Integrally-formed integrated inductor and manufacturing method thereof

Abstract

The invention discloses an integrally-formed integrated inductor and a manufacturing method thereof. The integrally-formed integrated inductor comprises a magnetic body, a conductive frame, a first coil and a second coil. The conductive frame is provided with a face A and a face B which are oppositely arranged, the first coil is welded to the face A of the conductive frame, and the second coil is welded to the face B of the conductive frame. The magnetic body wraps the first coil, the second coil and at least one part of the conductive frame, so that the first coil and the second coil are located in the middle area in the thickness direction of the magnetic body. The terminal part of the conductive frame is at least partially exposed out of the magnetic body and forms an external terminal of the inductor. The two coils are welded to the front face and the back face of the conductive frame respectively, the coils are centered in the thickness direction, the upper edge and the lower edge are evenly stressed during mold pressing, and displacement of the coils in a mold is small. The coil and the terminal in a finished product are positioned in the middle of the product, so that the risks of damage to the conductive frame and deformation of the terminal are reduced, the reliability is improved, the quality is more reliable, and the overall reliability is higher than that of a traditional structure; and meanwhile, the production efficiency is improved through synchronous mold pressing of the two coils.

Description

Technical Field

[0001] This invention relates to the field of electronic components technology, and in particular to a molded integrated inductor and its manufacturing method. Background Technology

[0002] Molded inductors typically employ a structure and process route of "coil + conductive frame (terminals) + soft magnetic material molding". In existing molded inductors, if the spatial positions of the coil and conductive frame within the mold cavity (especially their vertical positions in the thickness direction) are not centered or are asymmetrical, the pressure applied by the upper and lower molds to the coil and conductive frame can easily become uneven. This leads to inconsistent displacement of the coil or conductive frame in the vertical direction, resulting in problems such as terminal (conductive frame) deformation and damage to the conductive frame, thus affecting the consistency and reliability of the finished product. In contrast, ordinary molded inductors already exhibit a situation where "the coil is centered but the conductive frame is off-center from the mold cavity," leading to uneven pressure and terminal deformation.

[0003] Therefore, existing technologies have shortcomings and need to be improved. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide an integrated inductor and its manufacturing method, so that the coil and conductive frame are located in the middle region of the mold cavity during the molding process and the force is uniform from top to bottom, reducing the risk of displacement and deformation and improving the reliability of the finished product; at the same time, it can realize the integration of dual inductors to save space and improve production efficiency.

[0005] To achieve the above objectives, the present invention provides a molded integrated inductor, comprising: A magnetic body, a conductive frame, and a first coil and a second coil; The conductive frame has an A side and a B side that are arranged opposite to each other. The first coil is welded to the A side of the conductive frame, and the second coil is welded to the B side of the conductive frame. The magnetic body covers at least a portion of the first coil, the second coil, and the conductive frame, such that the first coil and the second coil are located in the central region in the thickness direction of the magnetic body; The terminal portion of the conductive frame is at least partially exposed to the magnetic body and forms an external terminal of the inductor.

[0006] Furthermore, the first coil and the second coil respectively constitute the first inductor unit and the second inductor unit, making the integrally molded integrated inductor a dual-inductor integrated device.

[0007] Furthermore, the first coil and the second coil are arranged symmetrically in the thickness direction about the plane containing the conductive frame.

[0008] Furthermore, the conductive frame includes a frame portion and a terminal portion. The frame portion is used for positioning and support during the manufacturing process, and the terminal portion is used to form an external terminal. The frame portion is removed after manufacturing, leaving only the terminal portion that forms the external terminal.

[0009] Furthermore, the terminal portion is a bendable terminal, and after molding, it is bent and shaped to form a predetermined pin shape.

[0010] Furthermore, the first coil and the second coil have the same coil specifications and parameters, and are respectively welded to the front and back sides of the conductive frame, thereby forming two inductor units of the same size after molding.

[0011] The present invention also provides a method for manufacturing an integrally molded integrated inductor, comprising the following steps: (1) Coil winding: Hollow coils are wound using enameled wire and a winding machine to obtain the first coil and the second coil; (2) Coil welding: The first coil and the second coil are welded to the A and B sides of the conductive frame respectively, forming an integrated assembly of the coil and the conductive frame; (3) Molding: The first coil, the second coil and the conductive frame assembly are placed in the mold cavity, and soft magnetic powder that has been treated with insulation granulation is filled into the mold cavity. The assembly is formed by applying pressure through the upper mold and the lower mold to form an inductor blank containing the coil. (4) Baking and curing: The inductor blank is baked and cured to fully cure the thermosetting resin contained therein to form a dense magnetic body; (5) Edge trimming and pin shaping: The frame of the conductive frame is cut off and the product pins are bent and shaped to obtain the integrated inductor product.

[0012] Furthermore, the welding method in step (2) includes one or more of reflow soldering, laser welding, and spot welding; The conductive frame is a planar frame structure, which includes a frame portion and a terminal portion. The frame portion is used for positioning and support during the manufacturing process, and the terminal portion is used to form external terminals.

[0013] Furthermore, in step (3), the conductive frame is located in the middle region of the mold cavity, and the first coil and the second coil are located on the A and B surfaces of the conductive frame, respectively, so that the upper and lower forces are uniform and the displacement is reduced during molding. The first coil and the second coil are arranged symmetrically about the plane containing the conductive frame in the thickness direction.

[0014] Furthermore, the temperature conditions used for baking and curing in step (4) are 150~180℃.

[0015] The soft magnetic powder is a mixture of magnetic powder or magnetic powder and thermosetting resin.

[0016] Using the above-described solution, this invention provides an integrally molded inductor and its manufacturing method. Two coils are welded to the front and back of the conductive frame respectively, ensuring the coils are centered in the thickness direction. During molding, the upper and lower edges experience uniform stress, resulting in minimal coil displacement within the mold. Uniform stress and reduced displacement prevent damage to the conductive frame from mold cutting. In the finished product, both the coils and terminals are located in the center, reducing the risk of conductive frame damage and terminal deformation, improving reliability, and resulting in higher overall reliability than traditional structures. The two coils are combined and molded simultaneously, resulting in two inductor units, saving space in the application; the synchronous molding of the two coils also improves production efficiency. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of the first coil and the second coil in this invention.

[0018] Figure 2 This is a schematic diagram of the structure in this invention where the coil is welded onto the conductive frame.

[0019] Figure 3 This is a schematic diagram of the structure after molding of the present invention.

[0020] Figure 4 This is a cross-sectional view of the molded product of the present invention.

[0021] Figure 5 This is a schematic diagram of the integrated inductor of the present invention.

[0022] Figure 6 This is a flowchart of the manufacturing method of the integrally molded integrated inductor of the present invention. Detailed Implementation

[0023] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0024] Example 1 Please see Figures 1 to 5This invention provides an integrally molded inductor, comprising: a magnetic body 6, a conductive frame 10, and a first coil 2 and a second coil 4. The conductive frame 10 has two opposing surfaces, A and B. The first coil 2 is welded to surface A of the conductive frame 10, and the second coil 4 is welded to surface B of the conductive frame 10. The first coil 2 and the second coil 4 are located on opposite sides of the conductive frame 10, and are symmetrically arranged about the plane of the conductive frame 10 in the thickness direction, placing them in the central region of the magnetic body 6. This centrally symmetrical structure (with the first coil 2 and the second coil 4 positioned centrally within the magnetic body 6) ensures more uniform stress and smaller displacement during molding, preventing damage to the conductive frame 10 and improving reliability.

[0025] The magnetic body 6 covers at least a portion of the first coil 2, the second coil 4, and the conductive frame 10. The terminal portion 12 of the conductive frame 10 is at least partially exposed to the magnetic body 6 and forms an external terminal of the inductor for electrical connection with an external circuit.

[0026] Specifically, the conductive frame 10 includes a frame portion 14 and a terminal portion 12. The frame portion 14 is used for positioning and support during manufacturing, and the terminal portion 12 is used to form external terminals. The frame portion 14 is removed after manufacturing by a trimming process, leaving only the terminal portion 12 as the external terminals. The terminal portion 12 is a bendable terminal, and after forming, it is bent and shaped into a predetermined pin shape to meet the requirements of surface mount or through-hole applications.

[0027] Example 2 Based on Embodiment 1, the first coil 2 and the second coil 4 respectively constitute the first inductor unit and the second inductor unit, making the integrally molded inductor a dual-inductor integrated device. The two coils can use the same coil specifications and parameters and are respectively welded to the front and back sides of the conductive frame 10, thereby forming two inductor units of the same size after molding. Combining and simultaneously molding the two coils results in two inductors in the final product, saving space for the application end, and synchronous molding helps improve production efficiency.

[0028] Example 3 Please see Figures 1 to 6 The present invention also provides a method for manufacturing an integrally molded integrated inductor, comprising the following steps: (1) Coil winding: Hollow coils are wound using enameled wire and a winding machine to obtain the first coil 2 and the second coil 4.

[0029] (2) Coil welding: The first coil 2 and the second coil 4 are welded to the A and B sides of the conductive frame 10 respectively, forming an integrated assembly of the coil and the conductive frame 10.

[0030] In optional embodiments, the welding method includes, but is not limited to, one or more of reflow soldering, laser welding, and spot welding.

[0031] (3) Molding: The first coil 2, the second coil 4 and the conductive frame 10 are placed in the mold cavity, and soft magnetic powder that has been treated with insulation granulation is filled into the mold cavity. The upper and lower molds are used to apply pressure to the assembly to form an inductor blank containing the coil.

[0032] During the molding process, the conductive frame 10 is positioned in the middle area of ​​the mold cavity, and the first coil 2 and the second coil 4 are positioned on the A and B sides of the conductive frame 10, respectively. This ensures that the coil and the conductive frame 10 are subjected to uniform pressure on both sides during the molding process, without any inconsistent displacement. This also ensures that the coil and the terminal part 12 are both located in the middle of the product, resulting in more reliable quality.

[0033] The soft magnetic powder is a mixture of magnetic powder or magnetic powder and thermosetting resin.

[0034] (4) Baking and curing: The inductor blank is baked and cured to fully cure the thermosetting resin contained therein to form a dense magnetic body 6.

[0035] The baking and curing temperature in this step is 150~180℃.

[0036] (5) Trimming and shaping: The frame portion 14 of the conductive frame 10 is cut off and the product pins are bent and shaped to obtain the integrated inductor product.

[0037] In the final product, the first coil 2 and the second coil 4 are centered in the magnetic body 6.

[0038] This invention provides a one-piece molded integrated inductor and its manufacturing method. Two coils are welded to the front and back of a conductive frame, respectively, centered in the thickness direction. During molding, the upper and lower edges are subjected to uniform force, and the displacement of the coils in the mold is small. Uniform force and reduced displacement prevent the conductive frame from being cut and damaged by the mold. In the finished product, the coils and terminals are located in the middle, reducing the risk of damage to the conductive frame and deformation of the terminals, improving reliability, and resulting in higher overall reliability than traditional structures. The two coils are combined and molded simultaneously, resulting in two inductor units, which saves space in the application; at the same time, the synchronous molding of the two coils also improves production efficiency.

[0039] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A one-piece molded integrated inductor, characterized in that, include: A magnetic body, a conductive frame, and a first coil and a second coil; The conductive frame has an A side and a B side that are arranged opposite to each other. The first coil is welded to the A side of the conductive frame, and the second coil is welded to the B side of the conductive frame. The magnetic body covers at least a portion of the first coil, the second coil, and the conductive frame, such that the first coil and the second coil are located in the central region in the thickness direction of the magnetic body; The terminal portion of the conductive frame is at least partially exposed to the magnetic body and forms an external terminal of the inductor.

2. The integrally molded integrated inductor according to claim 1, characterized in that, The first coil and the second coil respectively constitute the first inductor unit and the second inductor unit, making the integrally molded integrated inductor a dual-inductor integrated device.

3. The integrally molded integrated inductor according to claim 1, characterized in that, The first coil and the second coil are arranged symmetrically in the thickness direction about the plane containing the conductive frame.

4. The integrally molded integrated inductor according to claim 1, characterized in that, The conductive frame includes a frame portion and a terminal portion. The frame portion is used for positioning and support during the manufacturing process, and the terminal portion is used to form external terminals. The frame portion is removed after manufacturing, leaving only the terminal portion that forms the external terminals.

5. The integrally molded integrated inductor according to claim 4, characterized in that, The terminal portion is a bendable terminal, and after molding, it is bent and shaped to form a predetermined pin shape.

6. The integrally molded integrated inductor according to claim 2, characterized in that, The first and second coils have the same coil specifications and parameters, and are welded to the front and back sides of the conductive frame respectively, thereby forming two inductor units of the same size after molding.

7. A method for manufacturing an integrally molded integrated inductor, characterized in that, Includes the following steps: (1) Coil winding: Hollow coils are wound using enameled wire and a winding machine to obtain the first coil and the second coil; (2) Coil welding: The first coil and the second coil are welded to the A and B sides of the conductive frame respectively, forming an integrated assembly of the coil and the conductive frame; (3) Molding: The first coil, the second coil and the conductive frame assembly are placed in the mold cavity, and soft magnetic powder that has been treated with insulation granulation is filled into the mold cavity. The assembly is formed by applying pressure through the upper mold and the lower mold to form an inductor blank containing the coil. (4) Baking and curing: The inductor blank is baked and cured to fully cure the thermosetting resin contained therein to form a dense magnetic body; (5) Trimming and shaping: The frame of the conductive frame is cut off and the product pins are bent and shaped to obtain the integrated inductor product.

8. The method for manufacturing an integrally molded integrated inductor according to claim 7, characterized in that, The welding method in step (2) includes one or more of reflow soldering, laser welding, and spot welding; The conductive frame is a planar frame structure, which includes a frame portion and a terminal portion. The frame portion is used for positioning and support during the manufacturing process, and the terminal portion is used to form external terminals.

9. The method for manufacturing an integrally molded integrated inductor according to claim 7, characterized in that, In step (3), the conductive frame is located in the middle region of the mold cavity, and the first coil and the second coil are located on the A and B surfaces of the conductive frame, respectively, so that the upper and lower forces are evenly distributed and the displacement is reduced during molding. The first coil and the second coil are arranged symmetrically in the thickness direction about the plane containing the conductive frame.

10. The method for manufacturing an integrally molded integrated inductor according to claim 7, characterized in that, The baking and curing temperature in step (4) is 150~180℃. The soft magnetic powder is a mixture of magnetic powder or magnetic powder and thermosetting resin.

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