Conductive structure, aggregate and inductance element

Abstract

The utility model provides a conductive structure, aggregate and inductance element, the conductive structure includes at least one conductive main body, the conductive main body includes a first conductive portion, a connecting portion and a second conductive portion, the connecting portion has a first surface and a second surface opposite to each other, the first surface is connected with the middle of the first conductive portion, and the second surface is connected with the middle of the second conductive portion. The second surface is connected with the middle part of the second conductive part, and the conductive main body is in axial symmetry along the central line direction of the connecting part. According to the utility model, the inductor element size is reduced, the forming qualified rate in the preparation process is improved, and batch production is realized.

Description

Technical Field

[0001] The utility model belongs to the technical field of electronic components and relates to a conductive structure, an assembly and an inductor element. Background Art

[0002] An inductor is a component that can convert electrical energy into magnetic energy and store it. Currently, inductors are widely used in many electronic terminal products. With the rapid development of society, common electronic terminal products are developing towards high frequency, integration, and miniaturization. Smart phones, laptops and other products mostly use power management ICs to uniformly manage various functional modules, and power inductors play a role in reducing ripple current. The overall requirements for power inductors are miniaturization, thinness, high frequency, low DCR, high current, low EMI (electromagnetic interference) and low manufacturing cost. In other words, the demand for miniaturization of inductor specifications is also increasing, but its performance should also remain unchanged or improve.

[0003] At present, it is difficult to manufacture small-sized power inductors while ensuring high power, and it is difficult to mass produce them, so they cannot be widely used in common electronic terminal products. For example, CN111415813B uses a conductive structure to heat and press the inductor, which is easy to press and form, but the magnetic performance is low, which reduces the quality of the inductor.

[0004] Therefore, it is necessary to provide a miniaturized inductive component that is easy to mass produce. Utility Model Content

[0005] In view of the deficiencies in the prior art, the purpose of the utility model is to provide an inductor component and a preparation method thereof, which reduces the volume of the inductor component, ensures the stability of magnetic properties, improves the molding qualification rate in the preparation process, and realizes mass production.

[0006] To achieve this purpose, the utility model adopts the following technical solutions:

[0007] In a first aspect, the utility model provides a conductive structure, which includes a conductive body extending along a first direction, and includes a first conductive part, a connecting part and a second conductive part, wherein the connecting part has a first surface and a second surface relative to each other, the first surface is connected to the middle part of the first conductive part, and the second surface is connected to the middle part of the second conductive part.

[0008] It should be noted that the conductive structure in the present invention can be made of conductive metals, conductive alloys, or mixtures containing conductive metals commonly used in the art, and can be produced by any processing method known to those skilled in the art, including but not limited to corrosion, deposition, sputtering, stamping, welding or cutting, etc. The present invention does not make specific limitations on this.

[0009] As a preferred technical solution of the utility model, a plurality of conductive pins are arranged on a surface of one end of the first conductive part and / or the second conductive part away from the connecting part, and the plurality of conductive pins are arranged at intervals along the first direction.

[0010] That is, the present invention provides the following three solutions: (1) if a plurality of conductive pins arranged at intervals along the first direction are provided on the end surface of the first conductive part away from the connecting part; (2) if a plurality of conductive pins arranged at intervals along the first direction are provided on the end surface of the second conductive part away from the connecting part; (3) a plurality of conductive pins arranged at intervals along the first direction are independently provided on the end surfaces of the first conductive part and the second conductive part away from each other, and two guide holes respectively opened on the end surfaces of the first conductive part and the second conductive part away from each other are arranged in a one-to-one correspondence, that is, the conductive pin connected to the second conductive part extends along the second direction, and the conductive pin connected to the first conductive part extends in a direction opposite to the second direction.

[0011] As a preferred technical solution of the utility model, a plurality of the conductive pins are distributed at equal intervals along the first direction.

[0012] As a preferred technical solution of the utility model, the plurality of conductive pins are composed of two end pins located at the outermost ends and at least one middle pin located between the two end pins, and the linear length of the end pin along the first direction is half of the linear length of the middle pin along the first direction.

[0013] As a preferred technical solution of the present invention, the linear lengths of a plurality of the conductive pins along the first direction are the same.

[0014] As a preferred technical solution of the utility model, there is a first spacing and a second spacing between the conductive pin and two adjacent conductive pins, the first spacing and the second spacing are alternately arranged, and the first spacing is smaller than the second spacing.

[0015] In a second aspect, the utility model provides an assembly, wherein the assembly comprises a magnetic core, wherein the conductive structure described in the first aspect is arranged in the magnetic core.

[0016] In a third aspect, the utility model provides an inductor element, the inductor element comprising a magnetic core, a conductive winding embedded in the magnetic core, the conductive winding comprising a main body and two conductive pins, the main body extending along a first direction, the main body consisting of a first part and a second part stacked in layers, the conductive pins extending along a second direction, the two conductive pins being spaced apart and connected to an end surface of the first part away from the second part along the first direction.

[0017] As a preferred technical solution of the utility model, the side end surfaces of the two conductive pins that are away from each other are respectively flush with the side end surfaces at both ends of the first part.

[0018] As a preferred technical solution of the utility model, the side end surfaces of the two conductive pins that are away from each other form steps with the side end surfaces at both ends of the first part respectively.

[0019] Preferably, a maximum linear length of the first portion in the third direction is greater than a maximum linear length of the second portion in the third direction, and the first direction, the second direction and the third direction are different from each other.

[0020] Preferably, a maximum linear length of the conductive pin in the third direction is the same as or different from a maximum linear length of the first portion in the third direction.

[0021] The magnetic core is formed by combining magnetic powder materials, and the magnetic powder materials can be prepared by any processing method well known to those skilled in the art, including but not limited to insulation processing, coating processing or granulation processing, which is not specifically limited in the present invention.

[0022] Compared with the prior art, the beneficial effects of the utility model are:

[0023] The utility model provides a conductive structure, an assembly and an inductor element, which adopt an axisymmetric conductive body as a base material for making a conductive winding, which is beneficial to increasing the thickness of the magnetic core, reducing the process requirements for the fluidity of magnetic powder, and reducing the molding pressure, while improving the production molding rate, and the qualified rate can reach more than 99.9%, which is easy to mass produce and reduces the manufacturing cost, thereby realizing the miniaturization, large current and high magnetic performance of the inductor element. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 A schematic diagram of the structure of an inductor element provided for a specific embodiment of the utility model;

[0025] Figure 2 A schematic diagram of the structure of an inductor element provided for a specific embodiment of the utility model;

[0026] Figure 3A cross-sectional view of a compression-molded assembly provided in a specific embodiment of the utility model;

[0027] Figure 4 A top view of the distribution of guide holes provided for a specific embodiment of the utility model;

[0028] Figure 5 A top view of the distribution of guide holes provided for a specific embodiment of the utility model;

[0029] Figure 6 A schematic diagram of the structure of a compression-molded assembly provided in a specific embodiment of the utility model;

[0030] Figure 7 A cross-sectional view of a compression-molded assembly provided in a specific embodiment of the utility model;

[0031] Figure 8 A schematic structural diagram of conductive pins distributed equidistantly provided in a specific embodiment of the utility model.

[0032] Among them, 100-magnetic core; 200-conductive winding; 201-main body; 202-conductive pin; 2021-end pin; 2022-middle pin; 1-conductive body; 2-first conductive part; 3-connecting part; 4-second conductive part; 5-guide hole; P1-first cutting line; P2-second cutting line. DETAILED DESCRIPTION

[0033] It should be understood that, in the description of the present utility model, the terms "center", "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present utility model and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present utility model. In addition, the terms "first", "second", etc. are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, features defined as "first", "second", etc. may explicitly or implicitly include one or more of the features. In the description of the present utility model, unless otherwise specified, "multiple" and "several" mean two or more.

[0034] It should be noted that in the description of the present invention, unless otherwise clearly specified and limited, the terms "disposed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be directly connected, or indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood by specific circumstances.

[0035] The technical solution of the utility model is further explained below with reference to the accompanying drawings and through specific implementation methods.

[0036] In a specific embodiment, the utility model provides a conductive structure, wherein the conductive body includes a first conductive part, a connecting part and a second conductive part, the connecting part has a first surface and a second surface relative to each other, the first surface is connected to the middle part of the first conductive part, the second surface is connected to the middle part of the second conductive part, and the conductive body is axially symmetrical along the center line direction of the connecting part.

[0037] Specifically, the conductive body is axially symmetrical along the center line direction of the connecting portion, including axially symmetrical along the horizontal center line A of the connecting portion, or axially symmetrical along the vertical center line B of the connecting portion, or axially symmetrical along both the horizontal center line A and the vertical center line B of the connecting portion.

[0038] In a specific embodiment, the utility model provides a conductive structure, comprising at least one conductive body, wherein the conductive body extends along a first direction, the conductive body comprises a first conductive part, a connecting part and a second conductive part, the connecting part having a first surface and a second surface relative to each other, the first surface being connected to the middle part of the first conductive part, the second surface being connected to the middle part of the second conductive part, the conductive body being axially symmetrical along the center line direction of the connecting part, and a plurality of conductive pins are arranged on the end surface of the first conductive part and / or the second conductive part away from the connecting part, and the plurality of conductive pins are arranged at intervals along the first direction.

[0039] Preferably, the first conductive part and the second conductive part are arranged in parallel, and the connecting part is vertically connected to both the first conductive part and the second conductive part.

[0040] It should be noted that the conductive body extends along the first direction, and different conductive structures can be formed according to the length of the extension along the first direction. For example, when the conductive body extends along the first direction for a short length, two conductive pins can be arranged at intervals along the first direction; thus, at least two conductive bodies can be arranged at intervals along the first direction in the assembly. When the conductive body extends along the first direction for a long length, multiple conductive pins can be arranged at intervals along the first direction. The specific arrangement of the multiple conductive pins at intervals is described below.

[0041] In some embodiments, the plurality of conductive pins are equidistantly spaced along a first direction, and the plurality of conductive pins are composed of two end pins located at the outermost ends and at least one middle pin located between the two end pins, and the linear length of the end pin along the first direction is half of the linear length of the middle pin along the first direction.

[0042] In some embodiments, the linear lengths of several of the conductive pins along the first direction are the same, and there are a first spacing and a second spacing between the conductive pin and two adjacent conductive pins. The first spacing and the second spacing are alternately arranged, and the first spacing is smaller than the second spacing.

[0043] In another specific embodiment, the utility model provides an assembly, wherein the assembly includes a magnetic core, and a conductive structure described in the specific embodiment is disposed in the magnetic core.

[0044] In another specific embodiment, the utility model provides an inductor element, such as Figure 1 As shown, the inductor element magnetic core 100 has a conductive winding 200 embedded therein, the conductive winding 200 includes a main body 201 and two conductive pins 202, the main body 201 extends along a first direction X, the main body 201 is composed of a first part and a second part stacked, the conductive pins 202 extend along a second direction Y, and the two conductive pins 202 are spaced apart along the first direction X and connected to an end surface of the first part away from the second part.

[0045] Preferably, if Figure 1 As shown, the cross section of the main body 201 in the second direction Y is in an inverted "T" shape, that is, the first part is arranged horizontally, the second part is arranged vertically, and the conductive pin 202 is connected to the first part.

[0046] In some embodiments, Figure 2 As shown, the side end surfaces of the two conductive pins 202 that are away from each other are flush with the side end surfaces at both ends of the first part.

[0047] In some embodiments, Figure 1 As shown, the side end surfaces of the two conductive pins 202 that are away from each other form steps with the side end surfaces at both ends of the first part.

[0048] In some embodiments, the maximum linear length of the first portion in the third direction Z is greater than the maximum linear length of the second portion in the third direction Z, and the first direction X, the second direction Y and the third direction Z are different from each other. Preferably, the first direction X, the second direction Y and the third direction Z are perpendicular to each other.

[0049] In some embodiments, the maximum linear length of the conductive pin 202 in the third direction Z is the same as or different from the maximum linear length of the main body 201 in the third direction Z.

[0050] In another specific embodiment, the utility model provides a method for preparing the inductor element of a specific embodiment, the preparation method comprising:

[0051] Step 1: Provide a conductive structure such as Figure 3 As shown, the conductive structure includes a conductive body 1, the conductive body 1 extends along a first direction, the conductive body 1 includes a first conductive part 2, a connecting part 3 and a second conductive part 4, the connecting part 3 has a first surface and a second surface opposite to each other, the first surface is connected to the middle of the first conductive part 2, the second surface is connected to the middle of the second conductive part 4, and the conductive body 1 is axially symmetrical along the center line direction of the connecting part 3;

[0052] Step 2: molding the conductive structure and the magnetic powder material to form an assembly;

[0053] Step 3: Punching the assembly to independently form a plurality of guide holes 5 at the ends of the first conductive portion 2 and the second conductive portion 4 that are away from each other, wherein the plurality of guide holes 5 are spaced apart along the first direction, and the guide holes 5 are connected to the first conductive portion 2 or the second conductive portion 4;

[0054] Step 4: performing metallization treatment in the guide hole 5 to form a conductive pin 202, so that one end of the conductive pin 202 is connected to the first conductive part 2 or the second conductive part 4, and the other end extends out of the assembly, thereby obtaining a magnetic core blank;

[0055] Step 5: Cut the assembly to obtain a magnetic core 100 including a conductive winding 200 .

[0056] In step 1, two guide holes 5 are respectively provided on the surfaces of the first conductive part 2 and the second conductive part 4 at one end away from each other and are arranged one by one. Preferably, the first conductive part 2, the connecting part 3 and the second conductive part 4 are arranged in an I-shaped pattern.

[0057] In step 2, the compression molding comprises:

[0058] S1: providing a pressing mold, and laying a first magnetic powder in the pressing mold to form a first filling layer;

[0059] S2: placing one end of the first conductive part 2 or the second conductive part 4 of the conductive structure on the first filling layer;

[0060] S3: laying second magnetic powder on the first filling layer to form a second filling layer, so that the second filling layer at least covers the conductive structure;

[0061] S4: laying a third magnetic powder on the second filling layer to form a third filling layer until the pressing mold is filled;

[0062] S5: followed by pressing to obtain the aggregate.

[0063] In some embodiments, the first magnetic powder, the second magnetic powder and the third magnetic powder independently include any one of sendust powder, ferrosilicon powder, iron-nickel powder, amorphous nanocrystalline powder and carbonyl iron powder or a combination of at least two thereof. The first magnetic powder, the second magnetic powder and the third magnetic powder are the same or different. The first magnetic powder, the second magnetic powder and the third magnetic powder used in the magnetic powder material of the utility model may be the same or different. And the magnetic powder material may be prepared by any treatment method well known to those skilled in the art, including but not limited to insulation treatment, coating treatment or granulation treatment, which is not specifically limited in the utility model.

[0064] In step 2, when forming the first filling layer, the second filling layer, the third filling layer and the fourth filling layer, after laying the corresponding magnetic powder, it is necessary to perform vibration or compaction to increase the density and filling rate of the magnetic powder in the filling layer, so as to ensure that when the conductive structure is complex, the magnetic powder can be evenly filled around the conductive structure.

[0065] In some embodiments, the preparation method further comprises: after completing the compression molding, performing heat treatment to obtain the assembly.

[0066] The magnetic core is formed by combining magnetic powder and does not contain organic resin, which can effectively increase the density of the magnetic core and further enhance the magnetic induction effect.

[0067] In step 3, the drilling process includes any one of mechanical drilling, electric spark drilling or laser drilling, or a combination of at least two of them.

[0068] In step 4, the metallization treatment includes any one of metal casting, vacuum sputtering or electroplating, or a combination of at least two of them.

[0069] The metallization treatment of the present invention uses conductive metal materials, conductive alloy materials, or mixed materials containing conductive metals that are well known to those skilled in the art and can be used to make conductive pins 202 as raw materials, and forms conductive pins 202 through any one process of metal casting, vacuum sputtering or electroplating, or a combination of at least two of them. The present invention does not specifically limit the specific process steps of the above-mentioned processes, and conventional processing methods in the field can be used.

[0070] In step 5, the present invention provides the following two cutting processing solutions according to different distribution forms of the guide holes 5 on the assembly.

[0071] Option 1: If Figure 4 As shown, a plurality of the guide holes 5 are equidistantly spaced along the first direction, the linear lengths of the two guide holes 5 located at the outermost ends along the first direction are recorded as the first length, and the linear length of the guide hole 5 located in the middle of the assembly along the first direction is recorded as the second length, and the first length is half of the second length.

[0072] The cutting process includes:

[0073] Performing a first cutting on the assembly along a first cutting line to obtain two sub-assemblies;

[0074] Performing a second cutting on the sub-assembly along a second cutting line to obtain at least one magnetic core 100 including a conductive winding 200;

[0075] The first cutting line coincides with the center line of the connecting portion 3 in a direction perpendicular to the second direction, that is, the second cutting line does not pass through the first conductive portion 2 and the second conductive portion 4, and is located at the center line of the conductive pin 202 in the guide hole 5 having the second length. It should be noted that, in the case where the conductive pin 202 is provided on the conductive body 1, the first cutting line may not coincide with the center line of the connecting portion 3 in a direction perpendicular to the second direction, that is, the first cutting line only needs to be along a direction perpendicular to the second direction.

[0076] The connecting portion 3 of the present invention is divided into the same first end and second end after cutting, and the conductive pin 202 in the guide hole 5 with the second length is divided into two partial pins after cutting, and the partial pins are the same as the end pins in the guide hole 5 located at the outermost end. The obtained plurality of conductive windings 200 include the following combinations: (1) a single-turn conductive winding 200 composed of the first end, the first conductive portion 2, an end pin connected to the first conductive portion 2, and a partial pin connected to the first conductive portion 2, and the first end and the first conductive portion 2 constitute the main body 201; (2) a single-turn conductive winding 200 composed of the first end, the first conductive portion 2, an end pin connected to the first conductive portion 2, and a partial pin connected to the first conductive portion 2; , a first conductive part 2, and two partial pins connecting the first conductive part 2 together constitute a single-turn conductive winding 200, and the first end and the first conductive part 2 constitute a main body 201; (3) a second end, a second conductive part 4, an end pin connected to the second conductive part 4, and a partial pin connected to the second conductive part 4 together constitute a single-turn conductive winding 200, and the second end and the second conductive part 4 constitute a main body 201; (4) a second end, a second conductive part 4, and two partial pins connecting the second conductive part 4 together constitute a single-turn conductive winding 200, and the second end and the second conductive part 4 constitute a main body 201.

[0077] Option 2: If Figure 5 As shown, the linear lengths of several guide holes 5 along the first direction are the same, and there is a first spacing and a second spacing between the guide hole 5 and two adjacent guide holes 5 . The first spacing and the second spacing are alternately arranged, and the first spacing is smaller than the second spacing.

[0078] The cutting process includes:

[0079] Performing a first cutting on the assembly along a first cutting line to obtain two sub-assemblies;

[0080] Performing a second cutting on the sub-assembly along a second cutting line to obtain at least one magnetic core 100 including a conductive winding 200;

[0081] The first cutting line coincides with a center line of the connecting portion 3 in a direction perpendicular to the second direction, that is, the first cutting line does not pass through the first conductive portion 2 and the second conductive portion 4 , and the second cutting line is located between two guide holes 5 having a first spacing.

[0082] In the present invention, after the connecting portion 3 is cut, it is divided into the same first end and second end, wherein the first end and the two conductive pins 202 formed on one side of the first conductive portion 2 together form a single-turn conductive winding 200, and the second end and the two conductive pins 202 formed on one side of the second conductive portion 4 together form a single-turn conductive winding 200.

[0083] In some embodiments, when the number of the conductive bodies 1 in the assembly is at least two, the cutting process further includes cutting along a third cutting line P3 , where the third cutting line P3 is located between two adjacent conductive bodies 1 .

[0084] In another specific embodiment, the utility model provides a method for preparing the inductor element of a specific embodiment, the preparation method comprising:

[0085] Step 1: Provide a conductive structure, such as Figure 6 and Figure 7 As shown, the conductive structure includes at least one conductive body 1, the conductive body 1 extends along a first direction, the conductive body 1 includes a first conductive part 2, a connecting part 3 and a second conductive part 4, the connecting part 3 has a first surface and a second surface opposite to each other, the first surface is connected to the middle of the first conductive part 2, the second surface is connected to the middle of the second conductive part 4, the conductive body 1 is axially symmetrical along the center line direction of the connecting part 3, and the end surfaces of the first conductive part 2 and the second conductive part 4 that are away from each other are independently provided with a plurality of conductive pins 202, and the plurality of conductive pins 202 are spaced apart along the first direction;

[0086] Step 2: molding the conductive structure and the magnetic powder material to form an assembly;

[0087] Step three: cutting the assembly to obtain a magnetic core 100 including a conductive winding 200 .

[0088] The conductive structure in step 1 can be made of a common conductive metal, conductive alloy, or a mixture containing conductive metals in the art, and can be made by any processing method known to those skilled in the art, including but not limited to corrosion, deposition, sputtering, stamping, welding or cutting, etc., and the present invention does not specifically limit this. Preferably, the first conductive portion 2, the connecting portion 3 and the second conductive portion 4 are arranged in an I-shaped pattern.

[0089] In step 2, the compression molding includes:

[0090] (1) providing a pressing mold, laying a first magnetic powder in the pressing mold to form a first filling layer, and placing the conductive structure on the first filling layer;

[0091] (2) laying a second magnetic powder on the first filling layer to form a second filling layer, so that the second filling layer at least covers the first conductive part 2 and the conductive pin 202 connected to one side of the first conductive part 2, or at least covers the second conductive part 4 and the conductive pin 202 connected to one side of the second conductive part 4;

[0092] (3) laying third magnetic powder on the second filling layer to form a third filling layer, so that the third filling layer at least covers the connecting portion 3;

[0093] (4) laying fourth magnetic powder on the third filling layer to form a fourth filling layer, so that the fourth filling layer at least covers the second conductive part 4 and the conductive pin 202 connected to one side of the second conductive part 4, or at least covers the first conductive part 2 and the conductive pin 202 connected to one side of the first conductive part 2;

[0094] (5) The product is then pressed to form an aggregate.

[0095] In some embodiments, the compression molding further includes: after the first filling layer is formed, a plurality of limiting holes are formed on the first filling layer, and the conductive pins 202 connected to the first conductive part 2 or the second conductive part 4 are inserted into the limiting holes.

[0096] In step 2, when forming the first filling layer, the second filling layer, the third filling layer and the fourth filling layer, compaction treatment is required after laying the corresponding magnetic powder to ensure the structural strength of the magnetic core.

[0097] In some embodiments, the first magnetic powder, the second magnetic powder, the third magnetic powder and the fourth magnetic powder independently include any one of sendust powder, ferrosilicon powder, iron-nickel powder, amorphous nanocrystalline powder and carbonyl iron powder or a combination of at least two thereof. The first magnetic powder, the second magnetic powder, the third magnetic powder and the fourth magnetic powder used in the magnetic powder material of the utility model may be the same or different. And the magnetic powder material may be prepared by any treatment method well known to those skilled in the art, including but not limited to insulation treatment, coating treatment or granulation treatment, which is not specifically limited in the utility model. The magnetic core 100 of the utility model is composed of magnetic powder material, does not contain organic resin, can effectively increase the density of the magnetic core 100, and further enhance the magnetic induction effect.

[0098] In some embodiments, the preparation method further comprises: after completing the compression molding, performing heat treatment to obtain the assembly.

[0099] In step three, the present invention provides the following two cutting processing solutions according to different distribution forms of the conductive pins 202 in the conductive structure.

[0100] Option 1: If Figure 8 As shown, a plurality of the conductive pins 202 are equidistantly spaced along a first direction; the plurality of the conductive pins 202 are composed of two end pins 2021 located at the outermost ends, and at least one middle pin 2022 located between the two end pins 2021, and the linear length of the end pin 2021 along the first direction is half of the linear length of the middle pin 2022 along the first direction.

[0101] The cutting process includes:

[0102] Performing a first cutting on the assembly along a first cutting line to obtain two sub-assemblies;

[0103] Performing a second cutting on the sub-assembly along a second cutting line to obtain at least one magnetic core 100 including a conductive winding 200;

[0104] The first cutting line coincides with a center line of the connecting portion 3 in a direction perpendicular to the second direction, that is, the first cutting line does not pass through the first conductive portion 2 and the second conductive portion 4 , and the second cutting line is located at a center line of the middle pin 2022 .

[0105] The connecting portion 3 of the utility model is divided into the same first end and second end after cutting, and the middle pin 2022 is divided into two partial pins which are the same as the end pin 2021 after cutting, and the obtained conductive windings 200 include the following combinations: (1) a single-turn conductive winding 200 composed of the first end, the first conductive portion 2, an end pin 2021 connected to the first conductive portion 2, and a partial pin connected to the first conductive portion 2, and the first end and the first conductive portion 2 constitute the main body 201; (2) a single-turn conductive winding 200 composed of the first end, the first conductive portion 2, and (1) a single-turn conductive winding 200 consisting of two partial pins connecting the first conductive part 2, wherein the first end and the first conductive part 2 constitute a main body 201; (2) a single-turn conductive winding 200 consisting of the second end, the second conductive part 4, an end pin 2021 connected to the second conductive part 4, and a partial pin connected to the second conductive part 4, wherein the second end and the second conductive part 4 constitute a main body 201; (3) a single-turn conductive winding 200 consisting of the second end, the second conductive part 4, an end pin 2021 connected to the second conductive part 4, and a partial pin connected to the second conductive part 4, wherein the second end and the second conductive part 4 constitute a main body 201.

[0106] Option 2: If Figure 6 As shown, the linear lengths of several conductive pins 202 along the first direction are the same, and there is a first spacing and a second spacing between the conductive pin 202 and two adjacent conductive pins 202 . The first spacing and the second spacing are alternately arranged, and the first spacing is smaller than the second spacing.

[0107] The cutting process includes:

[0108] Performing a first cutting on the assembly along a first cutting line P1 to obtain two sub-assemblies;

[0109] Performing a second cutting on the sub-assembly along a second cutting line P2 to obtain at least one magnetic core 100 including a conductive winding 200;

[0110] The first cutting line P1 coincides with a center line of the connecting portion 3 in a direction perpendicular to the second direction, that is, it does not pass through the first conductive portion 2 and the second conductive portion 4 . The second cutting line P2 is located between two conductive pins 202 having a first interval.

[0111] After the connection part 3 of the utility model is cut, it is divided into the same first end and second end, and after cutting along the center line of the second slot, a plurality of conductive windings 200 are obtained. Among them, the conductive winding 200 is composed of the following combinations: (1) a single-turn conductive winding 200 consisting of the first end, the first conductive part 2, and two conductive pins 202 respectively connected to the first conductive part 2, and the first end and the first conductive part 2 constitute the main body 201; (2) a single-turn conductive winding 200 consisting of the second end, the second conductive part 4, and two conductive pins 202 respectively connected to the second conductive part 4, and the second end and the second conductive part 4 constitute the main body 201.

[0112] In some embodiments, when the number of the conductive bodies 1 in the assembly is at least two, the cutting process further includes cutting along a third cutting line P3 , where the third cutting line P3 is located between two adjacent conductive bodies 1 .

[0113] In another specific embodiment, the utility model provides a method for preparing the inductor element of a specific embodiment, the preparation method comprising:

[0114] Step S100: providing a conductive structure, the conductive structure comprising a conductive body, the conductive body extending along a first direction, the conductive body comprising a first conductive portion, a connecting portion and a second conductive portion, the connecting portion having a first surface and a second surface opposite to each other, the first surface being connected to a middle portion of the first conductive portion, the second surface being connected to a middle portion of the second conductive portion, a plurality of first conductive pins being disposed on a surface of one end of the first conductive portion or the second conductive portion away from the connecting portion, and the plurality of first conductive pins being disposed at intervals along the first direction;

[0115] Step S200: molding the conductive structure and the magnetic powder material to form an assembly;

[0116] Step S300: punching a hole on one side end surface of the assembly corresponding to the second conductive part or the first conductive part without the first conductive pin, so as to form a plurality of guide holes on the second conductive part or the first conductive part, wherein the plurality of guide holes are spaced apart along the first direction, the guide holes are connected to the second conductive part or the first conductive part, and the guide holes correspond to the first conductive pins one by one;

[0117] Step S400: performing metallization treatment in the guide hole to form a second conductive pin, so that one end of the second conductive pin is connected to the second conductive part or the first conductive part, and the other end extends out of the assembly, thereby obtaining a magnetic core blank;

[0118] Step S500: cutting the assembly to obtain a magnetic core including a conductive winding.

[0119] The conductive structure in step S100 can be made of a common conductive metal, conductive alloy, or a mixture containing conductive metals in the art, and can be made by any processing method known to those skilled in the art, including but not limited to corrosion, deposition, sputtering, stamping, welding or cutting, etc., and the present invention does not specifically limit this. Preferably, the first conductive portion, the connecting portion, and the second conductive portion are arranged in an I-shaped pattern.

[0120] In step S200, the compression molding includes:

[0121] (1) providing a pressing mold, laying a first magnetic powder in the pressing mold to form a first filling layer, and placing the conductive structure on the first filling layer from one end where the first conductive pin is provided;

[0122] (2) laying second magnetic powder on the first filling layer to form a second filling layer, so that the second filling layer at least covers the first conductive pin and the first conductive portion;

[0123] (3) laying third magnetic powder on the second filling layer to form a third filling layer, so that the third filling layer at least covers the connecting portion;

[0124] (4) laying fourth magnetic powder on the third filling layer to form a fourth filling layer, so that the fourth filling layer at least covers the second conductive portion 4;

[0125] (5) The product is then pressed to form an aggregate.

[0126] In some embodiments, the compression molding further includes: after the first filling layer is formed, forming a plurality of limiting holes on the first filling layer, and inserting the first conductive pins into the limiting holes.

[0127] In step S200, when forming the first filling layer, the second filling layer, the third filling layer and the fourth filling layer, compaction treatment is required after laying the corresponding magnetic powder to ensure the structural strength of the magnetic core.

[0128] It can be understood that when the conductive structure only includes a conductive body but not a conductive pin to form an assembly and is cut, the cutting can be performed along the vertical center line of the connecting part, that is, along the second direction, preferably coinciding with the center line of the connecting part along the second direction, so that the cutting line is always within the connecting part, dividing the first conductive part, the connecting part, and the second conductive part into two continuous parts.

[0129] In some embodiments, the first magnetic powder, the second magnetic powder, the third magnetic powder and the fourth magnetic powder independently include any one of sendust powder, ferrosilicon powder, iron-nickel powder, amorphous nanocrystalline powder and carbonyl iron powder, or a combination of at least two thereof. The first magnetic powder, the second magnetic powder, the third magnetic powder and the fourth magnetic powder used in the magnetic powder material of the utility model may be the same or different. And the magnetic powder material may be prepared by any treatment method well known to those skilled in the art, including but not limited to insulation treatment, coating treatment or granulation treatment, which is not specifically limited in the utility model. The magnetic core of the utility model is composed of magnetic powder material, does not contain organic resin, can effectively increase the density of the magnetic core, and further enhance the magnetic induction effect.

[0130] In some embodiments, the preparation method further comprises: after completing the compression molding, performing heat treatment to obtain the assembly.

[0131] In step S300, the present invention provides the following two cutting processing schemes for different distribution forms of the first conductive pins in the conductive structure, and the operation steps of the cutting processing are the same as those in the above specific implementation manner, which will not be repeated here.

[0132] The applicant declares that the above is only a specific implementation method of the present utility model, but the protection scope of the present utility model is not limited thereto. The technicians in the relevant technical field should understand that any changes or substitutions that can be easily thought of by the technicians in the relevant technical field within the technical scope disclosed in the present utility model fall within the protection scope and disclosure scope of the present utility model.

Claims

1. A conductive structure, characterized in that: The conductive structure includes a conductive body, which extends along a first direction. The conductive body includes a first conductive part, a connecting part and a second conductive part. The connecting part has a first surface and a second surface opposite to each other. The first surface is connected to the middle of the first conductive part, and the second surface is connected to the middle of the second conductive part. The conductive body is axially symmetrical along the center line direction of the connecting part.

2. The conductive structure according to claim 1, characterized in that: A plurality of conductive pins are disposed on a surface of one end of the first conductive portion and / or the second conductive portion away from the connecting portion, and the plurality of conductive pins are disposed at intervals along the first direction.

3. The conductive structure according to claim 2, characterized in that: A plurality of the conductive pins are distributed at equal intervals along the first direction.

4. The conductive structure according to claim 3, characterized in that: The plurality of conductive pins are composed of two end pins at the outermost ends and at least one middle pin between the two end pins, and the linear length of the end pin along the first direction is half of the linear length of the middle pin along the first direction.

5. The conductive structure according to claim 2, characterized in that: The linear lengths of the plurality of conductive pins along the first direction are the same.

6. The conductive structure according to claim 5, characterized in that: There is a first spacing and a second spacing between the conductive pin and two adjacent conductive pins, the first spacing and the second spacing are alternately arranged, and the first spacing is smaller than the second spacing.

7. An aggregate, characterized in that: The assembly comprises a magnetic core, and the conductive structure according to any one of claims 1 to 6 is arranged in the magnetic core.

8. An inductor element, characterized in that: The inductor element includes a magnetic core, a conductive winding is embedded in the magnetic core, the conductive winding includes a main body and two conductive pins, the main body extends along a first direction, the main body is composed of a first part and a second part stacked in sequence, the maximum linear length of the first part in the third direction is greater than the maximum linear length of the second part in the third direction; the conductive pins extend along the second direction, and the two conductive pins are connected to an end surface of the first part away from the second part at intervals along the first direction.

9. The inductor element according to claim 8, characterized in that: The side end surfaces of the two conductive pins that are away from each other are flush with the side end surfaces at both ends of the first part.

10. The inductor element according to claim 8, characterized in that: The side end surfaces of the two conductive pins that are away from each other form steps with the side end surfaces at both ends of the first part respectively.

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