Inductance element and manufacturing method thereof

Abstract

The invention provides an inductance element and a manufacturing method thereof. The inductance element comprises a magnetic main body; the coil is arranged in the magnetic main body; the end electrode is arranged outside the magnetic main body and is electrically connected with the coil; the magnetic main body comprises a first magnet and a second magnet which are arranged along a first direction; the thickness of the first magnet is greater than that of the second magnet in the first direction; the terminal electrode is arranged on the second magnet, the coil is arranged in the first magnet, and the leading-out end of the coil penetrates through the second magnet and then is electrically connected with the terminal electrode; the second magnet comprises a first insulation area, the insulation performance of the material of the first insulation area is higher than that of the material of the first magnet, and the end electrode and the first magnet are insulated through the first insulation area. According to the inductance element, the insulating capacity between the end electrodes can be achieved, meanwhile, the overall performance of a product is not affected, and the bonding strength of the end electrodes and the magnets is high.

Description

Technical Field

[0001] This invention relates to the field of inductance technology, and more specifically, to an inductor element and its manufacturing method. Background Technology

[0002] The AI ​​industry is developing rapidly. With the advent of the artificial intelligence era, AI server power consumption has increased by 6 to 8 times compared to ordinary servers. NVIDIA's B200 has reached 1000W per GPU. In the power supply design of this type of product, the trend is to reduce the number of power conversions. The voltage difference of inductor products is gradually increasing (such as directly converting from 54V / 48V to 12V / 5V). At the same time, in order to improve the response speed of inductors, coupling designs are used. There are multiple electrode coils inside an inductor. The instantaneous voltage difference between the electrode coils can reach 2 times or more of the input voltage, which increases the requirements for the insulation performance of the product.

[0003] Integrated high-temperature sintered inductors employ a one-piece molding process, but unlike traditional one-piece molding, magnetic powder granulation involves adding only a minimal amount of adhesive to alter the powder's flowability. After pressing, the product undergoes high-temperature annealing to remove the organic adhesive added during granulation and eliminate residual internal stress from molding, thus significantly improving the product's effective permeability. To ensure insulation, the electrode coils of this type of inductor require insulating coating, especially for multiphase inductors, where the insulation between electrodes is particularly crucial for operation in higher voltage conversion circuits.

[0004] Because copper-iron co-fired inductors use iron-nickel alloy powder as the magnetic material, the magnetic insulation performance is poor. Therefore, the bottleneck in the product's withstand voltage can be divided into insulation isolation between different phase copper electrodes and insulation isolation between each phase electrode and the iron-nickel magnet. Insulating the electrodes can achieve these goals. However, during the product's terminal electrode process, the terminal electrodes need to be connected to the inductor coil and have good adhesion to the product surface. Therefore, after the inductor is externally coated with insulating varnish, a portion of the magnet area is exposed for electroplating a copper-nickel-tin layer to form the product's terminal electrodes. At this point, the already insulated copper electrodes are reconnected to the magnet through the electroplated metal layer on the terminal electrodes. This adds another bottleneck to the product's withstand voltage capability: the insulation performance between the terminal electrodes and the surface magnet. This insulation performance is determined by the resistivity and insulation capacity of the magnet material, as well as the minimum spacing between the terminal electrodes. This significantly wastes the insulation capacity of the electrode coil, is sensitive to product dimensions, and has a considerable impact on the product's terminal electrode design and pad design.

[0005] In addition, there is an existing inductor element in which a resin coating is applied to the outside of the product, and then the terminal electrodes are placed on the resin. Although this method can avoid the external terminal electrodes from being affected by the insulation performance of the magnet to a certain extent, the bonding strength between the terminal electrodes and the product is low, the product quality stability is poor, and the application range is limited. Summary of the Invention

[0006] The first objective of this invention is to provide an inductor that can solve the insulation problem between the end electrodes without affecting the overall performance of the product, and has a high bonding strength between the end electrodes and the magnet.

[0007] A second objective of this invention is to provide a method for manufacturing the aforementioned inductor element.

[0008] To achieve the aforementioned first objective, the present invention provides an inductor element, comprising a magnetic body; a coil disposed within the magnetic body; and an end electrode disposed outside the magnetic body and electrically connected to the coil. The magnetic body includes a first magnet and a second magnet arranged along a first direction. Along the first direction, the thickness of the first magnet is greater than the thickness of the second magnet. The end electrode is disposed on the second magnet, and the coil is disposed within the first magnet. The lead end of the coil passes through the second magnet and is electrically connected to the end electrode. The second magnet includes a first insulating region, the insulation performance of the material of the first insulating region being higher than the insulation performance of the material of the first magnet. The end electrode is insulated from the first magnet through the first insulating region.

[0009] As can be seen from the above scheme, by setting a second magnet with a first insulating region, the present invention achieves good insulation between the end electrodes and the first magnet, thus avoiding the problem of poor withstand voltage performance of the inductor element due to low magnetic insulation resistance. Furthermore, compared to the prior art, the end electrodes of the inductor element of the present invention are directly formed on the metallic magnetic body, resulting in better adhesion than the end electrodes deposited on the resin layer in the prior art. In addition, the insulation capability between the end electrodes is affected by the resistivity, insulation capability, and distance of the magnetic material between the end electrodes. The electrode distance is determined by the product design. The present invention improves the insulation performance by replacing the magnetic material between the end electrodes with a magnetic material with higher insulation capability. High insulation performance and high magnetic performance of magnetic materials are mutually exclusive. Without affecting product performance, replacing the magnetic material in contact with the end electrodes with a high-insulation magnetic material while still using low-insulation ferromagnetic materials such as iron-nickel alloys in the main body of the product improves the insulation capability between the electrodes while having a smaller impact on the electrical performance of the product.

[0010] In a preferred embodiment, the material of the first magnet comprises an iron-nickel alloy; and / or the material of the first insulating region comprises at least one of an iron-silicon alloy, a nickel-zinc ferrite, amorphous iron powder, nanocrystalline iron powder, and carbonyl iron powder.

[0011] Therefore, it is evident that iron-silicon alloys, nickel-zinc ferrites, amorphous iron powder, nanocrystalline iron powder, and carbonyl iron powder possess high insulation properties, which can enhance the insulation withstand voltage between electrodes. Meanwhile, the first magnet still utilizes a low-insulation, high-permeability, high-B-value iron-nickel alloy material to provide the product with properties such as inductance, saturation current, and loss, thereby ensuring the product's electrical performance.

[0012] A preferred embodiment is that there are two or more coils and two or more sets of end electrodes; each coil is electrically connected to a set of end electrodes, and the coils are insulated from each other, as are the end electrodes.

[0013] Therefore, it can be seen that when the inductor is a multiphase inductor, it can better solve the insulation problem between the terminal electrodes connected to the coil, without affecting the overall performance of the product.

[0014] A further embodiment is that the projection of the terminal electrode along the first direction is located within the total projection of the coil lead-out end and the first insulation region along the first direction.

[0015] Therefore, the first insulating region ensures that the end electrode is separated from the first magnet, thereby achieving insulation between the two.

[0016] A further embodiment is that the second magnet also includes a second insulating region, which is arranged along a second direction with the first insulating region, and the second direction is perpendicular to the first direction; the insulating properties of the material of the second insulating region are less than those of the material of the first insulating region.

[0017] Therefore, the areas of the second insulation zone and the first insulation zone can be adjusted as needed to achieve the required electrical performance.

[0018] A further option is that the number of first insulating regions is less than or equal to the number of end electrodes, and one first insulating region is correspondingly disposed with at least one end electrode in a first direction.

[0019] Therefore, a first insulating region can be set under each end electrode, or two or more end electrodes can be set in a first insulating region.

[0020] A further option is to have two or more first insulation zones, with the second insulation zone located between two adjacent first insulation zones.

[0021] Therefore, the first insulating region can be reasonably selected according to the position of the terminal electrode, and then the material of the second insulating region can be filled in the remaining positions.

[0022] In a preferred embodiment, the second magnet further includes a second insulating region, which is arranged along a first direction with the first insulating region, and the second insulating region is located between the first insulating region and the first magnet; the insulating properties of the material of the second insulating region are less than those of the material of the first insulating region, but greater than those of the material of the first magnet.

[0023] Therefore, the first insulating region and the second insulating region can also be arranged along the arrangement direction of the first magnet and the second magnet, and the insulation performance of the material of the second insulating region is between the insulation performance of the material of the first insulating region and the insulation performance of the material of the first magnet.

[0024] In a preferred embodiment, the end electrodes are formed by an electroplating process; and / or the thickness of the second magnet is less than or equal to 10% of the thickness of the first magnet; and / or the permeability of the material of the first insulating region is lower than the permeability of the material of the first magnet; and / or the coil includes a coil body and a coil sheath, the coil sheath covering the outer surface of the coil body; and / or the inductor element further includes a surface sheath covering the magnetic body, the end electrodes being exposed on the surface sheath.

[0025] Therefore, the terminal electrodes are formed on the magnetic body through electroplating to improve the bonding strength between the two, and simultaneously connect to the coil to provide external electrical connection. The coil body is covered with a coil sheathing layer to achieve insulation between multiple coils and between the coil and the magnetic body. By covering the magnetic body with a surface sheathing made of resin material, the waterproof, rustproof, and wear-resistant capabilities of the inductor are improved.

[0026] To achieve the second objective mentioned above, the present invention provides a method for manufacturing the aforementioned inductor element, comprising: filling a mold cavity with powder of a first magnet and pre-pressing it into a substrate; placing a coil into the mold cavity and placing it on the substrate; filling the mold cavity with powder of the first magnet and performing a second pre-pressing; filling the mold cavity with powder of a second magnet; and pressing and molding it under a preset pressure to form a green blank of a magnetic body. Attached Figure Description

[0027] Figure 1 This is a perspective view of the first embodiment of the inductor element of the present invention.

[0028] Figure 2 This is a cross-sectional view of the first embodiment of the inductor element of the present invention.

[0029] Figure 3 This is a cross-sectional view of the seventh embodiment of the inductor element of the present invention.

[0030] Figure 4 This is a cross-sectional view of the eighth embodiment of the inductor element of the present invention.

[0031] The present invention will be further described below with reference to the accompanying drawings and embodiments. Detailed Implementation

[0032] First embodiment of the inductor element and its manufacturing method: See Figure 1 and Figure 2 In this embodiment, the inductor is a high-voltage co-fired multiphase inductor. This inductor includes a magnetic body 1, a coil 2, terminal electrodes 3, and a surface coating layer 4. The coil 2 is disposed within the magnetic body 1, and the terminal electrodes 3 are disposed outside the magnetic body 1 and electrically connected to the coil 2. The terminal electrodes 3 are formed through processes such as electroplating to improve the bonding strength between the two. The coil 2 includes a coil body and a coil coating layer. The coil coating layer covers the outer surface of the coil body. The material of the coil coating layer can be organic, inorganic, or an organic-inorganic composite layer. The coil coating layer covers the coil body to achieve insulation between multiple coils 2 and between the coil 2 and the magnetic body 1. The surface coating layer 4 covers the magnetic body 1, and the terminal electrodes 3 are exposed on the surface coating layer 4. The surface coating layer 4 is a non-magnetic resin insulating coating. By covering the magnetic body 1 with a surface coating layer 4 made of resin material, the waterproof, rustproof, and wear-resistant capabilities of the inductor are improved. The terminal electrodes 3 connect to the coil 2 to provide external electrical connection.

[0033] The magnetic body 1 includes a first magnet 11 and a second magnet 12 arranged along a first direction, which in this embodiment is a vertical direction. Along the first direction, the thickness of the first magnet 11 is greater than the thickness of the second magnet 12; preferably, the thickness of the second magnet 12 is less than or equal to 10% of the thickness of the first magnet 11. An end electrode 3 is disposed on the second magnet 12, and a coil 2 is disposed within the first magnet 11. The lead-out end 21 of the coil 2 passes through the second magnet 12 and is electrically connected to the end electrode 3. In this embodiment, the total thickness of the magnetic body 1 is 2 mm, and the thickness of the second magnet 12 is 60 μm.

[0034] In this embodiment, the second magnet 12 has a single-layer structure and includes a first insulating region 121. The insulation performance of the material of the first insulating region 121 is higher than that of the material of the first magnet 11. The terminal electrode 3 is insulated from the first magnet 11 through the first insulating region 121. The permeability of the material of the first insulating region 121 is lower than that of the material of the first magnet 11.

[0035] The material of the first magnet 11 includes an iron-nickel alloy. The material of the first insulating region 121, which is also the material of the second magnet 12, includes at least one of iron-silicon alloys, nickel-zinc ferrite, amorphous iron powder, nanocrystalline iron powder, and carbonyl iron powder. Iron-silicon alloys include iron-silicon powder, iron-silicon-aluminum powder, and iron-silicon-chromium powder. In this embodiment, the material of the first magnet 11 is an iron-nickel alloy, and the material of the second magnet 12 is an iron-silicon-aluminum alloy. Iron-silicon alloys, nickel-zinc ferrite, amorphous iron powder, nanocrystalline iron powder, and carbonyl iron powder have high insulation properties, which can improve the insulation withstand voltage between electrodes. Meanwhile, the first magnet 11 still uses an iron-nickel alloy material with low insulation, high permeability, and high B-value to provide the product with inductance, saturation current, and loss properties, thereby ensuring the electrical performance of the product.

[0036] In this embodiment, the insulation performance is reflected by the intrinsic insulation resistance of the magnetic material. The test method for the intrinsic insulation resistance of the magnetic material is as follows: after the magnetic powder is formed into a cube shape, two conductive pastes are coated on the same side and dried. The coating area of ​​each conductive paste is greater than 4 mm. 2 The distance between the two conductive coatings is 5 mm. The resistance between the two conductive coatings is measured using a resistance tester, which is the intrinsic insulation resistance of the magnet. In this embodiment, the first magnet 11 has a permeability of 110 and an intrinsic insulation resistance of 100 Ω, and the second magnet 12 has a permeability of 70 and an intrinsic insulation resistance of 1.5 MΩ. Optionally, the number of coils 2 is one or more, and the number of end electrodes 3 is one group or two or more. When there is one coil 2, the corresponding number of end electrodes 3 is one group, which includes two end electrodes 3 connected to the two ends of the coil 2 respectively. When there are two or more coils 2, the corresponding number of end electrodes 3 is two or more groups. One coil 2 is electrically connected to one group of end electrodes 3, and one group includes two end electrodes 3. The two end electrodes 3 in the same group are respectively connected to the two ends of the corresponding coil 2, and the coils 2 are mutually insulated from each other, and the end electrodes 3 are mutually insulated from each other. In this embodiment, there are two coils 2 and two groups of end electrodes 3.

[0037] The projection of the end electrode 3 along the first direction lies within the total projection of the lead-out end 21 of the coil 2 and the first insulating region 121 along the first direction, ensuring that the first insulating region 121 separates the end electrode 3 from the first magnet 11, thereby achieving insulation between the two. In this embodiment, the first insulating region 121 is the second magnet 12, and there is only one first insulating region 121, with all four end electrodes 3 located within the same first insulating region 121.

[0038] The method for manufacturing the inductor element in this embodiment includes the following steps: First, use glue or similar materials to bond the two coils 2 together to form an electrode assembly.

[0039] Next, the pressing process begins. First, the powder of the first magnet 11 is filled into the mold cavity, and a first pre-press is performed using low pressure to form a substrate. The substrate is not compacted, but only maintains its shape.

[0040] Next, the entire electrode is placed into the mold cavity and placed on the substrate.

[0041] Next, a second powder filling is performed, in which the powder of the first magnet 11 is filled into the mold cavity. The powder is exactly the same as that used in the first filling. A second pre-compression is performed using low pressure, and this pre-compression leaves a certain thickness of space in the mold cavity.

[0042] Next, a third powder filling is performed, in which the powder of the second magnet 12 is filled into the mold cavity.

[0043] Next, a third pressing is performed under preset pressure, and the green blank of the magnetic body 1 is formed by pressing and molding using product molding pressure.

[0044] Subsequently, a non-magnetic resin insulating coating is applied by debinding and annealing. Then, a laser window is used to remove the resin from the terminal electrode 3 and expose the lead-out terminal 21 and part of the first insulating area 121. The terminal electrode 3 is then formed by electroplating at the exposed position, and finally a complete inductor product is formed.

[0045] As can be seen from the above, by setting a second magnet with a first insulating region, the present invention achieves good insulation between the end electrodes and the first magnet, thus avoiding the problem of poor withstand voltage performance of the inductor due to low magnetic insulation resistance. Furthermore, compared to the prior art, the end electrodes of the inductor in the present invention are directly formed on the metallic magnetic body, resulting in better adhesion than the end electrodes deposited on the resin layer in the prior art. In addition, the insulation capability between the end electrodes is affected by the resistivity, insulation capability, and distance of the magnetic material between them. The electrode distance is determined by the product design. The present invention improves insulation performance by replacing the magnetic material between the end electrodes with a magnetic material with higher insulation capability. High insulation performance and high magnetic performance of magnetic materials are mutually exclusive. Without affecting product performance, replacing the magnetic material in contact with the end electrodes with a high-insulation magnetic material while still using low-insulation ferromagnetic materials such as iron-nickel alloys in the main body of the product improves the insulation capability between the electrodes while having a smaller impact on the product's electrical performance.

[0046] In the following embodiments, the structure and manufacturing method of the inductor are the same as those in the first embodiment, except that the permeability of the material of the second magnet, the intrinsic insulation resistance of the material of the second magnet, or the thickness of the second magnet are as follows: Second embodiment of the inductor element and its manufacturing method: In this embodiment, the second magnet has a permeability of 70, an intrinsic insulation resistance of 1.5 MΩ, and a thickness of 200 μm.

[0047] Third embodiment of the inductor element and its manufacturing method: In this embodiment, the second magnet has a permeability of 70, an intrinsic insulation resistance of 1.5 MΩ, and a thickness of 300 μm.

[0048] Fourth embodiment of inductor element and its manufacturing method: In this embodiment, the second magnet has a permeability of 45, an intrinsic insulation resistance of 5MΩ, and a thickness of 60μm.

[0049] Fifth embodiment of inductor element and its manufacturing method: In this embodiment, the second magnet has a permeability of 45, an intrinsic insulation resistance of 5MΩ, and a thickness of 200μm.

[0050] Sixth embodiment of the inductor element and its manufacturing method: In this embodiment, the second magnet has a permeability of 45, an intrinsic insulation resistance of 5MΩ, and a thickness of 300μm.

[0051] Seventh embodiment of inductor element and its manufacturing method: As an explanation of the seventh embodiment of the inductor element and its manufacturing method of the present invention, the following description only focuses on the differences from the first embodiment of the inductor element and its manufacturing method described above.

[0052] See Figure 3 In this embodiment, the second magnet 72 is also a single-layer structure. The second magnet 72 also includes a second insulating region 722. The second insulating region 722 and the first insulating region 721 are arranged along a second direction, which is perpendicular to the first direction. In this embodiment, the second direction is a horizontal direction, that is, the length direction of the inductor. The insulation performance of the material of the second insulating region 722 is less than that of the material of the first insulating region 721.

[0053] The number of first insulating regions 721 is less than or equal to the number of end electrodes 73, and one first insulating region 721 is correspondingly disposed with at least one end electrode 73 in a first direction. There may be two or more first insulating regions 721, and a second insulating region 722 is located between two adjacent first insulating regions 721. One first insulating region 721 may be disposed under each end electrode 73, or two or more end electrodes 73 may be disposed within one first insulating region 721. Furthermore, the first insulating regions 721 may be selected appropriately based on the position of the end electrodes 73, and then the remaining positions may be filled with the material of the second insulating region 722.

[0054] In this embodiment, there are two first insulating regions 721, four terminal electrodes 73, and one second insulating region 722. The two terminal electrodes 73 connected to the same coil 74 are located within the same first insulating region 721. The two first insulating regions 721 are arranged along a second direction and extend along a third direction, which is the width direction of the inductor element. The second insulating region 722 is located between the two first insulating regions 721. The materials of the two first insulating regions 721 can be the same or different, but the insulation performance of the materials of both first insulating regions 721 is greater than that of the material of the second insulating region 722, and the permeability of the materials of both first insulating regions 721 is less than that of the material of the second insulating region 722. The permeability of the material of the second insulating region 722 is less than that of the first magnet 71.

[0055] In this embodiment, the material of the second insulating region 722 and the first insulating region 721 are both iron-silicon-aluminum alloys, but their permeability and intrinsic insulation resistance are different. The material of the first magnet 71 has a permeability of 110 and an intrinsic insulation resistance of 100Ω. The materials of both first insulating regions 721 have a permeability of 45 and an intrinsic insulation resistance of 5MΩ. The material of the second insulating region 722 has a permeability of 70 and an intrinsic insulation resistance of 1.5MΩ. The thickness of the second magnet is 200μm. In other embodiments, the material of the second insulating region 722 can also be an iron-nickel alloy with good insulation properties, other iron-silicon alloys, or magnetic materials with high insulation properties such as nickel-zinc ferrite, amorphous iron powder, nanocrystalline iron powder, and carbonyl iron powder.

[0056] The projection of each end electrode 73 along the first direction is located within the total projection of the lead-out end 741 of the corresponding coil 74 and the corresponding first insulating region 721 along the first direction. That is, the outer periphery of the cross section of the end electrode 73 will not exceed the outer periphery of the lead-out end 741 of the coil 74 and the cross section of the first insulating region 721, so as to completely separate the end electrode 73 and the first magnet 71 by the first insulating region 721, thereby achieving insulation between the two.

[0057] The method for manufacturing the inductor element in this embodiment includes the following steps: First, use glue or similar materials to bond the two coils 74 together to form an electrode assembly.

[0058] Next, the pressing process begins. First, the powder of the first magnet 71 is filled into the mold cavity, and a first pre-press is performed using low pressure to form a substrate. The substrate is not compacted, but only maintains its shape.

[0059] Next, the entire electrode is placed into the mold cavity and placed on the substrate.

[0060] Next, a second powder filling is performed, in which the powder of the first magnet 71 is filled into the mold cavity. The powder is exactly the same as that used in the first filling. A second pre-compression is performed using low pressure, and this pre-compression leaves a certain thickness of space in the mold cavity.

[0061] Next, a third filling process is performed, in which the powder of the second magnet is filled into the mold cavity. Specifically, the first magnetic powder material is filled at the position of the first insulating area 721, and the second magnetic powder material is filled at the remaining positions of the second insulating area 722. The filling area is larger than the area of ​​the corresponding end electrode 73.

[0062] Next, a third pressing is performed under preset pressure, and the green blank of the magnetic body is formed by pressing and shaping using product forming pressure.

[0063] Subsequently, the product undergoes debinding, annealing, and coating, followed by subsequent processes such as the end electrode process to form a complete product.

[0064] Eighth embodiment of inductor element and its manufacturing method: As an explanation of the eighth embodiment of the inductor element and its manufacturing method of the present invention, the following description only focuses on the differences from the first embodiment of the inductor element and its manufacturing method described above.

[0065] See Figure 4 In this embodiment, the second magnet 82 has a multi-layer structure and further includes a second insulating region 822. The second insulating region 822 and the first insulating region 821 are arranged along a first direction, with the second insulating region 822 located between the first insulating region 821 and the first magnet 81. The insulating properties of the material of the second insulating region 822 are less than those of the material of the first insulating region 821, but greater than those of the material of the first magnet 81. The first insulating region 821 and the second insulating region 822 can also be arranged along the arrangement direction of the first magnet 81 and the second magnet 82. The insulating properties of the material of the second insulating region 822 are between those of the materials of the first insulating region 821 and the first magnet 81. The permeability of the material of the second insulating region 822 is also between those of the materials of the first insulating region 821 and the first magnet 81, and both the permeability of the materials of the first insulating region 821 and the second insulating region 822 are less than the permeability of the material of the first magnet 81.

[0066] In this embodiment, the material of the second insulating region 822 and the first insulating region 821 are both iron-silicon-aluminum alloys, but their permeability and intrinsic insulation resistance are different. The first magnet 81 has a permeability of 110 and an intrinsic insulation resistance of 100Ω. The first insulating region 821 has a permeability of 45 and an intrinsic insulation resistance of 5MΩ, with a thickness of 100μm. The second insulating region 822 has a permeability of 70 and an intrinsic insulation resistance of 1.5MΩ, with a thickness of 100μm. The second magnet 82 has a thickness of 200μm.

[0067] The method for manufacturing the inductor element in this embodiment includes the following steps: First, use glue or similar materials to bond the two coils 84 together to form an electrode assembly.

[0068] Next, the pressing process begins. First, the powder of the first magnet 81 is filled into the mold cavity, and a first pre-press is performed using low pressure to form a substrate. The substrate is not compacted, but only maintains its shape.

[0069] Next, the entire electrode is placed into the mold cavity and placed on the substrate.

[0070] Next, a second filling of powder is performed, in which the powder of the first magnet 81 is filled into the mold cavity. The powder is exactly the same as that used in the first filling. A second pre-compression is performed using low pressure, and this pre-compression leaves a certain thickness of space in the mold cavity.

[0071] Next, the third powder filling is carried out, and the powder of the second magnet 82 is filled into the mold cavity. Specifically, the second magnetic powder material that forms the second insulating region 822 is filled first, the third pre-pressing is carried out, leaving a space of a certain thickness in the mold cavity, and finally the first magnetic powder material that forms the first insulating region 821 is filled.

[0072] Next, a fourth pressing is performed under preset pressure, and the green blank of the magnetic body is formed by pressing and shaping using product forming pressure.

[0073] Subsequently, the product undergoes debinding, annealing, and coating, followed by subsequent processes such as the end electrode process to form a complete product.

[0074] Comparison of inductor components: In this comparative example, the magnetic body of the inductor element only includes the first magnet, without the second magnet, and the thickness of the first magnet is 2mm.

[0075] The performance test results of the above embodiments and comparative examples are shown in Table 1.

[0076] Table 1 Performance test results of each embodiment and comparative example

[0077] As can be seen from the above, compared with the comparative examples, the insulation resistance between the end electrodes in the first to eighth embodiments of the present invention is significantly improved. Therefore, by providing a second magnet with a first insulating region, good insulation between the end electrodes can be achieved. Furthermore, the end electrodes of the inductor element of the present invention are directly formed on the metallic magnetic body, resulting in stronger adhesion of the end electrodes. In addition, in the seventh embodiment, the second magnet is composed of multiple materials. Compared with the fourth to sixth embodiments, its insulation performance is slightly insufficient, but the impact on the electromagnetic performance of the product is small. Moreover, since different materials need to be filled at different locations when filling the magnetic powder of the second magnet, the manufacturing process is more complex. In the eighth embodiment, the second magnet is also composed of multiple materials. Compared with the fourth to sixth embodiments, its insulation performance is slightly insufficient, but the impact on the electromagnetic performance of the product is also small. In addition, the manufacturing process is simpler than that of the seventh embodiment.

[0078] Furthermore, when the second magnet comprises multiple insulating regions, regardless of whether the insulating regions are arranged laterally (e.g., in the second or third direction) or longitudinally (i.e., in the first direction), the intrinsic insulation resistance of the material of the insulating region in direct contact with the end electrode is greater than or equal to the intrinsic insulation resistance of the material of the remaining insulating regions. In the second magnet, the intrinsic insulation resistance of the material of the insulating region in direct contact with the end electrode is more than ten times that of the material of the first magnet, and its permeability is not less than 40% of the permeability of the material of the first magnet.

[0079] Finally, it should be emphasized that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. For those skilled in the art, the present invention can have various changes and modifications. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. Inductor components, including: Magnetic main body; A coil, wherein the coil is disposed within the magnetic body; End electrode, wherein the end electrode is disposed outside the magnetic body and electrically connected to the coil; Its features are: The magnetic body includes a first magnet and a second magnet arranged along a first direction; Along the first direction, the thickness of the first magnet is greater than the thickness of the second magnet; The end electrode is disposed on the second magnet, the coil is disposed in the first magnet, and the lead end of the coil passes through the second magnet and is electrically connected to the end electrode; The second magnet includes a first insulating region, the insulating properties of the material of the first insulating region are higher than the insulating properties of the material of the first magnet, and the end electrode is insulated from the first magnet through the first insulating region.

2. The inductor element according to claim 1, characterized in that: The material of the first magnet includes an iron-nickel alloy; and / or The material of the first insulating region includes at least one of the following: iron-silicon alloy, nickel-zinc ferrite, amorphous iron powder, nanocrystalline iron powder, and carbonyl iron powder.

3. The inductor element according to claim 1, characterized in that: The number of coils is two or more, and the number of terminal electrodes is two or more sets; One of the coils is electrically connected to a set of the end electrodes, and the coils are insulated from each other, as are the end electrodes.

4. The inductor element according to claim 3, characterized in that: The projection of the terminal electrode along the first direction lies within the total projection of the coil lead-out end and the first insulation region along the first direction.

5. The inductor element according to claim 4, characterized in that: The second magnet further includes a second insulating region, which is arranged along a second direction with the first insulating region, and the second direction is perpendicular to the first direction; The insulation performance of the material in the second insulation region is less than that of the material in the first insulation region.

6. The inductor element according to claim 5, characterized in that: The number of the first insulating regions is less than or equal to the number of the end electrodes, and one first insulating region is correspondingly disposed with at least one end electrode in the first direction.

7. The inductor element according to claim 6, characterized in that: The number of first insulating regions is two or more, and the second insulating region is located between two adjacent first insulating regions.

8. The inductor element according to claim 1, characterized in that: The second magnet further includes a second insulating region, which is arranged along the first insulating region and the first insulating region in the first direction, and the second insulating region is located between the first insulating region and the first magnet; The insulation performance of the material in the second insulating region is less than that of the material in the first insulating region, but greater than that of the material in the first magnet.

9. The inductor element according to any one of claims 1 to 4, characterized in that: The terminal electrodes are formed by an electroplating process; and / or The thickness of the second magnet is less than or equal to 10% of the thickness of the first magnet; and / or The permeability of the material in the first insulating region is lower than that of the material in the first magnet; and / or The coil includes a coil body and a coil sheathing layer, the coil sheathing layer covering the outer surface of the coil body; and / or The inductor element further includes a surface coating layer, which covers the magnetic body, and the terminal electrodes are exposed outside the surface coating layer.

10. A method for manufacturing an inductor element, characterized in that, The method of manufacturing an inductor as described in any one of claims 1 to 9 comprises: The powder of the first magnet is filled into the mold cavity and pre-pressed into a substrate; The coil is placed into the mold cavity and then placed on the substrate; The powder of the first magnet is filled into the mold cavity and a second pre-compression is performed; The powder of the second magnet is filled into the mold cavity; The green body is formed by pressing and molding under preset pressure to create a magnetic body.

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