Integrated inductance element and production process thereof

Abstract

The invention discloses an integrated inductance element and a production process thereof, the integrated inductance element comprises two groups of inductance unit pieces, and each group of inductance unit piece comprises a soft magnetic cladding body upper assembly and a soft magnetic cladding body lower assembly; wherein the soft magnetic wrapping body upper assembly comprises a soft magnetic wrapping body base and a coil, the coil is installed on the soft magnetic wrapping body base, the coil is provided with a first terminal pin and a second terminal pin, the soft magnetic wrapping body base comprises a base plate, a limiting groove is formed in the middle of the top face of the base plate, and a limiting opening is formed in one end of the limiting groove; mounting columns are arranged in the centers of the bottom surfaces of the limiting grooves; the soft magnetic wrapping body lower assembly comprises a soft magnetic wrapping body cover plate. By the adoption of the structure, element short circuit and cracking damage defects caused by coil package damage and displacement due to non-protection positioning pressing can be reduced, the inductance value and saturation temperature rise performance of the formed inductance element are improved, and the reliability and performance of the formed inductance element are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of electronic components, in particular to an integrated inductor and a production process thereof. BACKGROUND

[0002] The original model of an inductor is a cylindrical coil wound by a wire. When current i flows through the coil, magnetic flux Φ is generated in the coil, and energy is stored. Electromagnetic induction of an inductor includes self-induction and mutual induction. The electromagnetic induction phenomenon caused by the change of the self magnetic field in the coil is called "self-induction" phenomenon. The electromagnetic induction phenomenon caused by the change of the external magnetic field in the coil is called "mutual induction" phenomenon.

[0003] However, in the existing inductor, the coil is installed without protection, positioning and pressing, which causes the coil position to deviate, and further causes the thickness of the two side walls to be uneven, resulting in the problem of smaller single-sided wall thickness. The structure strength will be poor when the wall thickness becomes smaller, so it will cause cracking, which will cause the inductor to be damaged due to the short circuit of the coil winding and the deviation, resulting in damage of the inductor. The quality of the inductor produced is insufficient, and it lacks competitiveness in the market for similar products. SUMMARY

[0004] In order to overcome the above technical problems, the purpose of the present application is to provide an integrated inductor and a production process thereof.

[0005] The purpose of the present application can be achieved by the following technical solutions.

[0006] An integrated inductor includes two groups of inductor elements, which are symmetrically distributed. Each group of inductor elements includes a soft magnetic cladding body upper assembly and a soft magnetic cladding body lower assembly.

[0007] The soft magnetic cladding body upper assembly includes a soft magnetic cladding body base and a coil. The coil is installed on the soft magnetic cladding body base. The coil is provided with a first lead pin and a second lead pin. The soft magnetic cladding body base includes a base plate. A mounting column is arranged in the middle of the top surface of the base plate.

[0008] The soft magnetic cladding body lower assembly includes a soft magnetic cladding body cover plate.

[0009] As a further scheme of the present application, the height of the mounting column is higher than the height of the coil.

[0010] As a further scheme of the present application, the height of the mounting column is equal to the height of the coil.

[0011] As a further scheme of the present application, the height of the mounting column is less than the height of the coil.

[0012] As a further scheme of the present application: the soft magnetic cladding body cover plate and the insulation part are integrally formed.

[0013] As a further scheme of the present application: the soft magnetic cladding body cover plate and the insulation part are integrally formed.

[0014] As a further scheme of the present application: the soft magnetic cladding body cover plate and the insulation part are integrally formed.

[0015] As a further scheme of the present application: a production process of an integrated inductance element, comprising the following steps:

[0016] Step one: the coil is sleeved on the mounting column of the soft magnetic cladding body base, then the first lead pin and the second lead pin are bent, and the limiting opening is limited corresponding to the first lead pin, to obtain a soft magnetic cladding body upper assembly;

[0017] Step two: a soft magnetic cladding body upper assembly is placed in the extrusion die, then a prefabricated soft magnetic cladding body lower assembly is placed in the extrusion die in a normal position;

[0018] Step three: a prefabricated soft magnetic cladding body lower assembly is placed in the extrusion die in an inverted position, then an inverted soft magnetic cladding body upper assembly is placed, wherein the orientations of the two first lead pins and the second lead pin are located on the same side;

[0019] Step four: extrusion is performed to obtain a semi-finished inductance element, the semi-finished inductance element is taken out, and the exposed first lead pin and the second lead pin are electroplated with tin to obtain a finished inductance element.

[0020] The beneficial effects of the present application are:

[0021] 1. The present application forms a soft magnetic cladding body base in advance, sets a mounting column, ensures positioning protection when the coil is installed, fixes the coil by the mounting column during pressing, ensures the stability of the position of the coil during pressing, and reduces the coil wire package damage, element short circuit, cracking and breakage caused by the lack of protection positioning and pressing.

[0022] 2. The present application further reduces the size of the finished inductance element, especially the thickness is reduced by 3mm, the small integrated inductance element is made, which provides better space utilization precondition for more elements mounted on the small circuit board, and reduces the loss of raw materials such as iron powder, copper material and tin required for manufacturing.

[0023] 3. The inductance element of the present application realizes the miniaturization of the integrated inductance element, improves the inductance of the integrated inductance element by about 14%, the saturation performance by 10% and the DCR characteristic by 50%, and further improves the reliability and performance of the formed inductance element. BRIEF DESCRIPTION OF DRAWINGS

[0024] The application will be further described in conjunction with the accompanying drawings.

[0025] Figure 1 is the structure schematic diagram of the finished inductance element of the application;

[0026] Figure 2 is the structure schematic diagram of the coil of the application;

[0027] Figure 3 is the structure schematic diagram of the soft magnetic covering body base of the embodiment one of the application;

[0028] Figure 4 is the structure schematic diagram of the soft magnetic covering body lower assembly of the embodiment one of the application;

[0029] Figure 5 is the structure schematic diagram of the soft magnetic covering body upper assembly of the embodiment one of the application;

[0030] Figure 6 is the structure schematic diagram of the extrusion position of the production process of the embodiment one of the application;

[0031] Figure 7 is the structure schematic diagram of the soft magnetic covering body base of the embodiment two of the application;

[0032] Figure 8 is the structure schematic diagram of the soft magnetic covering body lower assembly of the embodiment two of the application;

[0033] Figure 9 is the structure schematic diagram of the soft magnetic covering body upper assembly of the embodiment two of the application;

[0034] Figure 10 is the structure schematic diagram of the extrusion position of the production process of the embodiment two of the application;

[0035] Figure 11 is the structure schematic diagram of the soft magnetic covering body cover of the embodiment two of the application; Figure 1 ;

[0036] Figure 12 is the structure schematic diagram of the soft magnetic covering body base of the embodiment two of the application; Figure 1 ;

[0037] Figure 13 is the structure schematic diagram of the soft magnetic covering body cover of the embodiment two of the application; Figure 2 ;

[0038] Figure 14 is the structure schematic diagram of the soft magnetic covering body base of the embodiment two of the application; Figure 2 ;

[0039] Figure 15 is the structure schematic diagram of the soft magnetic covering body cover of the embodiment two of the application;Figure 3 ;

[0040] Figure 16 is the soft magnetic cladding body base structure deformation schematic in the embodiment two of the present application Figure 3 ;

[0041] Figure 17 is the soft magnetic cladding body cover structure deformation schematic in the embodiment two of the present application Figure 4 ;

[0042] Figure 18 is the soft magnetic cladding body base structure deformation schematic in the embodiment two of the present application Figure 4 ;

[0043] Figure 19 is the soft magnetic cladding body base structure deformation schematic in the embodiment two of the present application Figure 5 .

[0044] In the figure: 1, coil; 101, first lead pin; 102, second lead pin; 2, soft magnetic cladding body base; 21, mounting column; 22, base plate; 23, limiting groove; 24, limiting opening; 202, bottom plate; 203, first recess; 204, second recess; 3, soft magnetic cladding body lower assembly; 30, soft magnetic cladding body cover plate; 31, soft magnetic cladding body cover; 311, placing recess; 312, positioning opening; 4, soft magnetic cladding body upper assembly; 5, inductance unit element. DETAILED DESCRIPTION

[0045] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the protection scope of the present application.

[0046] Embodiment one:

[0047] As shown in Figures 1-6 , an integrated inductance element includes two groups of inductance unit elements 5, the two groups of inductance unit elements 5 are symmetrically distributed about a joint surface, each group of inductance unit elements 5 includes a soft magnetic cladding body upper assembly 4 and a soft magnetic cladding body lower assembly 3, the inductance unit elements 5 are formed by assembling the corresponding soft magnetic cladding body upper assembly 4 and soft magnetic cladding body lower assembly 3, and then the two groups of inductance unit elements 5 are placed in an extrusion die to be pressed into one body to form the inductance element.

[0048] Further as shown in Figure 2 , Figure 3 and Figure 5As shown in the figure, the soft magnetic cladding upper assembly 4 comprises a soft magnetic cladding base 2 and a coil 1 mounted on the soft magnetic cladding base 2, wherein the coil 1 is provided with a first lead pin 101 and a second lead pin 102, the soft magnetic cladding base 2 comprises a base plate 22, a limiting groove 23 is formed in the middle of the top surface of the base plate 22, one end of the limiting groove 23 is arc-shaped, one end is rectangular, a limiting opening 24 is formed at one end of the rectangular surface for positioning the first lead pin 101 or the second lead pin 102 installed thereon, and the limiting position is convenient for subsequent pressing, and a mounting column 21 is further arranged at the center of the bottom surface of the limiting groove 23 for assembly positioning, and the shape of the mounting column 21 includes but is not limited to a circle and an ellipse, and the soft magnetic cladding upper assembly 4 is formed by assembling the coil 1 and the soft magnetic cladding base 2, wherein the first lead pin 101 and the second lead pin 102 need to be bent twice during the mounting process of the coil 1, the first bending makes the first lead pin 101 and the second lead pin 102 bent to the side surface of the base plate 22, and the second bending makes the first lead pin 101 and the second lead pin 102 bent to the bottom surface of the base plate 22 and tightly fit with the bottom surface of the base plate 22.

[0049] Further as shown in the figure, Figure 3 The height of the mounting column 21 in the figure can be higher than the height of the coil 1, equal to the height of the coil 1 or lower than the height of the coil 1, and various sizes are available.

[0050] Further as shown in the figure, Figure 4 The soft magnetic cladding lower assembly 3 comprises a soft magnetic cladding cover plate 30 and an insulation part 32, wherein the soft magnetic cladding cover plate 30 is a flat plate for sealing the coil 1 in cooperation with the soft magnetic cladding upper assembly 4, and the insulation part 32 is located on the top surface of the soft magnetic cladding cover plate 30; it should be noted that the soft magnetic cladding cover plate 30 and the insulation part 32 can be integrally formed or separately formed, and finally placed and extruded in sequence to form an inductor element, and further two soft magnetic cladding lower assemblies 3 can be integrally formed or separately formed.

[0051] Further, the soft magnetic cladding base 2 and the soft magnetic cladding cover plate 30 are made of soft magnetic powder, and common soft magnetic materials include ferrite, iron powder core and amorphous alloy, which can be deformed under pressure, and the material of the insulation part 32 is a metal particle material coated with insulation.

[0052] Further, the soft magnetic cladding cover plate 30 and the insulation part 32 can be filled with powder during pre-fabrication or cut into blocks during pre-fabrication.

[0053] Further, the production process of the integrated inductor element comprises the following schemes:

[0054] Scheme one:

[0055] Step A1: coil 1 is sleeved on the mounting column 21 of the soft magnetic cover body base 2 and placed in the limiting groove 23, and then the first lead pin 101 and the second lead pin 102 are bent, wherein the limiting opening 24 is limited corresponding to the first lead pin 101, and the bending number is twice, the first bending is to bend the first lead pin 101 and the second lead pin 102 to one side of the limiting opening 24 opened in the base plate 22, and the second bending is to bend the first lead pin 101 and the second lead pin 102 to the bottom surface of the base plate 22 and tightly fit with the bottom surface of the base plate 22, to obtain the soft magnetic cover body upper assembly 4;

[0056] Step A2: a soft magnetic cover body upper assembly 4 is placed in the extrusion mold, and then a prefabricated soft magnetic cover body lower assembly 3 (wherein the soft magnetic cover body cover plate 30 and the insulating part 32 are integrally formed) is placed in the extrusion mold;

[0057] Step A3: a prefabricated soft magnetic cover body lower assembly 3 (wherein the soft magnetic cover body cover plate 30 and the insulating part 32 are integrally formed) is placed in the extrusion mold, and then a inverted soft magnetic cover body upper assembly 4 is placed, wherein the directions of the two first lead pins 101 and the second lead pins 102 are located on the same side;

[0058] Step A4: extrusion is performed to obtain a semi-finished inductance element, the semi-finished inductance element is taken out, and the exposed first lead pin 101 and the second lead pin 102 are electroplated with tin to obtain a finished inductance element (wherein the size of the tin plating is based on the longer lead pin).

[0059] Scheme two:

[0060] Step B1: coil 1 is sleeved on the mounting column 21 of the soft magnetic cover body base 2 and placed in the limiting groove 23, and then the first lead pin 101 and the second lead pin 102 are bent, wherein the limiting opening 24 is limited corresponding to the first lead pin 101, and the bending number is twice, the first bending is to bend the first lead pin 101 and the second lead pin 102 to one side of the limiting opening 24 opened in the base plate 22, and the second bending is to bend the first lead pin 101 and the second lead pin 102 to the bottom surface of the base plate 22 and tightly fit with the bottom surface of the base plate 22, to obtain the soft magnetic cover body upper assembly 4;

[0061] Step B2: a soft magnetic cover body upper assembly 4 is placed in the extrusion mold, and then a prefabricated soft magnetic cover body lower assembly combination (wherein the soft magnetic cover body lower assembly combination is integrally pressed by two soft magnetic cover body lower assemblies 3 in advance) is placed in the extrusion mold;

[0062] Step B3: Put one soft magnetic cladding upper assembly 4 in the extrusion die again, wherein the two first lead pins 101 and the second lead pin 102 are on the same side;

[0063] Step B4: Perform extrusion to obtain a semi-finished inductance element, take out the semi-finished inductance element, and electroplate the exposed first lead pins 101 and the second lead pin 102 with tin to obtain a finished inductance element (wherein the tin plating size is based on the longer lead pin).

[0064] Scheme Three:

[0065] Step C1: Put the coil 1 on the mounting column 21 of the soft magnetic cladding base 2 and place it in the limiting groove 23, and then bend the first lead pin 101 and the second lead pin 102, wherein the limiting opening 24 is limited with the first lead pin 101, and the bending number is twice, the first bending is to bend the first lead pin 101 and the second lead pin 102 to the side of the base plate 22 opening the limiting opening 24, and the second bending is to bend the first lead pin 101 and the second lead pin 102 to the bottom surface of the base plate 22 and tightly fit with the bottom surface of the base plate 22, to obtain a soft magnetic cladding upper assembly 4;

[0066] Step C2: Put one soft magnetic cladding upper assembly 4 in the extrusion die, and then put a pre-prepared soft magnetic cladding cover plate 30 (wherein the soft magnetic cladding cover plate 30 and the insulating part 32 are separately formed) upside down into the extrusion die;

[0067] Step C3: Put two pre-prepared insulating parts 32 in the extrusion die, and then put a pre-prepared soft magnetic cladding cover plate 30 (wherein the soft magnetic cladding cover plate 30 and the insulating part 32 are separately formed) upside down into the extrusion die, and then put one soft magnetic cladding upper assembly 4 upside down into the extrusion die, wherein the two first lead pins 101 and the second lead pin 102 are on the same side;

[0068] Step C4: Perform extrusion to obtain a semi-finished inductance element, take out the semi-finished inductance element, and electroplate the exposed first lead pins 101 and the second lead pin 102 with tin to obtain a finished inductance element (wherein the tin plating size is based on the longer lead pin).

[0069] Example Two:

[0070] Compared with Example One, the difference of the present embodiment is that, as shown in FIG. 6, the soft magnetic cladding cover plate 30 is provided with a limiting opening 34 corresponding to the first lead pin 101, and the first lead pin 101 is limited by the limiting opening 34. Figures 7-10As shown, the structure of the soft magnetic cladding body base 2 is not the same, and the soft magnetic cladding body base 2 in the embodiment includes a bottom plate 202, a mounting column 21 identical to that in Embodiment One is arranged at the middle of the top surface of the bottom plate 202, a first recess 203 and a second recess 204 are arranged on one side surface of the bottom plate 202, wherein the first recess 203 and the second recess 204 are symmetrically distributed about the longitudinal center line of the bottom plate 202, the soft magnetic cladding body upper assembly 4 is formed by assembling the coil 1 and the soft magnetic cladding body base 2, wherein the first lead pin 101 and the second lead pin 102 need to be bent twice during the mounting process of the coil 1, the first bending is to bend the first lead pin 101 and the second lead pin 102 into the corresponding first recess 203 and second recess 204, and the second bending is to bend the first lead pin 101 and the second lead pin 102 to the bottom surface of the bottom plate 202 and tightly fit with the bottom surface of the bottom plate 202.

[0071] Similarly, the height of the mounting column 21 in Embodiment Two can also be higher than the height of the coil 1, equal to the height of the coil 1, or lower than the height of the coil 1, and various sizes are available.

[0072] Further, the embodiment is different in that, as shown in Figure 8 The soft magnetic cladding body lower assembly 3 is replaced by a soft magnetic cladding body cover 31 instead of the soft magnetic cladding body cover plate 30, wherein one side of the soft magnetic cladding body cover 31 is provided with a placing recess 311 for assembling with the coil 1 in the soft magnetic cladding body upper assembly 4, and further, one end of the placing recess 311 is provided with a positioning opening 312 for positioning the first lead pin 101 or the second lead pin 102, wherein the insulating part 32 is located on the opposite side of the soft magnetic cladding body cover 31 provided with the placing recess 311; it should be noted that the soft magnetic cladding body cover 31 and the insulating part 32 are integrally formed or separately formed, and finally, the inductor element is placed and extruded in sequence, and the soft magnetic cladding body cover 31 and the soft magnetic cladding body cover plate 30 are made of the same material.

[0073] Further, as shown in Figures 11-18 The soft magnetic cladding body cover 31 and the soft magnetic cladding body base 2 of the embodiment can adopt various corresponding structures for cooperation:

[0074] A: As shown in Figure 11 and Figure 12 The mounting column 21 is the same as in the embodiment, the positioning opening 312 is a full-through opening, and the placing recess 311 is in communication with the positioning opening 312;

[0075] B: As shown in Figure 13 and Figure 14As shown, the placement groove 311 and the bottom plate 202 are both provided with mounting columns 21, and the two mounting columns 21 are mutually matched in size, and the positioning opening 312 is a full-through opening, which is in communication with the placement groove 311, and two grooves are provided below the positioning opening 312 and correspond to the first groove 203 and the second groove 204;

[0076] C: As Figures 15-16 shown, the placement groove 311 and the bottom plate 202 are both provided with mounting columns 21, and the two mounting columns 21 are mutually matched in size, and the positioning opening 312 is a full-through opening, which is in communication with the placement groove 311, and two grooves are provided below the positioning opening 312 and correspond to the first groove 203 and the second groove 204;

[0077] D: As Figures 17-18 shown, the mounting column 21 is unchanged, and the difference lies in that the bottom plate 202 is rounded away from one end of the positioning protrusion 205, and a step surface is formed on one side of the placement groove 311 corresponding to the soft magnetic cover body cover 31, and the step height is equal to the thickness of the bottom plate 202, and the rounded bottom plate 202 is adapted on the soft magnetic cover body cover 31 of the ladder.

[0078] E: As Figure 19 shown, the mounting column 21 is unchanged, and the difference lies in that the bottom plate 202 is in the shape of a cross, and the corresponding soft magnetic cover body cover 31 can be any shape.

[0079] The embodiment is different from the first embodiment in the structural features of the above-mentioned differences.

[0080] Further, the production process of the integrated inductor element includes the following schemes:

[0081] Scheme four:

[0082] Step D1: The coil 1 is sleeved on the mounting column 21 of the soft magnetic cover body base 2, and then the first lead pin 101 and the second lead pin 102 are bent, and the bending number is twice, the first bending is to bend the first lead pin 101 and the second lead pin 102 into the corresponding first groove 203 and second groove 204, and the second bending is to bend the first lead pin 101 and the second lead pin 102 to the bottom surface of the bottom plate 202 and tightly adhere to the bottom surface of the bottom plate 202, to obtain a soft magnetic cover body upper assembly 4;

[0083] Step D2: Put a soft magnetic cover body upper assembly 4 into the extrusion mold, then put a prefabricated soft magnetic cover body lower assembly 3 into the extrusion mold upside down, and limit the positioning opening 312 corresponding to the first lead pin 101;

[0084] Step D3: Put another prefabricated soft magnetic cover body lower assembly 3 into the extrusion mold again, and then put a soft magnetic cover body upper assembly 4 upside down, wherein the directions of the two first lead pins 101 and the second lead pins 102 are located on the same side;

[0085] Step D4: extrusion is performed to obtain a semi-finished inductance element, the semi-finished inductance element is taken out, and the exposed first lead pin 101 and the second lead pin 102 are electroplated with tin to obtain a finished inductance element (wherein the size of the tin plating is based on the longer lead pin).

[0086] Scheme five;

[0087] Step E1: the coil 1 is sleeved on the mounting column 21 of the soft magnetic cover body base 2, then the first lead pin 101 and the second lead pin 102 are bent twice, the first bending is to bend the first lead pin 101 and the second lead pin 102 into the corresponding first groove 203 and second groove 204, and the second bending is to bend the first lead pin 101 and the second lead pin 102 to the bottom surface of the bottom plate 202 and tightly fit with the bottom surface of the bottom plate 202, to obtain a soft magnetic cover body upper assembly 4;

[0088] Step E2: a soft magnetic cover body upper assembly 4 is placed in an extrusion mold, then a pre-prepared soft magnetic cover body cover 31 is placed in the extrusion mold in an inverted manner, and the positioning opening 312 is positioned corresponding to the first lead pin 101;

[0089] Step E3: two pre-prepared insulation parts 32 are placed in the extrusion mold, then a pre-prepared soft magnetic cover body cover 31 is placed in the extrusion mold in a normal manner, then a soft magnetic cover body upper assembly 4 is placed in the extrusion mold in an inverted manner, wherein the directions of the two first lead pins 101 and the second lead pins 102 are located on the same side;

[0090] Step E4: extrusion is performed to obtain a semi-finished inductance element, the semi-finished inductance element is taken out, and the exposed first lead pin 101 and the second lead pin 102 are electroplated with tin to obtain a finished inductance element (wherein the size of the tin plating is based on the longer lead pin).

[0091] Scheme six;

[0092] Step F1: the coil 1 is sleeved on the mounting column 21 of the soft magnetic cover body base 2, then the first lead pin 101 and the second lead pin 102 are bent twice, the first bending is to bend the first lead pin 101 and the second lead pin 102 into the corresponding first groove 203 and second groove 204, and the second bending is to bend the first lead pin 101 and the second lead pin 102 to the bottom surface of the bottom plate 202 and tightly fit with the bottom surface of the bottom plate 202, to obtain a soft magnetic cover body upper assembly 4;

[0093] Step F2: a soft magnetic cover body upper assembly 4 is placed in an extrusion mold, then a pre-prepared soft magnetic cover body cover 31 is placed in the extrusion mold in an inverted manner, and the positioning opening 312 is positioned corresponding to the first lead pin 101;

[0094] Step F3: Put a pre-made soft magnetic cladding cover 31 in a right position in the extrusion die, and then put a soft magnetic cladding upper assembly 4 in an upside-down position, wherein the two first lead pins 101 and the second lead pin 102 are on the same side;

[0095] Step F4: Perform extrusion to obtain a semi-finished inductance element, take out the semi-finished inductance element, and electroplate the exposed first lead pin 101 and the second lead pin 102 with tin to obtain a finished inductance element (wherein the size of the tin plating is based on the longer lead pin).

[0096] Further, the performance of the integrated inductance element of the present application and the conventional integrated inductance element is tested, wherein the thickness is detected by a vernier caliper, the inductance is detected by an inductance meter (model HIOKI IM3536), the saturated inductance is detected by a winding element pulse tester (model Chroma 3302), and the DC resistance is detected by a DCR meter (model GOM804), and the experimental data are shown in Table 1 and Table 2.

[0097] Table 1 is the data of the integrated inductance element of the present application:

[0098]

[0099]

[0100]

[0101]

[0102] Table 2 is the data of the conventional integrated inductance element:

[0103]

[0104]

[0105]

[0106] From the comparison of the experimental data in Table 1 and Table 2, it can be seen that, compared with the conventional integrated inductance element, the integrated inductance element of the present application is more miniaturized in size, the thickness is reduced by 0.3 mm, the inductance of the integrated inductance element of the present application is increased by about 14%, the saturation characteristic of the integrated inductance element of the present application is increased by about 10% under the condition of 6.6 A, and the DCR characteristic is further increased by about 50%.

[0107] where DCR is the direct current resistance in mΩ. For inductors of the same size, the direct current resistance will generally exhibit the following characteristics: if the inductance value is high, the direct current resistance value will be high and if the inductance value is low, the direct current resistance value will be low.

[0108] The above detailed description of the application is only a preferred embodiment of the application, and cannot be considered as limiting the scope of the application. Any equivalent changes and improvements made according to the scope of the application should still belong to the patent scope of the application.

Claims

1. A process for producing an integrated inductive element, characterized by, It comprises the following steps: Step one: put the coil (1) into the mounting column (21) of the soft magnetic cover body base (2), and place it in the limiting groove (23), then bend the first lead pin (101) and the second lead pin (102), and limit the limiting opening (24) with the first lead pin (101), to get the soft magnetic cover body upper assembly (4); Wherein the coil (1) needs to be bent twice during installation, the first time to bend the first lead pin (101) and the second lead pin (102) to the corresponding side of the base plate (22), and the second time to bend the first lead pin (101) and the second lead pin (102) to the bottom surface of the base plate (22) and tightly fit with the bottom surface of the base plate (22); Step two: put a soft magnetic cover body upper assembly (4) into the extrusion mold, then put a prefabricated soft magnetic cover body lower assembly (3) into the extrusion mold; Step three: put another prefabricated soft magnetic cover body lower assembly (3) into the extrusion mold again, then put an inverted soft magnetic cover body upper assembly (4) into the extrusion mold, wherein the directions of the two first lead pins (101) and the second lead pins (102) are on the same side; Step four: extrude to get a semi-finished inductor, take out the semi-finished inductor, and electroplate the exposed first lead pin (101) and the second lead pin (102) with tin to get a finished inductor; The integrated inductor element comprises two groups of inductor unit elements (5), which are symmetrically distributed, and each group of inductor unit elements (5) comprises a soft magnetic cover body upper assembly (4) and a soft magnetic cover body lower assembly (3); The soft magnetic cover body upper assembly (4) comprises a soft magnetic cover body base (2) and a coil (1), the coil (1) is installed on the soft magnetic cover body base (2), the coil (1) is provided with a first lead pin (101) and a second lead pin (102), and the soft magnetic cover body base (2) comprises a base plate (22), the middle part of the top surface of the base plate (22) is provided with a mounting column (21); The directions of the two first lead pins (101) and the second lead pins (102) are on the same side; The soft magnetic cover body lower assembly (3) comprises a soft magnetic cover body cover plate (30), and the soft magnetic cover body cover plate (30) is provided with a placing groove (311) on one side.

2. An integrated inductive element produced using the production process of an integrated inductive element as claimed in claim 1, characterized in that, It comprises two groups of inductor unit elements (5), which are symmetrically distributed, and each group of inductor unit elements (5) comprises a soft magnetic cover body upper assembly (4) and a soft magnetic cover body lower assembly (3); The soft magnetic cover body upper assembly (4) comprises a soft magnetic cover body base (2) and a coil (1), the coil (1) is installed on the soft magnetic cover body base (2), the coil (1) is provided with a first lead pin (101) and a second lead pin (102), and the soft magnetic cover body base (2) comprises a base plate (22), one end of the base plate (22) is provided with a limiting opening (24), and the middle part of the base plate (22) is provided with a mounting column (21); The two first lead pins (101) and the second lead pin (102) are oriented on the same side; The soft magnetic cladding body lower assembly (3) comprises a soft magnetic cladding body cover plate (30).

3. An integral inductive element as defined in claim 2, wherein The height of the mounting column (21) is higher than the height of the coil (1).

4. An integral inductive element as defined in claim 2, wherein The height of the mounting column (21) is equal to the height of the coil (1).

5. An integral inductive element as defined in claim 2, wherein The height of the mounting column (21) is smaller than the height of the coil (1).

6. An integral inductive element as defined in claim 2, wherein The soft magnetic cladding body base (2) and the soft magnetic cladding body cover plate (30) are both made of soft magnetic powder.

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