves the tolerance of the cutting process, thereby reducing the cutting difficulty, and has the effects of improving production efficiency and reducing production cost; moreover, this structural setting does not require using multiple screens to print lead conductive members with multiple different patterns, nor does it require stacking multiple lead electrodes. Only one screen is used to print one kind of lead conductive member, which can not only improve production efficiency, reduce production cost, but also reduce the thickness of the stacked inductor, thereby increasing the upper limit of the number of layers of the middle inner electrode 600.

[0062] Optionally, as Figures 1 to 6 shown, the first end 330 includes a first surface 331. The first surface 331 is in contact with the outer electrode. The connection direction of the first end 330 and the second end 340 is the first direction ( Figure 6 the D1 direction in Figure 6 ). The first surface 331 extends along the second direction ( Figure 6extends in the D2 direction in []. The second direction is perpendicular to the first direction. In the cutting process, even if there is an angle between the actual cutting line and the second direction (i.e., the cutting is skewed), since the first surface 331 extends in the second direction, part of the first surface 331 can still be exposed. Furthermore, an external electrode can be electroplated on the exposed first surface 331. It can be seen that this structural setting improves the fault tolerance of the cutting process, and only one stencil is used to print one kind of lead conductive part, which has the effects of improving production efficiency, reducing production costs, reducing the thickness of the stacked inductor, and increasing the upper limit of the number of layers of the intermediate internal electrode 600.

[0063] Preferably, as Figures 1 to 6 shown, the second surface 332, the first surface 331, and the third surface 333 are connected in sequence. That is to say, the first end 330 of the lead conductive part is generally in a square structure, and three surfaces of the first end 330 are in contact with the same external electrode, which has the effect of further improving the fault tolerance of the cutting process, and only one stencil is used to print the lead conductive part.

[0064] Optionally, as Figures 1 to 6 shown, the lead electrode includes a first lead electrode 310 and a second lead electrode 320, the external electrode includes a first external electrode 410 and a second external electrode 420. The first lead electrode 310 includes a first lead conductive part 311 and a third conductive column 312. The first end 330 of the first lead conductive part 311 is connected to the first external electrode 410, the second end 340 of the first lead conductive part 311 is connected to the third conductive column 312, and the third conductive column 312 is connected to the electrical input end of the intermediate internal electrode 600. The second lead electrode 320 includes a second lead conductive part 321. The first end 330 of the second lead conductive part 321 is connected to the second external electrode 420, and the second end 340 of the second lead conductive part 321 is connected to the electrical output end of the intermediate internal electrode 600, thereby realizing the flow of current in the intermediate internal electrode 600.

[0065] It should be noted that the electrical input end and the electrical input end of the above-mentioned intermediate internal electrode 600 change with the change in the number of the first internal electrode 100 and the second internal electrode 200. At the same time, the electrical input end and the electrical input end of the intermediate internal electrode 600 also change with the change in the stacking order of the first internal electrode 100, the second internal electrode 200, the first lead electrode 310, and the second lead electrode 320.

[0066] Exemplarily, as Figures 1 to 6As shown, in this embodiment, the number of the first inner electrodes 100 and the second inner electrodes 200 is two each. The two first inner electrodes 100 and the two second inner electrodes 200 are stacked alternately. The top and bottom of the middle inner electrode 600 are the first inner electrode 100 and the second inner electrode 200 respectively. The first lead electrode 310 is located at the top of the middle inner electrode 600, and the second lead electrode 320 is located at the bottom of the middle inner electrode 600. Therefore, the inner end of the first inner electrode 100 located at the top of the middle inner electrode 600 is the electrical input end of the middle inner electrode 600, and the inner end of the second inner electrode 200 located at the bottom of the middle inner electrode 600 is the electrical output end of the middle inner electrode 600.

[0067] In one embodiment, the first lead electrode 310 is located at the bottom of the middle inner electrode 600, and the second lead electrode 320 is located at the top of the middle inner electrode 600. Then, the outer end of the second inner electrode 200 located at the bottom of the middle inner electrode 600 is the electrical input end of the middle inner electrode 600, and the outer end of the first inner electrode 100 located at the top of the middle inner electrode 600 is the electrical output end of the middle inner electrode 600.

[0068] In another embodiment, the number of the first inner electrodes 100 is two, and the number of the second inner electrodes 200 is one. The two first inner electrodes 100 and the one second inner electrode 200 are stacked alternately. The top and bottom of the middle inner electrode 600 are both the first inner electrodes 100. Then, the inner end of one of the two first inner electrodes 100 is the electrical input end of the middle inner electrode 600, and the outer end of the other of the two first inner electrodes 100 is the electrical output end of the middle inner electrode 600.

[0069] In yet another embodiment, the number of the first inner electrodes 100 is one, and the number of the second inner electrodes 200 is two. The one first inner electrode 100 and the two second inner electrodes 200 are stacked alternately. The top and bottom of the middle inner electrode 600 are both the second inner electrodes 200. Then, the outer end of one of the two second inner electrodes 200 is the electrical input end of the middle inner electrode 600, and the inner end of the other of the two second inner electrodes 200 is the electrical output end of the middle inner electrode 600.

[0070] Other numbers of the first inner electrodes 100 and other numbers of the second inner electrodes 200 are not listed one by one here. Other stacking orders of the first inner electrode 100, the second inner electrode 200, the first lead electrode 310, and the second lead electrode 320 are not listed one by one here.

[0071] Optionally, as Figures 1 to 6As shown, the first lead-out electrode 310 further includes a third substrate 313. A third groove is provided on the third substrate 313. One end of the third groove is a square groove, and a third through-hole is provided at the bottom of the other end. The first lead-out conductive member 311 is embedded in the third groove, and the third conductive column 312 is embedded in the third through-hole. The second lead-out electrode 320 further includes a fourth substrate 322. A fourth groove is provided on the fourth substrate 322. One end of the fourth groove is a square groove, and the second lead-out conductive member 321 is embedded in the fourth groove. This structural design is beneficial to reducing the thickness of the first lead-out electrode 310 and the second lead-out electrode 320, and finally achieving the effect of reducing the overall thickness of the stacked inductor. When the overall thickness dimension of the stacked inductor is a fixed value, this structural setting can increase the upper limit of the number of intermediate internal electrodes 600, achieving the effect of increasing the overall inductance strength of the stacked inductor. In addition, this structural setting can also avoid the problems that the first lead-out conductive member 311 and the second lead-out conductive member 321 are damaged or deformed during the lamination process, improving the overall performance of the stacked inductor.

[0072] This embodiment also provides a method for manufacturing a stacked inductor, which can not only increase the inductance strength of the stacked inductor, but also reduce the production cost of the stacked inductor.

[0073] Specifically, please refer to Figures 1 to 6 , and the method for manufacturing the stacked inductor includes:

[0074] 1) Manufacturing the first internal electrode 100: Printing a spiral first conductive member 110 on the first substrate 130, and printing a first conductive column 120 at the outer end of the first conductive member 110;

[0075] Manufacturing the second internal electrode 200: Printing a spiral second conductive member 210 on the second substrate 230. The spiral direction of the second conductive member 210 is opposite to that of the first conductive member 110, and printing a second conductive column 220 at the inner end of the second conductive member 210;

[0076] Manufacturing the first lead-out electrode 310: Printing a first lead-out conductive member 311 on the third substrate 313, and printing a third conductive column 312 at the second end 340 of the first lead-out conductive member 311;

[0077] Manufacturing the second lead-out electrode 320: Printing a second lead-out conductive member 321 on the fourth substrate 322;

[0078] 2) Glue spraying: Spraying the adhesive diluent on the first internal electrode 100, the second internal electrode 200, the first lead-out electrode 310, and the second lead-out electrode 320, and drying the first internal electrode 100, the second internal electrode 200, the first lead-out electrode 310, and the second lead-out electrode 320 to cure the slurry printed on them;

[0079] 3) Lamination: At least one first internal electrode 100 and at least one second internal electrode 200 are alternately laminated to form an intermediate internal electrode 600, and a first lead electrode 310 and a second lead electrode 320 are respectively laminated at the starting end and the ending end of the intermediate internal electrode 600 to form a laminated component. Along the lamination direction, the first conductive column 120 of one first internal electrode 100 is connected to the outer end of the next second conductive member 210, the second conductive column 220 of one second internal electrode 200 is connected to the inner end of the next first conductive member 110, the third conductive column 312 is connected to the electrical input end of the intermediate internal electrode 600 (in this embodiment, the third conductive column 312 is connected to the inner end of the first conductive member 110 at the top of the intermediate internal electrode 600), the second end 340 of the second lead conductive member 321 is connected to the electrical output end of the intermediate internal electrode 600 (in this embodiment, the second end 340 of the second lead conductive member 321 is connected to the inner end of the second conductive member 210 at the bottom of the intermediate internal electrode 600), and the first end 330 of the first lead conductive member 311 and the first end 330 of the second lead conductive member 321 extend in a direction away from each other;

[0080] 4) Pressing: Press the laminated component to form a laminated product;

[0081] 5) Cutting: Cut the laminated product (cut around the periphery of the intermediate internal electrode 600) to form a plurality of laminated inductor bodies, so that the first end 330 of the first lead conductive member 311 and the first end 330 of the second lead conductive member 321 are exposed on each laminated inductor body, and the first end 330 of the first lead conductive member 311 and the first end 330 of the second lead conductive member 321 are respectively located on opposite sides of the laminated inductor body;

[0082] 6) Debinding and sintering: Heat the laminated inductor body, keep the heated laminated inductor body warm to complete debinding, and perform sintering after debinding to completely solidify the laminated inductor body;

[0083] 7) Electroplating external electrodes: Electroplate metal on opposite sides of the laminated inductor body to form a first external electrode 410 and a second external electrode 420. Among them, at least one of the first surface 331, the second surface 332, and the third surface 333 of the first lead conductive member 311 is in contact with the first external electrode 410, and at least one of the first surface 331, the second surface 332, and the third surface 333 of the second lead conductive member 321 is in contact with the second external electrode 420.

[0084] Based on the above design, the preparation method of the stacked inductor respectively manufactures the first inner electrode 100, the second inner electrode 200, the first lead electrode 310 and the second lead electrode 320, such that the spiral directions of the first conductive member 110 and the second conductive member 210 are opposite. At least one first inner electrode 100 and at least one second inner electrode 200 are alternately stacked to form an intermediate inner electrode 600, and a first lead electrode 310 and a second lead electrode 320 are respectively stacked at the starting end and the ending end of the intermediate electrode. Along the stacking direction, the first conductive column 120 of a first inner electrode 100 is connected to the outer end of the next second conductive member 210, and the second conductive column 220 of a second inner electrode 200 is connected to the inner end of the next first conductive member 110. The third conductive column 312 of the first lead electrode 310 is connected to the core input end of the intermediate inner electrode 600, and the second conductive member 210 of the second lead electrode 320 is connected to the electrical output end of the intermediate inner electrode 600. This preparation method increases the number of turns of each first conductive member 110 and each second conductive member 210, thereby increasing the inductance intensity of each first inner electrode 100 and each second inner electrode 200, and ultimately can greatly increase the overall inductance intensity of the stacked inductor. In addition, when manufacturing the intermediate inner electrode 600, only two electrode patterns with opposite spiral directions need to be printed, so that the overall spiral direction of the stacked intermediate inner electrode 600 is consistent, ultimately ensuring that the overall current spiral direction of the stacked inductor is consistent, effectively reducing the number of screen plates used when manufacturing the intermediate inner electrode 600, and having the effect of greatly reducing production costs.

[0085] Further, step 1) further includes:

[0086] When manufacturing the first inner electrode 100, a spiral first groove is formed on the first substrate 130 by means of laser etching or etching or the like. The depth of the first groove can be determined according to actual production and usage requirements. A first through hole is formed at the bottom of the first groove, and the first through hole is located at the outer end of the spiral first groove. A metal conductor is printed in the first groove and the first through hole by means of screen printing. After the metal conductor in the first groove is cured, it becomes the first conductive member 110, and after the metal conductor in the first through hole is cured, it becomes the first conductive column 120.

[0087] When manufacturing the second internal electrode 200, a spiral second groove is formed on the second substrate 230 by means of laser etching or etching, etc., and the spiral direction of the second groove is opposite to that of the first groove (for example, in this embodiment, the spiral direction of the first groove from the outer end to the inner end is clockwise, and the spiral direction of the second groove from the outer end to the inner end is counterclockwise). The depth of the second groove can be determined according to actual production and usage requirements. A second through hole is formed at the bottom of the second groove, and the second through hole is located at the inner end of the spiral second groove. A metal conductor is printed in the second groove and the second through hole by means of screen printing. After the metal conductor in the second groove is cured, it becomes the second conductive member 210, and after the metal conductor in the second through hole is cured, it becomes the second conductive post 220.

[0088] When manufacturing the first lead electrode 310, a third groove extending in the first direction is formed on the third substrate 313 by means of laser etching or etching, etc. The depth of the third groove can be determined according to actual production and usage requirements. A square groove is formed at one end of the third groove (i.e., the first end 330 of the first lead conductive member 311) to communicate the third groove with the square groove. A third through hole is formed at the bottom of the third groove and at the other end of the third groove (i.e., the second end 340 of the first lead conductive member 311). A metal conductor is printed in the third groove and the third through hole by means of screen printing. After the metal conductor in the third groove is cured, it becomes the first lead conductive member 311, and after the metal conductor in the third through hole is cured, it becomes the third conductive post 312.

[0089] When manufacturing the second lead electrode 320, a fourth groove extending in the first direction is formed on the fourth substrate 322 by means of laser etching or etching, etc. The depth of the fourth groove can be determined according to actual production and usage requirements. A square groove is formed at one end of the fourth groove (i.e., the first end 330 of the second lead conductive member 321) to communicate the fourth groove with the square groove. A metal conductor is printed in the fourth groove by means of screen printing. After the metal conductor in the fourth groove is cured, it becomes the second lead conductive member 321.

[0090] The above method of forming a groove on the substrate and printing a metal conductor in the groove can make the cured conductive member embedded in the groove. On the one hand, it can reduce the thickness of the first internal electrode 100, the second internal electrode 200, the first lead electrode 310, and the second lead electrode 320, achieving the effect of reducing the overall thickness of the stacked inductance and increasing the upper limit of the number of layers of the intermediate internal electrode 600. On the other hand, it can also avoid the problems of the conductive member being damaged and deformed during the stacking process, providing a strong guarantee for the overall performance of the stacked inductance.

[0091] Preferably, the printed metal conductor is preferably silver paste.

[0092] It should be noted that although a third through hole needs to be opened at the bottom of the third groove when manufacturing the first lead electrode 310, and no through hole needs to be opened when manufacturing the second lead electrode 320, the shapes of the third groove and the fourth groove are the same. Therefore, the electrode patterns printed in the third groove and the fourth groove are the same. That is to say, when manufacturing the first lead electrode 310 and the second lead electrode 320, only one stencil can be used. It can be seen that for the structure and preparation method of the stacked inductor provided in this embodiment, only three stencils are required to prepare a stacked inductor with multiple layers. That is to say, a stacked inductor with a high inductance value can be prepared only by using three stencils, which greatly reduces the stencil cost and has extremely high repeatability for mass production, further reducing the production cost.

[0093] Optionally, the above-mentioned stacked component further includes a fifth substrate 500, and the above step 3) further includes: after stacking the first lead electrode 310, the intermediate internal electrode 600, and the second lead electrode 320, stack a fifth substrate 500 above the first lead electrode 310.

[0094] Optionally, the above-mentioned first substrate 130, second substrate 230, third substrate 313, fourth substrate 322, and fifth substrate 500 are all made of ferrite diaphragms.

[0095] Optionally, in the above step 4), the pressing environment is: carried out under warm water isostatic pressing, where the pressure of isostatic pressing is 10 MPa - 50 MPa, and the temperature of isostatic pressing is 60 °C - 90 °C.

[0096] Optionally, in the above step 6), the sintering temperature is 800 °C - 950 °C, and the holding time is 0.5 h - 2.5 h.

[0097] Optionally, in the above step 7), before electroplating the metal, first chamfer the sintered stacked inductor body, and then electroplate the outer electrode. When electroplating the outer electrode, silver is applied to the first surface 331, second surface 332, and third surface 333 of the first lead conductive member 311, and then the first outer electrode 410 is electroplated. For example, nickel and solder are electroplated in sequence, so that the first lead conductive member 311 is connected to the first outer electrode 410, and the first outer electrode 410 made by this method has good solderability and solder resistance; similarly, silver is applied to the first surface 331, second surface 332, and third surface 333 of the second lead conductive member 321, and then the second outer electrode 420 is electroplated. For example, nickel and solder are electroplated in sequence, so that the second lead conductive member 321 is connected to the second outer electrode 420, and the second outer electrode 420 made by this method has good solderability and solder resistance.

[0098] Figure 7It is the inductance performance parameter table of the stacked inductor provided in this embodiment. Among them, the dotted line is the inductance value L, and the solid line is the quality factor Q. It can be seen from this inductance performance parameter table that the inductance value of the stacked inductor provided in this embodiment is much higher than that of the common stacked inductors in the art.

[0099] Specifically, Figure 7 The specific parameters of the shown stacked inductor are as follows:

[0100] The stacked inductor includes a total of seven layers of diaphragms, namely two first inner electrodes 100, two second inner electrodes 200, a first lead electrode 310, a second lead electrode 320, and a fifth substrate 500. The size of the stacked inductor is 1.6 mm × 0.8 mm × 0.8 mm (length × width × height). The width of the first conductive member 110 (i.e., the width of the first groove) and the width of the second conductive member 210 (i.e., the width of the second groove) are both 50 μm, and the thickness of the first conductive member 110 (i.e., the depth of the first groove) and the thickness of the second conductive member 210 (i.e., the depth of the second groove) are both 20 μm.

[0101] When the frequency of this stacked inductor is 1 MHz, its inductance value L is 8.984 microhenries, and its quality factor Q is 10.8. In the prior art, for stacked inductors with the same material and the same size, the inductance value L at 1 MHz is usually in the order of nanohenries. The inductance value L of the stacked inductor provided in this embodiment has reached the order of microhenries. Thus, it can be seen that the stacked inductor provided in this embodiment has a higher inductance intensity.

[0102] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, rather than limitations on the implementation manners of the present invention. For those of ordinary skill in the art, various obvious changes, re-adjustments, and substitutions can be made without departing from the protection scope of the present invention. It is not necessary and impossible to enumerate all the implementation manners here. Any modifications, equivalent substitutions, and improvements made within the spirit and principle of the present invention shall be included within the protection scope of the claims of the present invention.

Claims

1. Stacked inductor, characterized in that, it includes: at least one first internal electrode (100), the first internal electrode (100) includes a first conductive member (110), and the first conductive member (110) is spiral; at least one second internal electrode (200), the second internal electrode (200) includes a second conductive member (210), the second conductive member (210) is spiral, at least one of the first internal electrodes (100) and at least one of the second internal electrodes (200) are stacked, and at least one of the first conductive members (110) and at least one of the second conductive members (210) are connected in series.

2. The stacked inductor according to claim 1, characterized in that, at least one of the first internal electrodes (100) and at least one of the second internal electrodes (200) are staggeredly stacked, the spiral direction of the first conductive member (110) is opposite to the spiral direction of the second conductive member (210), the inner end of the first conductive member (110) is the electrical input end of the first conductive member (110), the outer end of the first conductive member (110) is the electrical output end of the first conductive member (110), the outer end of the second conductive member (210) is the electrical input end of the second conductive member (210), and the inner end of the second conductive member (210) is the electrical output end of the second conductive member (210).

3. The stacked inductor according to claim 2, characterized in that, the first internal electrode (100) further includes a first conductive post (120), the first conductive post (120) is connected to the outer end of the first conductive member (110), the second internal electrode (200) further includes a second conductive post (220), the second conductive post (220) is connected to the inner end of the second conductive member (210), along the stacking direction of at least one of the first internal electrodes (100) and at least one of the second internal electrodes (200), the first conductive post (120) of one of the first internal electrodes (100) is connected to the outer end of the next second conductive member (210), and the second conductive post (220) of one of the second internal electrodes (200) is connected to the inner end of the next first conductive member (110).

4. The stacked inductor according to any one of claims 1-3, characterized in that, the stacked inductor further includes a lead-out electrode and an outer electrode, at least one of the first internal electrodes (100) and at least one of the second internal electrodes (200) are stacked to form an intermediate internal electrode (600), and the intermediate internal electrode (600) is electrically connected to the outer electrode through the lead-out electrode.

5. The stacked inductor according to claim 4, characterized in that, The lead-out electrode includes a first lead-out electrode (310) and a second lead-out electrode (320), the outer electrode includes a first outer electrode (410) and a second outer electrode (420), the first lead-out electrode (310) includes a first lead-out conductive member (311) and a third conductive column (312), one end of the first lead-out conductive member (311) is connected to the first outer electrode (410), the other end of the first lead-out conductive member (311) is connected to the third conductive column (312), the third conductive column (312) is connected to the electrical input end of the intermediate inner electrode (600), the second lead-out electrode (320) includes a second lead-out conductive member (321), one end of the second lead-out conductive member (321) is connected to the second outer electrode (420), and the other end of the second lead-out conductive member (321) is connected to the electrical output end of the intermediate inner electrode (600).

6. The stacked inductor according to claim 4, wherein, the lead-out electrode includes a lead-out conductive member, the lead-out conductive member includes a first end (330) and a second end (340), the first end (330) is electrically connected to the outer electrode, and the second end (340) is electrically connected to one of the electrical input end of the intermediate inner electrode (600) and the electrical output end of the intermediate inner electrode (600).

7. The stacked inductor according to claim 6, wherein, the first end (330) includes a first surface (331), the first surface (331) is in contact with the outer electrode, the connecting direction of the first end (330) and the second end (340) is a first direction, the first surface (331) extends along a second direction, and the second direction is perpendicular to the first direction.

8. The stacked inductor according to claim 6, wherein, the first end (330) includes a second surface (332) and a third surface (333), both the second surface (332) and the third surface (333) are in contact with the outer electrode, the second surface (332) and the third surface (333) are oppositely arranged with respect to the connecting line of the first end (330) and the second end (340), the connecting direction of the first end (330) and the second end (340) is a first direction, and both the second surface (332) and the third surface (333) extend along the first direction.

9. The stacked inductor according to any one of claims 1-3, wherein, the first inner electrode (100) further includes a first substrate (130), a spiral first groove is provided on the first substrate (130), and the first conductive member (110) is embedded in the first groove. The second inner electrode (200) further includes a second substrate (230), a spiral second groove is provided on the second substrate (230), and the second conductive member (210) is embedded in the second groove.

10. A method for manufacturing a stacked inductor, wherein, comprising: 1) Fabricate the first internal electrode (100): Print a spiral first conductive member (110) on the first substrate (130), and print a first conductive post (120) at the outer end of the first conductive member (110); Fabricate the second internal electrode (200): Print a spiral second conductive member (210) on the second substrate (230), with the spiral direction of the second conductive member (210) opposite to that of the first conductive member (110), and print a second conductive post (220) at the inner end of the second conductive member (210); Fabricate the first lead electrode (310): Print a first lead conductive member (311) on the third substrate (313), and print a third conductive post (312) at one end of the first lead conductive member (311); Fabricate the second lead electrode (320): Print a second lead conductive member (321) on the fourth substrate (322); 2) Spray glue: Spray the adhesive on the first internal electrode (100), the second internal electrode (200), the first lead electrode (310), and the second lead electrode (320), and dry the first internal electrode (100), the second internal electrode (200), the first lead electrode (310), and the second lead electrode (320) to cure the paste printed on them; 3) Stacking: Stack at least one first internal electrode (100) and at least one second internal electrode (200) alternately to form an intermediate internal electrode (600), and stack a first lead electrode (310) and a second lead electrode (320) at the starting end and the ending end of the intermediate internal electrode (600) respectively to form a stacked component. Along the stacking direction, the first conductive post (120) of one first internal electrode (100) is connected to the outer end of the next second conductive member (210), the second conductive post (220) of one second internal electrode (200) is connected to the inner end of the next first conductive member (110), the third conductive post (312) is connected to the electrical input end of the intermediate internal electrode (600), one end of the second lead conductive member (321) is connected to the electrical output end of the intermediate internal electrode (600), and the other end of the first lead conductive member (311) and the other end of the second lead conductive member (321) extend in a direction away from each other; 4) Pressing: Press the stacked component to form a laminated component; 5) Cutting: Cut the laminated component to form a number of stacked inductor bodies, so that the other end of the first lead conductive member (311) and the other end of the second lead conductive member (321) are exposed on each stacked inductor body, and the other end of the first lead conductive member (311) and the other end of the second lead conductive member (321) are located on opposite sides of the stacked inductor body; 6) Debinding and sintering: Heat the stacked inductor body, keep the heated stacked inductor body warm to complete debinding, and perform sintering after debinding to completely cure the stacked inductor body; 7) Electroplating the outer electrodes: On the side of the stacked inductor body where the first lead conductive member (311) is exposed, electroplate metal to form the first outer electrode (410), so that the first outer electrode (410) contacts the other end of the first lead conductive member (311). On the side of the stacked inductor body where the second lead conductive member (321) is exposed, electroplate metal to form the second outer electrode (420), so that the second outer electrode (420) contacts the other end of the second lead conductive member (321).

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