Integrally-formed inductor production process

Abstract

The invention relates to the technical field of electronic components, in particular to an integrally formed inductor production process, comprising: a conductor comprising a wire portion in a bent shape and leading-out portions arranged at two ends of the wire portion, the leading-out portions being provided with leading-out ends; the mould pressing part comprises a mixture of magnetic and / or non-magnetic materials which are mould-pressed around the conductor, the leading-out end is exposed outside the mould pressing part, the wire part is in a loop bending shape, the conductor is formed by integral stamping, the conductor is formed by stamping to form a needed loop bending shape, soft magnetic powder is coated on the outer peripheral surface of the conductor, and the soft magnetic powder is coated on the outer peripheral surface of the conductor. The production efficiency is high, short circuit is avoided, large current can pass through the inductor, the requirement that large current passes through the inductor while low inductance is achieved is met, and manufacturing procedures are reduced.

Description

Technical Field

[0001] The present invention belongs to the technical field of electronic components, and particularly relates to a production process for an integrally formed inductor. Background Art

[0002] Power inductors are generally used in DC-DC circuits to stabilize current and store energy. It is required that the power inductor can pass a relatively large current, usually greater than 10A. Therefore, when designing, the wire diameter of the coil is relatively thick to achieve a lower DC resistance. However, the thickening of the wire diameter will cause problems such as large coil size, inability to be fixed, and falling off during the drop test. Therefore, a production process for an integrally formed inductor is needed to solve the above problems. Summary of the Invention

[0003] To solve the above technical problems, the present invention provides a production process for an integrally formed inductor to solve the problems in the existing market mentioned in the above background art.

[0004] To achieve the above object, the technical solution of the present invention is as follows:

[0005] A production process for an integrally formed inductor, comprising:

[0006] A conductor, including a wire portion that is bent, and lead-out portions provided at both ends of the wire portion, and lead-out ends are provided on the lead-out portions;

[0007] A molding portion, including molding a mixture of magnetic and / or non-magnetic materials around the conductor, and the lead-out ends are exposed outside the molding portion.

[0008] As a preferred solution of the present invention, the wire portion is bent in a loop shape, and the conductor is integrally stamped.

[0009] Through the above technical solution, the conductor is formed into the required shape - a loop shape by stamping, the soft magnetic powder is coated on the outer peripheral surface of the conductor, and the lead-out ends are exposed to form an inductor. The production efficiency is relatively high, short circuits can be avoided, a relatively large current can be passed, the requirements of passing a relatively large current while achieving a low inductance are met, and the manufacturing process is reduced.

[0010] As a preferred solution of the present invention, the conductor includes a first wire body, and a second wire body provided on the first wire body through an insulating component.

[0011] Through the above technical solution, the first wire body and the second wire body form a low coefficient coupling inductor, which is convenient for adapting to different requirements.

[0012] As a preferred solution of the present invention, the lead-out ends of the first wire body and the second wire body are staggered from each other.

[0013] Through the above technical solution, the staggering of the lead-out ends is convenient for subsequent welding and avoids adhesion at the welding positions.

[0014] As a preferred embodiment of the present invention, the insulating assembly includes an insulating elastic block. The insulating elastic block is provided with a first groove on the upper end surface and a second groove opposite to the first groove. The first groove is adapted to the first wire body, and the second groove is adapted to the second wire body.

[0015] Through the above technical solution, the insulating elastic block is convenient for avoiding the rupture of the insulating layers on the surfaces of the first wire body and the second wire body during the pressing process, which may cause conductor short circuit, and the insulating elastic block is convenient for increasing the insulating performance.

[0016] As a preferred embodiment of the present invention, a support block is provided inside the insulating elastic block.

[0017] Through the above technical solution, the support block is convenient for avoiding the damage of the insulating elastic block after being subjected to a large pressure, and the support block maintains the distance between the first wire body and the second wire body.

[0018] As a preferred embodiment of the present invention, the conductor is made of a metal material, and the molding part is a soft magnetic powder.

[0019] As a preferred embodiment of the present invention, the thickness of the conductor is 2 / 5 of the overall thickness of the inductor.

[0020] As a preferred embodiment of the present invention, a part of the lead-out portion is arranged inside the molding part, and a part is exposed outside the molding part. The part exposed outside the molding part is bent to both sides of the inductor.

[0021] Through the above technical solution, the exposed lead-out end outside the molding part is convenient for connecting to an external terminal.

[0022] As a preferred embodiment of the present invention, an insulating layer is coated on the outer periphery of the conductor.

[0023] Through the above technical solution, it is beneficial to improve the insulation of the conductor.

[0024] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0025] The conductor is formed into a required shape - a loop bending shape by stamping, the soft magnetic powder is coated on the outer periphery of the conductor, and the lead-out end is exposed to form an inductor. The production efficiency is relatively high, short circuit can be avoided, a relatively large current can be passed, the requirement of passing a relatively large current while achieving a low inductance is met, and the manufacturing process is reduced.

[0026] The present invention uses a metal material to stamp different shapes to form a loop, without copper wire winding and without short circuit. It is integrally formed, without the welding problem of a lead frame and copper wire, and is a low-inductance inductor that can pass a relatively large current. Brief Description of the Drawings

[0027] 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 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, without creative efforts, other drawings can be obtained based on these drawings.

[0028] Figure 1 Schematic diagram of the inductance structure of the present invention;

[0029] Figure 2 Of the present invention Figure 1 Schematic diagram of the conductor structure in;

[0030] Figure 3 Of the present invention Figure 1 Schematic diagram of the conductor structure in;

[0031] Figure 4 Of the present invention Figure 1 Schematic diagram of the insulation component structure in.

[0032] 2. Conductor; 21. Wire part; 22. Lead-out part; 23. Lead-out end; 1. Molding part, 3. Insulation component; 31. Insulating elastic block; 32. First groove; 33. Second groove; 34. Support block. Detailed implementation manners

[0033] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in combination with the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts belong to the scope of protection of the present invention.

[0034] The present invention provides the following embodiments:

[0035] An integrated inductor production process, including:

[0036] Conductor 2, including a wire part 21 that is curved, lead-out parts 22 provided at both ends of the wire part 21, and a lead-out end 23 provided on the lead-out part 22. The outer periphery of the conductor 2 is coated with an insulating layer, which is beneficial to improving the insulation of the conductor 2;

[0037] Molding part 1, including molding a mixture of magnetic and / or non-magnetic materials around the conductor 2, and the lead-out end 23 is exposed outside the molding part 1.

[0038] As a further improvement of the present invention, the wire part 21 is in a loop-bent shape, and the conductor 2 is integrally stamped. The conductor 2 is formed into the required shape - a loop-bent shape by stamping. Soft magnetic powder is coated on the outer peripheral surface of the conductor 2, and the lead-out end 23 is exposed to form an inductor. The production efficiency is relatively high. Short circuit can be avoided, and a relatively large current can be passed. While achieving a low inductance value, the requirement of passing a relatively large current is met, and the manufacturing process is reduced.

[0039] As a further improvement of the present invention, the conductor 2 includes a first wire body and a second wire body provided on the first wire body through an insulating component 3. The first wire body and the second wire body form a low-coefficient coupling inductor, which is convenient for adapting to different requirements.

[0040] As a further improvement of the present invention, the lead-out ends 23 of the first wire body and the second wire body are staggered from each other. The staggering of the lead-out ends 23 is convenient for subsequent welding and avoids adhesion at the welding positions.

[0041] As a further improvement of the present invention, the insulating component 3 includes an insulating elastic block 31. The insulating elastic block 31 is provided with a first groove 32 on the upper end surface and a second groove 33 opposite to the first groove 32. The first groove 32 is adapted to the first wire body, and the second groove 33 is adapted to the second wire body. The insulating elastic block 31 is convenient for preventing the insulating layers on the surfaces of the first wire body and the second wire body from being broken during the pressing process, resulting in a short circuit of the conductor 2. The insulating elastic block 31 is convenient for increasing the insulating performance; a support block 34 is provided in the insulating elastic block 31. The support block 34 is convenient for preventing the insulating elastic block 31 from being damaged after being subjected to a relatively large pressure, and the support block 34 maintains the distance between the first wire body and the second wire body.

[0042] As a further improvement of the present invention, the conductor 2 is made of a metal material, the molding part 1 is made of soft magnetic powder, and the thickness of the conductor 2 is 2 / 5 of the overall thickness of the inductor. Preferably, the material of the conductor 2 is the same as that of the tin-plated material.

[0043] As a preferred embodiment of the present invention, a part of the lead-out part 22 is provided inside the molding part 1, and a part is exposed outside the molding part 1. The part exposed outside the molding part 1 is bent to both sides of the inductor. The lead-out end 23 exposed outside the molding part 1 is convenient for connecting to an external terminal.

[0044] The conductor 2 is formed into the required loop-bent shape by stamping. Soft magnetic powder is coated on the outer peripheral surface of the conductor 2, and the lead-out end 23 is exposed to form an inductor. The production efficiency is relatively high. Short circuit can be avoided, and a relatively large current can be passed. While achieving a low inductance value, the requirement of passing a relatively large current is met, and the manufacturing process is reduced. The complex production process and technology are reduced, and the market can be better served and developed.

[0045] The foregoing description of the disclosed embodiments enables those skilled in the art to practice or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A one-piece molded inductor production process, characterized in that ,include: The conductor (2) comprises a wire portion (21) in a bent shape, lead portions (22) provided at both ends of the wire portion (21), and the lead portion (22) is provided with a lead end (23); The molded part (1) comprises a mixture of magnetic and / or non-magnetic materials molded around the conductor (2), and the lead end (23) is exposed outside the molded part (1).

2. The one-piece molded inductor production process according to claim 1, characterized in that: The lead wire portion (21) is in a loop-bent shape, and the conductor (2) is integrally punched.

3. The one-piece molded inductor production process according to claim 2, characterized in that: The conductor (2) comprises a first wire body and a second wire body arranged on the first wire body through an insulating component (3).

4. The one-piece molded inductor production process according to claim 3, characterized in that: The lead-out ends (23) of the first wire body and the second wire body are staggered with each other.

5. The one-piece molded inductor production process according to claim 4, characterized in that: The insulating assembly (3) comprises an insulating elastic block (31), the insulating elastic block (31) being provided with a first groove (32) arranged on an upper end surface and a second groove (33) arranged opposite to the first groove (32), the first groove (32) being adapted to the first wire body, and the second groove (33) being adapted to the second wire body.

6. The one-piece molded inductor production process according to claim 5, characterized in that: A supporting block (34) is provided inside the insulating elastic block (31).

7. The one-piece molded inductor production process according to claim 6, characterized in that: The conductor (2) is made of metal, and the molded portion (1) is made of soft magnetic powder.

8. The one-piece molded inductor production process according to claim 7, characterized in that: The thickness of the conductor (2) is 2 / 5 of the overall thickness of the inductor.

9. The one-piece molded inductor production process according to claim 8, characterized in that: A portion of the lead-out portion (22) is disposed inside the molded portion (1), and a portion is exposed outside the molded portion (1), and the portion exposed outside the molded portion (1) is bent to two sides of the inductor.

10. The one-piece molded inductor production process according to claim 9, characterized in that: The outer periphery of the conductor (2) is covered with an insulating layer.

Images