Integrally-formed inductor and manufacturing method thereof

Abstract

According to the integrally-formed inductor and the manufacturing method thereof, a winding is wound on a closed annular magnetic core, the magnetic density of the annular magnetic core is higher than that of other parts of a main body, transmission channels with the consistent density are provided for magnetic lines of force, and therefore the favorite characteristic value of the inductor is higher under the condition that the number of turns of the winding is the same. The inductor comprises a main body and a winding; the main body comprises a first part and a second part; the winding is uniformly wound on at least one part of the second part; the first part wraps the winding and the second part and fills a gap between the winding and the second part; the density of the second part is far greater than that of the first part; and the second part is provided with an annular magnetic line transmission channel.

Description

Technical Field

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

[0002] At present, the inductors on the market are all developing towards high frequency, low loss, and low impedance. The mainstream method is to use low-loss metal powder and multi-turn coils to be formed in one step under high temperature and high pressure. There are coils inside this kind of inductor, resulting in different densities in various regions of the internal structure. The loss of magnetic flux lines during transmission causes the inductance value to decrease. When designing the inductor, more turns are needed to compensate for the characteristics, resulting in an increase in impedance. At the same time, this kind of inductor needs to be formed under high temperature and high pressure, and the coil is easily broken by metal powder to form a short circuit failure. Summary of the Invention

[0003] The present invention provides an integrally formed inductor and a manufacturing method thereof. The winding is wound around a closed annular magnetic core, and the annular magnetic density is higher than the rest of the main body, providing a transmission channel with consistent density for the magnetic flux lines, so that the inductor has a higher characteristic value under the same number of winding turns.

[0004] The present invention provides an integrally formed inductor, including a main body and a winding; the main body includes a first part and a second part; the winding is evenly wound around at least a part of the second part; the first part covers the winding and the second part and fills the gap between the winding and the second part; the density of the second part is much greater than that of the first part; the second part has an annular magnetic flux line transmission channel.

[0005] Further: The second part is made by sintering.

[0006] Further: The second part is formed by pressing magnetic powder.

[0007] Further: The first part is made by injecting magnetic glue.

[0008] The present invention also provides a manufacturing method of the integrally formed inductor in claim 1, including the following steps:

[0009] S1. Prepare the second part;

[0010] S2. Directly wind the winding around the second part to obtain a winding magnetic core;

[0011] S3. Form the first part outside the winding magnetic core;

[0012] S4. Electroplate electrodes at both ends of the winding.

[0013] Further: The second part in step S1 is made by sintering.

[0014] Furthermore, the second part in the step S1 is made by pressing magnetic powder.

[0015] Furthermore, the step S3 includes placing the winding core into the die cavity of the mold, filling magnetic powder and then compacting to obtain a semi-finished inductor.

[0016] Furthermore, the step S3 includes placing the winding core into the die cavity of the mold, injecting magnetic glue and then solidifying to obtain a semi-finished inductor.

[0017] The beneficial effect of the present invention is that by setting the second part as an annular structure and forming it by high pressure or sintering, the density of the second part is higher than that of the first part, so that a transmission channel with uniform density can be provided for magnetic force lines, reducing the transmission of magnetic force lines in the first part. Therefore, the density requirement for the first part is relatively low, and the first part can be formed by low pressure or injection molding process, reducing the manufacturing difficulty. Description of the Drawings

[0018] Figure 1 It is a schematic structural diagram of an integrated inductor;

[0019] Figure 2 It is a schematic structural diagram of another integrated inductor;

[0020] Figure 3 It is a schematic flow diagram of the manufacturing method of an integrated inductor.

[0021] The marks in the figure are: 100, the first part; 200, the second part; 300, the winding. Detailed Embodiments

[0022] To deepen the understanding of the present invention, exemplary embodiments will be described in detail here, and the examples are shown in the drawings. When the following description refers to the drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all the embodiments consistent with the present application.

[0023] The terms used in this application are for the purpose of describing specific embodiments only and are not intended to limit this application. Unless otherwise defined, the technical terms or scientific terms used in this application shall have the ordinary meanings understood by those of ordinary skill in the art to which this invention pertains. The "first", "second" and similar terms used in this application do not denote any order, quantity or importance, but are only used to distinguish different components. Similarly, the terms such as "a" or "an" do not denote a quantity limitation, but mean that there is at least one. "Plurality" or "several" means two or more. Unless otherwise indicated, the similar terms such as "front part", "rear part", "lower part" and / or "upper part" are for convenience of description only and are not limited to one position or a spatial orientation. The terms such as "comprising" or "including" mean that the elements or objects appearing before "comprising" or "including" cover the elements or objects listed after "comprising" or "including" and their equivalents, and do not exclude other elements or objects. The similar terms such as "connected" or "coupled" are not limited to physical or mechanical connections, and may include electrical connections, whether direct or indirect. The singular forms of "a", "the" and "said" used in the specification and appended claims of this application are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the term "and / or" used herein refers to any and all possible combinations including one or more of the associated listed items.

[0024] Please refer to Figure 1 , this application provides an integrally formed inductor, comprising a main body and a winding; the main body includes a first part and a second part; the winding is evenly wound around at least a part of the second part; the first part covers the winding and the second part and fills the gap between the winding and the second part; the density of the second part is much greater than that of the first part; the second part has an annular magnetic field transmission channel.

[0025] In this embodiment, the second part is made by sintering and thus has a high density, which can make the magnetic field lines basically only transmit within the second part. In another embodiment, the second part can also be made by high-pressure pressing of magnetic powder, such as 10 T / cm 2 , 20 T / cm 2 or even higher.

[0026] Due to the existence of a high-efficiency transmission channel, the influence of the first part on the overall characteristics of the inductor is small. Therefore, the density of the first part can be lower than that of the second part within a certain range. In this embodiment, the first part is made by injection molding of magnetic glue. In another embodiment, the first part can be formed by low-pressure pressing of magnetic powder, such as 0.5 T / cm 2 or even lower.

[0027] To reduce the influence of the second part on the overall size of the inductor, the second part 200 can be "tilted" and arranged within the first part 100, as Figure 2 shown.

[0028] Please refer to Figure 3 , the present application also provides a manufacturing method for the above-mentioned integrally formed inductor, including the following steps:

[0029] S1. Prepare the second part;

[0030] S2. Wind the winding directly on the second part to obtain a wound magnetic core;

[0031] S3. Form the first part on the outer side of the winding magnetism;

[0032] S4. Electroplate electrodes at both ends of the winding.

[0033] On the above basis, the second part in step S1 is made by sintering.

[0034] On the above basis, the second part in step S1 is formed by pressing magnetic powder.

[0035] On the above basis, step S3 includes placing the wound magnetic core into the mold cavity, filling magnetic powder and then compacting to obtain a semi-finished inductor.

[0036] On the above basis, step S3 includes placing the wound magnetic core into the mold cavity of the mold, injecting magnetic glue and then solidifying to obtain a semi-finished inductor.

[0037] The above are only the preferred embodiments of the present application, and do not impose any formal restrictions on the present application. Although the present application has been disclosed above with the preferred embodiments, it is not intended to limit the present application. Any person skilled in the art can make some changes or modifications to equivalent embodiments by using the above-disclosed technical content within the scope of the technical solution of the present application. However, as long as it does not depart from the content of the technical solution of the present application, any simple modification, equivalent change and modification made to the above embodiments according to the technical essence of the present application still fall within the scope of the technical solution of the present application.

Claims

1. An integrally formed inductor, comprising a main body and a winding; characterized in that: The main body comprises a first part and a second part; the winding is evenly wound on at least a part of the second part; the first part covers the winding and the second part and fills the gap between the winding and the second part; the density of the second part is much greater than that of the first part; The second part has an annular magnetic field line transmission channel.

2. The one-piece molded inductor according to claim 1, characterized in that: The second part is produced by sintering.

3. The one-piece molded inductor according to claim 1, characterized in that: The second part is formed by pressing magnetic powder.

4. The one-piece molded inductor according to claim 1, characterized in that: The first part is made of magnetic glue injection molding.

5. A method for manufacturing the integrally formed inductor according to claim 1, characterized in that: The following steps are involved: S1, preparing the second part; S2, winding the winding directly on the second part to obtain a winding magnetic core; S3, forming a first portion outside the winding magnetically; S4. Electrodes are formed by electroplating at both ends of the winding.

6. The method for manufacturing an integrally formed inductor according to claim 5, characterized in that: The second part in step S1 is manufactured by sintering.

7. The method for manufacturing an integrally formed inductor according to claim 5, characterized in that: The second part in step S1 is formed by pressing magnetic powder.

8. The method for manufacturing an integrally formed inductor according to claim 5, characterized in that: The step S3 includes placing the winding magnetic core into a mold cavity, filling it with magnetic powder and compacting it to obtain a semi-finished inductor.

9. The method for manufacturing an integrally formed inductor according to claim 5, characterized in that: The step S3 includes placing the winding core into a mold cavity of a mold, injecting magnetic glue, and then solidifying to obtain a semi-finished inductor.

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