Integrally-formed parallel inductor and preparation method thereof

Abstract

The invention relates to the technical field of electronic components, in particular to an integrally-formed parallel inductor, which comprises a magnetic core, an inductor core and an inductor core, the outer surfaces of the wires are coated with insulating layers, the conductors are arranged in the magnetic core, the middle portions of the conductors are lower than or higher than the two ends of the conductors, the conductors extend to the outside of the magnetic core, the conductors comprise the first wires and the second wires connected with the two ends of the first wires, the conductors are arranged in the magnetic core, and the insulating layers are arranged between the first wires and the second wires. The cross section of the conductor is round, square or polygonal, the insulating layer is beneficial to insulation of the surface of the conductor, the two ends of the first wire and the two ends of the second wire are connected, the middle parts are separated to form a parallel circuit, the resistance of the inductor is increased and reduced, the inductance value of the inductor is increased, and the performance of the inductor is improved. Miniaturization and precision of the inductor are facilitated, the thickness of the inductor is lower, and the use requirement is met.

Description

Technical Field

[0001] The present invention belongs to the technical field of electronic components, and particularly relates to an integrally formed parallel inductor and a preparation method thereof. Background Art

[0002] An inductor is one of the most common components in electronic devices and is also an important component in a circuit. It is widely used in various circuits and can achieve functions such as filtering, energy storage, matching, and resonance.

[0003] Generally speaking, common inductors mostly have a combined structure, which consists of three parts: a coil, a middle column of a magnetic core, and a housing. During the assembly process of such an inductor, the coil needs to be sleeved on the middle column of the magnetic core first, and then the middle column of the magnetic core is placed into the housing, and then each part is combined together by welding or bonding to finally complete the assembly of the inductor.

[0004] With the continuous development of computer communication technology in recent years, the update and iteration of various hardware devices have become increasingly frequent. Taking the manufacturing and processing of a whole server as an example, the requirements for the power inductors used therein have become more and more stringent, including high frequency, low DCR (direct current resistance), high current, low EMI (electromagnetic interference), high reliability, etc. Under the requirements such as the above, the various defects of existing inductors have gradually emerged.

[0005] Under the development trend of miniaturization and intensification of electronic devices, the excessive volume and high space occupancy rate severely restrict the overall layout of the circuit and affect the simplified design of the circuit.

[0006] Secondly, due to the trend of inductors towards miniaturization, and at the same time having the requirements of high current and high inductance value, existing inductor devices have a combined design and the overall structure is relatively complex, and the process requirements and precision requirements are more stringent.

[0007] Due to the above-mentioned defects in the existing technology, several improved production processes for high-current power inductors have emerged at present. However, there are still many problems such as high manufacturing difficulty, high production cost, and inconvenience for automated production in the actual application stage. Therefore, an integrally formed parallel inductor is needed to solve the above problems. Summary of the Invention

[0008] To solve the above technical problems, the present invention provides an integrally formed parallel inductor, aiming to provide a solution that simplifies the inductor structure, improves the inductor manufacturing efficiency, and reduces the production cost to solve the problems in the existing market as proposed in the above background art under the condition of meeting the requirements of high current and high inductance value.

[0009] To achieve the above object, the technical solution of the present invention is as follows:

[0010] An integrally formed parallel inductor, comprising:

[0011] A magnetic core, which is made by pressing soft magnetic powder;

[0012] A conductor, the outer surface of the wire is coated with an insulating layer, the conductor is arranged inside the magnetic core, the middle part of the conductor is lower or higher than the two ends of the conductor, the conductor extends outside the magnetic core, and the conductor includes a first wire and a second wire connected to both ends of the first wire.

[0013] Through the above technical solution, the conductor is arranged inside the magnetic core, the cross-section of the conductor is one of a circle, a square, and a polygon. The insulating layer is beneficial to insulate the surface of the conductor. The middle parts of the first wire and the second wire are separated while being connected at both ends to form a parallel circuit, which is beneficial to increasing or decreasing the resistance of the inductor, increasing the inductance value of the inductor, and improving the performance of the inductor. At the same time, since the conductor is an integral structure, it is convenient for the miniaturization and precision of the inductor, and also makes the thickness of the inductor lower to meet the usage requirements.

[0014] As a preferred solution of the present invention, there is a gap in the middle parts of the first wire and the second wire, the diameter of the gap is 0.01 - 3 cm, and an elastic insulator is arranged in the gap, and the material of the elastic insulator is an insulating material.

[0015] Through the above technical solution, the gap is convenient for forming a parallel circuit of the conductor, and the elastic insulator is convenient for preventing the first wire and the second wire from being squeezed and connected into one body during the molding process, and is also convenient for further increasing the insulation and keeping the first wire and the second wire in a parallel state.

[0016] As a preferred solution of the present invention, clamping grooves are arranged at both ends of the elastic insulator, one side of the first wire and the second wire is arranged in the clamping grooves, and anti-slip layers are arranged on the inner side walls of the clamping grooves of the elastic insulator in contact with the first wire and the second wire.

[0017] Through the above technical solution, the clamping grooves are convenient for more stable connection with the first conductor and the second conductor, and prevent the elastic insulator from falling off.

[0018] As a preferred solution of the present invention, the conductor is made of a conductive metal material.

[0019] Through the above technical solution, the conductor being made of a conductive metal material is convenient for conducting electricity.

[0020] As a preferred solution of the present invention, the middle part of the conductor is bent, and the height difference between the middle part of the conductor and the two ends of the conductor is 0.01 - 3 cm.

[0021] Through the above technical solution, there is a certain height difference between the two ends of the conductor and the middle part of the conductor, which is convenient for better generating magnetic induction lines.

[0022] As a preferred embodiment of the present invention, the two ends of the conductor are pins disposed opposite to each other on both sides of the magnetic core, and the pins are exposed outside the magnetic core.

[0023] As a preferred embodiment of the present invention, the two ends of the conductor are pins disposed opposite to each other on both sides of the magnetic core, and the ends of the pins are connected to a lead frame, and the lead frame extends in a curved shape to the outer side surface of the magnetic core.

[0024] As a preferred embodiment of the present invention, the magnetic core includes a lower mold, an upper mold disposed on the lower mold, and a connecting block disposed between the upper mold and the lower mold, and the connecting block is pressed integrally with the upper mold or the lower mold.

[0025] Through the above technical solution, when the upper mold and the lower mold are integrally formed by pressing, and the connecting block is integrally formed with the lower mold, a groove is provided in the middle of the lower end surface of the upper mold, and the groove is adapted to the connecting block. When the connecting block is integrally formed with the upper mold, a groove is provided in the middle of the upper end surface of the lower mold, and the groove is adapted to the connecting block.

[0026] As a preferred embodiment of the present invention, the inductor further includes a magnetic isolation plate disposed on the side of the inductor, and the magnetic isolation plate is made of a magnetic isolation material.

[0027] Through the above technical solution, the magnetic isolation plate is beneficial to reducing the magnetic leakage of the inductor, and further improving the inductance value and performance of the inductor.

[0028] A method for manufacturing an integrally formed parallel inductor includes the following steps:

[0029] S1. Obtain the conductor, spray an insulating layer on the outer surface of the conductor, flatten the leads at both ends of the conductor, and dispose an elastic insulator in the gap of the conductor;

[0030] S2. Manufacture the lower mold, and press and form it through a soft magnetic powder mold, and the connecting block is integrally pressed and formed with the lower mold;

[0031] S3. Place the conductor on the lower mold, dispose the middle part of the conductor on the connecting block, and apply pressure to the conductor so that the middle part of the conductor is bent and deformed to fit the surface of the connecting block;

[0032] S4. Assemble and press the upper mold and the lower mold into one body;

[0033] S5. Strip the paint from the lead portions at both ends of the conductor and bend them to the upper or lower end surface of the inductor;

[0034] S6. Bond the magnetic isolation plate to the side of the inductor.

[0035] Compared with the prior art, the beneficial effects of the present invention are:

[0036] The conductor is disposed within the magnetic core. The cross-section of the conductor is one of circular, square, and polygonal. The insulating layer is beneficial for insulating the surface of the conductor. The middle parts of the two ends of wire one and wire two are separated and connected to form a parallel circuit, which is beneficial for increasing or decreasing the resistance of the inductor and increasing the inductance value of the inductor, thereby improving the performance of the inductor. At the same time, since the conductor is an integral structure, it is convenient for the miniaturization and precision of the inductor, and also makes the thickness of the inductor lower to meet the usage requirements;

[0037] When meeting the requirements of high current and high inductance value, the inductor structure is simplified, the production efficiency of the inductor is improved, and the production cost is reduced. Brief Description of the Drawings

[0038] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the drawings in the following description are some embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

[0039] Figure 1 Schematic diagram of the inductor structure of the present invention;

[0040] Figure 2 For the present invention Figure 1 Schematic diagram of the structure in;

[0041] Figure 3 For the present invention Figure 1 Schematic diagram of the structure in;

[0042] Figure 4 For the present invention Figure 1 Schematic diagram of the elastic insulator structure in. Detailed Description of the Embodiments

[0043] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, rather than all embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts belong to the scope of protection of the present invention.

[0044] The present invention provides the following embodiments:

[0045] Embodiment 1:

[0046] An integrally formed parallel inductor, comprising:

[0047] A magnetic core 1, which is formed by pressing soft magnetic powder. The soft magnetic powder includes an alloy soft magnetic powder core and an inorganic coating layer covering the surface of the alloy soft magnetic powder core. The soft magnetic powder is selected from metal and / or alloy materials containing Fe elements;

[0048] Conductor 2 has an insulating layer covering its outer surface. Conductor 2 is made of conductive metal material, which facilitates conduction. Conductor 2 is disposed within magnetic core 1, with the middle part of conductor 2 being lower or higher than both ends of conductor 2. Conductor 2 extends outside magnetic core 1. Conductor 2 includes wire one 21 and wire two 22 connected to both ends of wire one 21.

[0049] As a further improvement of the present invention, there is a gap 23 between the middle parts of wire one 21 and wire two 22. The diameter of gap 23 is 0.01 - 3 cm. An elastic insulator 24 is provided within gap 23. The material of elastic insulator 24 is an insulating material. Gap 23 facilitates forming a parallel circuit for conductor 2. Elastic insulator 24 facilitates preventing wire one 21 and wire two 22 from being extruded and connected together during molding, and also facilitates further increasing insulation and keeping wire one 21 and wire two 22 in a parallel state. Both ends of elastic insulator 24 are provided with card slots 25. One side of wire one 21 and wire two 22 is disposed within card slots 25. The inner side wall of card slots 25 of elastic insulator 24 and the contact surfaces of wire one 21 and wire two 22 are provided with anti-slip layers 26, and anti-slip blocks are provided on anti-slip layers 26. Card slots 25 facilitate more stable connection with conductor 2 one and conductor 2 two, and prevent elastic insulator 24 from falling off.

[0050] As a further improvement of the present invention, the middle part of conductor 2 is bent, and the height difference between the middle part of conductor 2 and both ends of conductor 2 is 0.01 - 3 cm. There is a certain height difference between both ends of conductor 2 and the middle part of conductor 2, which facilitates better generation of magnetic induction lines.

[0051] As a further improvement of the present invention, both ends of conductor 2 are pins disposed on both sides of magnetic core 1 relatively, and the pins are exposed outside magnetic core 1.

[0052] As a further improvement of the present invention, magnetic core 1 includes lower mold 12, upper mold 11 disposed on lower mold 12, and connecting block 13 disposed between upper mold 11 and lower mold 12. Connecting block 13 is pressed into one body with upper mold 11 or lower mold 12. Upper mold 11 and lower mold 12 are integrally molded by pressing. When connecting block 13 is integrally formed with lower mold 12, a groove is provided in the middle of the lower end surface of upper mold 11, and the groove is adapted to connecting block 13. When connecting block 13 is integrally formed with upper mold 11, a groove is provided in the middle of the upper end surface of lower mold 12, and the groove is adapted to connecting block 13.

[0053] As a further improvement of the present invention, the cross-section of connecting block 13 can be one or more of rectangle, circle, triangle, quadrilateral, polygon, irregular shape, etc. Preferably, connecting block 13 is semi-circular; preferably, connecting block 13 is rectangular.

[0054] As a further improvement of the present invention, the inductor further includes a magnetic isolation plate 3 provided on the side of the inductor. The magnetic isolation plate 3 is made of a magnetic isolation material, and the magnetic isolation plate 3 is beneficial to reducing the magnetic leakage of the inductor and further improving the inductance value and performance of the inductor.

[0055] Example 2:

[0056] A method for manufacturing an integrally formed parallel inductor includes the following steps:

[0057] S1. Prepare the conductor 2, spray an insulating layer on the outer surface of the conductor 2, stamp the conductor 2 into a curved shape with the middle part higher than both ends, flatten the leads at both ends of the conductor 2, and place the elastic insulator 24 in the gap 23 of the conductor 2;

[0058] S11. Prepare the elastic insulator 24, which can be a rubber insulating block;

[0059] S12. Remove parts on both sides of the insulating block to form a card slot 25, and the card slot 25 is adapted to the lead wire 21 and the lead wire 22;

[0060] S13. Form an anti-slip layer 26 on the inner side of the card slot 25, and a number of protrusions are provided on the anti-slip layer 26.

[0061] Among them, the insulator in step S11 can also be obtained by the following method: partially immerse the gap 23 of the conductor 2 in glue, and wait for the glue to dry to form an insulator;

[0062] Among them, the insulator in step S11 can also be obtained by the following method: squeeze the prepared rubber strip at the gap 23 and dry it to form an insulator;

[0063] S2. Manufacture the lower mold 12, press and form it through a soft magnetic powder mold, and integrally press and form the connecting block 13 and the lower mold 12;

[0064] S3. Place the conductor 2 on the lower mold 12, place the middle part of the conductor 2 on the connecting block 13, and apply pressure to the conductor 2 so that the middle part of the conductor 2 is bent and deformed to fit the surface of the connecting block 13;

[0065] Among them, step s3 further includes:

[0066] S4. Assemble and press the upper mold 11 and the lower mold 12 into one body;

[0067] S5. Strip the paint from the lead parts at both ends of the conductor 2 and bend them to the upper or lower end surface of the inductor;

[0068] S6. Bond the magnetic isolation plate 3 to the side of the inductor.

[0069] Example 3:

[0070] The difference from Embodiment 1 is that the two ends of the conductor 2 are pins oppositely arranged on both sides of the magnetic core 1, the ends of the pins are connected to the lead frame, and the lead frame extends in a bent shape to the outer side of the magnetic core 1.

[0071] The conductor 2 is arranged inside the magnetic core 1. The cross-section of the conductor 2 is any one of a circle, a square, and a polygon. The insulating layer is beneficial to insulating the surface of the conductor 2. The two ends of the first wire 21 and the second wire 22 are connected and separated in the middle to form a parallel circuit, which is beneficial to increasing the resistance for reducing the inductance, increasing the inductance value of the inductance, and improving the performance of the inductance. At the same time, since the conductor 2 is an integral structure, it is convenient for the miniaturization and precision of the inductance, and also makes the thickness of the inductance lower to meet the usage requirements, and can better serve and explore the market.

[0072] The above description of the disclosed embodiments enables those skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to those skilled in the art, and the general principles defined herein can be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but rather to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An integrally formed parallel inductor, characterized in that ,include: The magnetic core (1) is formed by pressing soft magnetic powder; A conductor (2), the outer surface of the conductor being coated with an insulating layer, the conductor (2) being arranged in the magnetic core (1), the middle of the conductor (2) being lower or higher than the two ends of the conductor (2), the conductor (2) extending to the outside of the magnetic core (1), the conductor (2) comprising a conductor 1 (21), and a conductor 2 (22) connected to the two ends of the conductor 1 (21) as a whole.

2. The one-piece shunt inductor according to claim 1, characterized in that: A gap (23) is provided in the middle of the first conductor (21) and the second conductor (22), the diameter of the gap (23) is 0.01-3 cm, an elastic insulator (24) is provided in the gap (23), and the material of the elastic insulator (24) is an insulating material.

3. The one-piece shunt inductor according to claim 2, characterized in that: The elastic insulator (24) is provided with a clamping groove (25) at both ends, one side of the wire 1 (21) and the wire 2 (22) is arranged in the clamping groove (25), and the inner side wall of the clamping groove (25) of the elastic insulator (24) and the contact surface between the wire 1 (21) and the wire 2 (22) are provided with an anti-slip layer (26).

4. The one-piece shunt inductor according to claim 3, characterized in that: The conductor (2) is made of conductive metal, the middle part of the conductor (2) is curved, and the height difference between the middle part of the conductor (2) and the two ends of the conductor (2) is 0.01-3 cm.

5. The one-piece shunt inductor according to claim 4, characterized in that: The two ends of the conductor (2) are pins arranged on two sides of the magnetic core (1) opposite to each other, and the pins are exposed outside the magnetic core (1).

6. The one-piece shunt inductor according to claim 5, characterized in that: The two ends of the conductor (2) are pins arranged on two sides of the magnetic core (1) opposite to each other, the ends of the pins are connected to a lead frame, and the lead frame extends in a curved shape to the outer side of the magnetic core (1).

7. The one-piece shunt inductor according to claim 6, characterized in that: The magnetic core (1) comprises a lower mold (12), an upper mold (11) arranged on the lower mold (12), and a connecting block (13) arranged between the upper mold (11) and the lower mold (12), wherein the connecting block (13) is pressed into one piece with the upper mold (11) or the lower mold (12).

8. The one-piece shunt inductor according to claim 7, characterized in that: The inductor further comprises a magnetic isolation plate (3) arranged on the side of the inductor, and the magnetic isolation plate (3) is made of magnetic isolation material.

9. A method for manufacturing an integrally formed shunt inductor, according to the integrally formed shunt inductor according to claims 1-8, characterized in that: The following steps are involved: S1, stamping the conductor (2), adding an insulating layer on the outer surface of the conductor (2), flattening the leads at both ends of the conductor (2), and placing an elastic insulator (24) in the gap (23) of the conductor (2); S2, manufacturing the lower mold (12), pressing and molding the connection block (13) and the lower mold (12) by using a soft magnetic powder mold; S3, placing the conductor (2) on the lower mold (12), placing the middle part of the conductor (2) on the connecting block (13), and applying pressure to the conductor (2) so that the middle part of the conductor (2) is bent and deformed and fits the surface of the connecting block (13); S4, assembling and pressing the upper mold (11) and the lower mold (12) into one body; S5. Strip the paint from the lead wires at both ends of the conductor (2) and bend them to the upper or lower end surface of the inductor.

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