Method for manufacturing multiphase inductor with heterostructure

Abstract

The invention provides a heterostructure multiphase inductor manufacturing method, which comprises the following steps that a full-page coil assembly is manufactured, the full-page coil assembly comprises full-page coils with bottom electrodes and magnets wrapping the coils, and the coils are arranged in an array; the whole coil assembly is cut, a plurality of separated coil monomers are obtained, and each coil monomer comprises a single coil and a magnet wrapping the single coil; filling a colloid material into a cutting channel between the adjacent coil monomers, and curing to obtain a full-page isolation coil assembly; and cutting the full-page isolation coil assembly to obtain multi-phase inductor monomers which comprise a plurality of coil monomers and colloid materials between the adjacent coil monomers. The coil monomers are obtained by cutting the whole coil assembly, and the colloid material is filled in the cutting channel between the adjacent coil monomers and is cured, so that the physical isolation between the coil monomers is realized, the mutual inductance effect between inductors is obviously reduced, the electromagnetic coupling is reduced, and the crosstalk problem is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of inductor manufacturing, and particularly to a manufacturing method for a multi-phase inductor with a heterogeneous structure. Background Art

[0002] In the field of design and manufacturing of multi-phase inductors, the existing technologies mainly face two major challenges: electromagnetic coupling between inductors and low production efficiency. Both of these challenges stem from the structural design and material application in the inductor manufacturing process.

[0003] I. Electromagnetic coupling problem between inductors

[0004] One traditional manufacturing method for multi-phase inductors is to arrange multiple coils neatly and then uniformly coat them with a magnet. The advantage of this method is that it is easy to operate and can quickly apply the magnet to the coils, thereby enhancing the performance of the inductor. However, the significant drawback of this method is that due to all inductors using the same magnet and without effective isolation, a strong mutual inductance effect will occur between the inductors. This mutual inductance effect will not only cause electromagnetic coupling between the inductors but also lead to crosstalk problems, seriously affecting the performance and stability of the inductors. Especially in high-frequency or complex circuits, this problem is particularly prominent, restricting the effective application of inductors in multi-phase circuits.

[0005] II. Low production efficiency problem

[0006] To solve the mutual inductance effect and electromagnetic coupling problem between inductors, another manufacturing method has been proposed: splicing several inductors together by adhesion to achieve physical isolation between the inductors. Although this method reduces the electromagnetic coupling between inductors to a certain extent, it brings new problems - low production efficiency. Since each inductor needs to be manufactured separately and then spliced together by adhesion, this process is not only time-consuming and laborious but also difficult to ensure the consistency and stability between the inductors. In addition, the adhesive used in the adhesion process may also have an adverse effect on the performance of the inductors, further increasing the manufacturing difficulty and cost. Summary of the Invention

[0007] To solve the above problems, the object of the present invention is to provide a manufacturing method for a multi-phase inductor with a heterogeneous structure. By cutting a whole-board coil assembly to obtain coil monomers and filling and curing a gelatinous material in the cutting channels between adjacent coil monomers, physical isolation between the coil monomers is achieved, significantly reducing the mutual inductance effect between the inductors, reducing electromagnetic coupling, and thus reducing crosstalk problems.

[0008] The present invention is achieved through the following technical solutions:

[0009] A manufacturing method for a multi-phase inductor with a heterogeneous structure, the steps are as follows:

[0010] Fabricate a full - panel coil assembly. The full - panel coil assembly includes a coil with a bottom electrode on the full - panel and a magnet wrapped outside the coil, and the coils are arranged in an array;

[0011] Cut the full - panel coil assembly to obtain a number of mutually separated coil monomers. The coil monomer includes a single coil and a magnet that wraps the single coil;

[0012] Fill the cutting channels between adjacent coil monomers with a gelling material and cure it to obtain a full - panel isolated coil assembly;

[0013] Cut the full - panel isolated coil assembly to obtain multi - phase inductor monomers. The multi - phase inductor monomer includes a number of coil monomers and the gelling material between adjacent coil monomers.

[0014] A method for manufacturing a multi - phase inductor with a heterogeneous structure, the steps are as follows:

[0015] Fabricate a full - panel coil assembly. The full - panel coil assembly includes a coil with a bottom electrode on the full - panel and a magnet wrapped outside the coil;

[0016] Cut the full - panel coil assembly to obtain a number of mutually separated coil monomers. The coil monomer includes a single coil and a magnet that wraps the single coil;

[0017] Fill the specified cutting channels with a gelling material and cure it. The adjacent coil monomers are connected by the gelling material to form multi - phase inductor monomers.

[0018] Further, the gelling material includes one or several of epoxy resin, silicone resin, and phenolic resin.

[0019] Further, before cutting the full - panel inductor, it also includes setting a pyrolytic mucous membrane or a blue film under the full - panel coil assembly; after cutting the full - panel isolated coil assembly to obtain multi - phase inductor monomers or after filling the specified cutting channels with a gelling material and curing to obtain multi - phase inductor monomers, perform threshing on the multi - phase inductor monomers.

[0020] Further, the threshing method includes: heating to make the multi - phase inductor monomers detach from the pyrolytic mucous membrane; or, by one of the methods of manual tearing, particulate dry - ice cleaning, and laser degumming, to make the multi - phase inductor monomers detach from the blue film.

[0021] Further, it also includes the steps of: grinding the ends of the multi - phase inductor monomers and electroplating electrodes.

[0022] Further, the specified cutting channels refer to the cutting channels located between adjacent coil monomers in the same multi - phase inductor monomer.

[0023] Compared with the prior art, the technical solution of the present invention and its beneficial effects are as follows:

[0024] (1) The present invention obtains coil monomers by cutting a whole - plate coil assembly, and fills and cures a gelling material in the cutting channels between adjacent coil monomers, achieving physical isolation between the coil monomers, significantly reducing the mutual inductance effect between inductors, reducing electromagnetic coupling, thus reducing crosstalk problems, improving the performance and stability of inductors, and is particularly suitable for high - frequency or complex circuits. By first manufacturing the whole - plate coil assembly and then performing operations such as cutting and filling the gelling material, the cumbersome process of individually manufacturing and bonding each inductor is avoided, greatly improving production efficiency and reducing manufacturing difficulty and cost.

[0025] (2) By specifying the filling of the gelling material in the cutting channels, the present invention can flexibly adjust the arrangement mode and quantity between inductor monomers according to different circuit designs and application requirements, improving the flexibility and adaptability of multi - phase inductors, enabling them to better meet diverse market demands. And it reduces the amount of gelling material filled and reduces one cutting process, further improving production efficiency and reducing manufacturing costs. Brief Description of the Drawings

[0026] Figure 1 is a schematic diagram of the whole - plate coil assembly provided in Embodiment 1 of the present invention;

[0027] Figure 2 is a schematic diagram of arranging a mucosa below the whole - plate coil assembly provided in Embodiment 1 of the present invention;

[0028] Figure 3 is a schematic diagram of cutting the whole - plate coil assembly provided in Embodiment 1 of the present invention;

[0029] Figure 4 is a schematic diagram of the whole - plate isolated coil assembly provided in Embodiment 1 of the present invention;

[0030] Figure 5 is a schematic diagram of cutting the whole - plate isolated coil assembly provided in Embodiment 1 of the present invention;

[0031] Figure 6 is a schematic diagram of a multi - phase inductor monomer provided in Embodiment 1 of the present invention;

[0032] Figure 7 is a schematic diagram of the whole - plate isolated coil assembly provided in Embodiment 2 of the present invention.

[0033] Illustration Description:

[0034] Whole - plate coil assembly - 100; Coil - 101; Electrode - 102; Magnet - 103; Coil monomer - 110; Cutting channel - 120; Isolation channel - 130; Separation channel - 140;

[0035] Mucosa - 200. Detailed Embodiments

[0036] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, rather than all of them. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention. 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.

[0037] Embodiment 1

[0038] Refer to Figures 1 to 6 , a method for manufacturing a heterogeneous multi-phase inductor, the steps are as follows:

[0039] S1. Fabricate a full-panel coil assembly 100, the full-panel coil assembly includes a coil 101 of a full-panel bottom electrode 102 and a magnet 103 wrapped outside the coil 101, as Figure 1 .

[0040] The full-panel coil assembly 100 can be a full-panel double-layer multi-turn coil assembly, a full-panel multi-layer single-turn coil assembly, a full-panel multi-layer multi-turn coil assembly, etc. The specific number of layers and the number of turns of a single coil are not limited. As long as the coils of the full-panel coil assembly are arranged in an array and the electrodes are on the same side. The manufacturing methods of various full-panel coil assemblies are described in detail in Chinese invention patents with publication numbers CN119092287A, CN118919258A, CN118919258A, CN115516585A, etc., and will not be elaborated here.

[0041] S2. Arrange a mucosa 200 below the full-panel coil assembly 100. The mucosa 200 can be a pyrolytic mucosa or a blue film, as Figure 2 .

[0042] S3. Cut the full-panel coil assembly to obtain a number of mutually separated coil monomers 110. The coil monomer includes a single coil 101 and a magnet wrapping the single coil, as Figure 3 . It can be understood that since the mucosa 200 is arranged on the bottom surface of the full-panel coil assembly 100, when the full-panel coil assembly 100 is cut into a number of coil monomers 110, the positions of the coil monomers 110 are relatively orderly fixed, avoiding destroying the array arrangement of the coil monomers 110.

[0043] S4. Fill the cutting channels 120 between adjacent coil monomers 110 with a gum-like material and cure it to form isolation channels 130, obtaining a full-panel isolated coil assembly, as Figure 4。The colloidal material should have good insulation, mechanical strength, and chemical stability, which can effectively isolate the electromagnetic coupling between the inductance monomers, while ensuring the connection strength and stability between the inductance monomers, and improving the overall performance and reliability of the multiphase inductor. In this embodiment, the colloidal material used is epoxy resin, silicone resin, or phenolic resin.

[0044] S5. Cut the whole-board isolation coil assembly to obtain multiphase inductance monomers, such as Figure 5 。The multiphase inductance monomer includes a number of coil monomers 110 and the colloidal material 130 between adjacent coil monomers. That is, free cutting enables the quantity and arrangement mode contained in each multiphase inductance monomer to meet the requirements of production design, greatly improving the flexibility of production. Adjacent multiphase inductance monomers are separated by the separation channels 140 formed by cutting, while the coil monomers 110 in the same multiphase inductance monomer are isolated and fixedly connected through the colloidal material 130.

[0045] S6. Thresh the whole-board isolation coil assembly cut in S5. According to the production environment and the material of the mucosa, appropriately select the threshing method. For example, if the mucosa is a pyrolytic mucosa, heating can be used to make the glue of the pyrolytic mucosa lose its viscosity, so that the multiphase inductance monomers are threshed; for another example, if the mucosa is a blue film, various methods such as manual tearing, particulate dry ice cleaning, and laser debonding can be used, providing more choices in the production process. The threshed multiphase inductance monomers are as Figure 6 shown, including a number of coil monomers isolated and fixed together by the isolation channels 13.

[0046] S7. Perform subsequent operations such as end grinding and electroplating electrodes on the threshed multiphase inductance monomers to make their surfaces smoother and flatter, improving the aesthetics and consistency of the products. At the same time, electroplating electrodes can enhance the conductivity and corrosion resistance of the inductance monomers, improving the electrical performance and reliability of the inductors in the circuit. Of course, there can also be other operations, such as end face treatment, potting, laser marking, etc., which are consistent with the existing processes.

[0047] In the present invention, coil monomers are obtained by cutting the whole-board coil assembly, and the cutting channels between adjacent coil monomers are filled with a colloidal material and cured, realizing the physical isolation between the coil monomers, significantly reducing the mutual inductance effect between the inductors, reducing the electromagnetic coupling, thereby reducing the crosstalk problem, and improving the performance and stability of the inductors, which is especially suitable for high-frequency or complex circuits. By first manufacturing the whole-board coil assembly and then performing operations such as cutting and filling the colloidal material, the cumbersome process of manufacturing and bonding each inductor separately is avoided, greatly improving the production efficiency, reducing the manufacturing difficulty and cost. And because the manufacturing process of the whole-board coil assembly is relatively unified and standardized, and the processes of cutting and filling the colloidal material are also relatively controllable and unified, the consistency and stability between the inductors can be better guaranteed, and the product quality can be improved.

[0048] Embodiment 2

[0049] This embodiment is different from S4 and S5 of Embodiment 1.

[0050] S4’: Fill the specified cutting lanes with a gelling material and cure it. The adjacent coil monomers are connected by the gelling material to form a multiphase inductance monomer. As Figure 7 shown, in this embodiment, it is not necessary to apply the gluing process to all the cutting lanes 12. Instead, specific cutting lanes are selected for dispensing and curing. The filled cutting lanes 12 form separation lanes 13, which isolate and connect several adjacent coil monomers to form a multiphase inductance monomer. The unfilled cutting lanes 12 finally serve as separation lanes 14, so that the multiphase inductance monomers are separated from each other. After threshing, single multiphase inductance monomers can be obtained.

[0051] Compared with Embodiment 1, after the process of filling with glue in this embodiment, multiphase inductance monomers have been formed without the need for secondary cutting (i.e., S5 of Embodiment 1), reducing the amount of gelling material filled and one cutting process, further improving production efficiency and reducing manufacturing costs. Moreover, by filling the gelling material in the specified cutting lanes, the arrangement and quantity between inductance monomers can be flexibly adjusted according to different circuit designs and application requirements, improving the flexibility and adaptability of the multiphase inductor, enabling it to better meet the diverse market demands.

[0052] Of course, when filling the gelling material in the specified cutting lanes, there is a certain overflow situation, that is, part of the colloid exceeds the isolation lane, which is dealt with in the subsequent end grinding process of the multiphase inductance monomer without additional processes.

[0053] The above description illustrates and describes the preferred embodiments of the present invention. It should be understood that the present invention is not limited to the forms disclosed herein, should not be regarded as excluding other embodiments, but can be used in various other combinations, modifications and environments, and can be changed within the scope of the inventive concept herein through the above teachings or the techniques or knowledge in related fields. Any changes and variations made by those skilled in the art without departing from the spirit and scope of the present invention shall fall within the protection scope of the appended claims of the present invention.

Claims

1. A method for manufacturing a multiphase inductor with a heterogeneous structure, characterized in that The steps are as follows: Fabricate a full-panel coil assembly, which includes a full-panel coil with a bottom electrode and a magnet wrapped around the coil. The coils are arranged in an array. Cut the full-panel coil assembly to obtain a number of mutually separated coil monomers. Each coil monomer includes a single coil and a magnet wrapped around the single coil. Fill the cutting channels between adjacent coil monomers with a gum-like material and cure it to obtain a full-panel isolated coil assembly. Cut the full-panel isolated coil assembly to obtain poly-phase inductance monomers, where each poly-phase inductance monomer includes a number of coil monomers and the gum-like material between adjacent coil monomers.

2. Method for manufacturing a multiphase inductor with a heterogeneous structure, characterized in that, The steps are as follows: Fabricate a full-panel coil assembly, which includes a coil with a full-panel bottom electrode and a magnet wrapped around the coil. Cut the full-panel coil assembly to obtain a number of mutually separated coil monomers. Each coil monomer includes a single coil and a magnet wrapped around the single coil. Fill a specified cutting channel with a gum-like material and cure it. The adjacent coil monomers are connected by the gum-like material to form poly-phase inductance monomers.

3. The method for manufacturing a heterogeneous multi-phase inductor according to claim 1 or 2, characterized in that, The gum-like material includes one or several of epoxy resin, silicone resin, and phenolic resin.

4. The method for manufacturing a heterogeneous multi-phase inductor according to claim 1, wherein Before cutting the full-panel inductance, it also includes setting a pyrolytic mucous membrane or a blue film under the full-panel coil assembly. After cutting the full-panel isolated coil assembly to obtain poly-phase inductance monomers or filling a specified cutting channel with a gum-like material and curing it to obtain poly-phase inductance monomers, perform threshing on the poly-phase inductance monomers.

5. The method for manufacturing a heterogeneous multi-phase inductor according to claim 4, wherein The threshing method includes: heating to make the poly-phase inductance monomers detach from the pyrolytic mucous membrane; or, by one of the methods of manual tearing, microparticle dry ice cleaning, and laser degumming, to make the poly-phase inductance monomers detach from the blue film.

6. The method for manufacturing a heterogeneous multi-phase inductor according to claim 1 or 2, characterized in that It also includes the steps of grinding the ends and electroplating electrodes of the poly-phase inductance monomers.

7. According to the method for manufacturing a poly-phase inductance with a heterogeneous structure described in claim 2, the specified cutting channel refers to the cutting channel located between adjacent coil monomers in the same poly-phase inductance monomer.

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