Flat coil hot press molding integrated inductor

Abstract

The utility model discloses a flat coil hot press molding integrated inductor which comprises a flat coil, the flat coil comprises a base magnet and a winding body, a bending part is arranged at the bottom of the winding body, the winding body is arranged on the inner side of the bending part, and an inductor wrapping insulator is arranged on the outer side of the flat coil. The inductor is an integrated inductor which is formed by bending a flat coil, implanting the flat coil into an I CORE hot press forming structure, heating the flat coil through a mold and pressing the flat coil. The integrated inductor formed by hot press molding of the flat coil has the advantages of low loss alloy powder die casting, low impedance, no lead end, small parasitic capacitance, unique integrated structure, firmness, accurate product thickness, lasting rust prevention, small volume, large current, low cost and the like. Excellent temperature rise current and saturation current characteristics are still kept in high-frequency and high-temperature environments, and the working frequency coverage range is wide.

Description

Technical Field

[0001] This utility model relates to the field of inductor technology, specifically a flat coil hot-pressed integral inductor. Background Technology

[0002] With societal development, inductors are being used more and more widely. An inductor, also known as a choke, reactor, or inductor coil, is a two-terminal circuit element that converts electrical energy into magnetic energy and stores it. The working principle of an inductor is that an inductor is made by winding a wire into a coil shape. When current flows through it, a strong magnetic field is generated across the coil (inductor). Due to electromagnetic induction, this magnetic field impedes changes in current. Therefore, an inductor presents very little resistance to direct current (approximately a short circuit) and relatively high impedance to alternating current (AC). Its resistance value is related to the frequency of the AC signal passing through it. For the same inductor, the higher the frequency of the AC current passing through it, the greater the resistance.

[0003] However, existing inductors cannot maintain excellent temperature rise current and saturation current characteristics under high frequency and high temperature environments, have a relatively small operating frequency coverage, and have poor performance. Therefore, we propose a flat coil hot-pressed integral inductor to solve the above-mentioned problems. Utility Model Content

[0004] The purpose of this invention is to provide a flat coil hot-pressed integral inductor to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, this utility model provides the following technical solution:

[0006] A flat coil thermoforming integrated inductor includes a flat coil, the flat coil including a base magnet and a winding body, and the bottom of the winding body is provided with a bending part, the winding body is located inside the bending part, and the outside of the flat coil is provided with an inductor-coated insulator; the inductor is formed by bending the flat coil and embedding it into an I CORE thermoforming structure, and then pressing it into an integrated inductor after heating with a mold.

[0007] As a further embodiment of this utility model, the base magnet is formed by die-casting the winding body into the interior of metallic magnetic powder.

[0008] As a further embodiment of this utility model, the bending portions are symmetrically distributed, and the bending portions are directly formed on the surface of the base magnet at the lead-out feet of the winding body.

[0009] As a further embodiment of this invention, the bottom of the inductor-coated insulator is formed with pins that match the bent portion.

[0010] Compared with the prior art, the beneficial effects of this utility model are:

[0011] This flat coil hot-pressed integrated inductor features low-loss alloy powder die casting, low impedance, no lead ends, small parasitic capacitance, and a unique integrated structure that is robust and sturdy. The product has precise thickness, long-lasting rust prevention, small size, and high current capacity. It maintains excellent temperature rise current and saturation current characteristics even in high-frequency and high-temperature environments, and has a wide operating frequency coverage. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of the structure of the flat coil hot-pressed integral inductor of this utility model.

[0013] Figure 2 This is an exploded view of the flat coil hot-pressed integral inductor of this utility model.

[0014] Figure 3 This is a schematic diagram of the integrated flat coil assembly structure formed by hot pressing of the flat coil in this utility model.

[0015] Figure 4 This is a circuit diagram of the flat coil hot-pressed integral inductor of this utility model.

[0016] The components are: 1. Flat coil; 2. Base; 3. Winding body; 4. Bending section; 5. Inductor-coated insulator; 6. Pins. Detailed Implementation

[0017] In one embodiment, such as Figures 1-4 As shown, a flat coil thermoformed integrated inductor is composed of metal powder and a flat coil 1. The flat coil 1 includes a base magnet 2 and a winding body 3. The base magnet 2 is formed by die-casting the winding body 3 by embedding it inside the metal magnetic powder. A bending portion 4 is provided at the bottom of the winding body 3, and the winding body 3 is located inside the bending portion 4. The bending portion 4 is formed by directly forming the lead of the winding body 3 on the surface of the base magnet 2. An inductor-coated insulator 5 is provided on the outside of the flat coil 1, which has higher inductance and lower leakage inductance than traditional inductors. The bottom of the inductor-coated insulator 5 is formed with leads 6 that match the bending portion 4. The inductor is formed by bending the flat coil 1 and embedding it with I. The CORE hot-press molding structure design is used to press the inductor into an integrated unit after heating in a mold. The metal powder material includes 40% carbon-based magnetic powder, 50% alloy magnetic powder, and 10% amorphous magnetic powder. It features a magnetic shielding structure, closed magnetic circuit, strong anti-electromagnetic interference, ultra-low hum, high-density installation, low-loss composite metal powder core die casting, low impedance, integrated molding structure, and solid and firm welding with PCB pads. The product is precise, small in size, and can handle high current. It can maintain excellent temperature rise current and saturation current characteristics at high temperatures.

[0018] Flat coil thermoforming integrated inductors are a new type of inductor in which the coil is embedded in the I CORE within soft magnetic powder. Due to its closed magnetic circuit structure and the variety of soft magnetic materials available, it possesses many characteristics different from traditional inductors:

[0019] Saturation resistance: Under DC superposition conditions, it has good anti-saturation characteristics and strong application capability.

[0020] Impact resistant: It adopts a metal powder core die-casting structure, which overcomes the shortcomings of traditional inductors such as fragility and magnetic noise.

[0021] Excellent performance: The magnetic shielding structure makes its EMI characteristics far superior to those of ordinary power inductors.

[0022] Low wear and tear: Powder die casting significantly reduces eddy currents, thereby reducing temperature rise and overall machine wear and tear.

[0023] Wide frequency range: can be achieved from "low frequency to up to 30MHz".

[0024] Zero pollution: No harmful substances are released from raw materials to the production process.

[0025] Low temperature rise: It exhibits stable and good temperature rise performance under long-term working conditions.

[0026] The manufacturing process includes pressing the prepared composite magnetic powder into a single I CORE as the base magnet 2 using a molding machine, bending the wound flat coil 1 into the I CORE for assembly, and then molding the I CORE after heating the mold to a certain molding temperature. It uses flat wire with high UI and BS values, low impedance, and low loss. Compared with traditional one-piece molded products, the coil inner diameter can be increased, the saturation current characteristics can be improved by about 10%-20%, and the DCR can be reduced by about 10%. The utilization rate of traditional round copper wire is generally around 40%, while that of flat wire can be increased to 70%. Because the cross-section of a round wire is circular, irregular gaps inevitably exist between the conductors, while the gaps in flat wire are smaller, resulting in a higher slot fill factor.

[0027] Compared to cold pressing, hot pressing can reduce the molding force by about 50% while still achieving the required iron powder density and strength. Therefore, the lower pressure significantly reduces the deformation of the coil and the damage to the enameled layer during the molding process, which can prevent the risk of coil short circuit and improve the reliability of the product.

[0028] This integrated inductor is suitable for high-temperature commercial products, including mobile devices, laptops, desktop computers, servers, computer graphics cards, portable game consoles, car navigation systems, and high-current power supplies. It can also be used in communication equipment, smart home appliances, automotive electronics, and compact power modules.

[0029] This utility model features a hot-pressed integrated inductor with low-loss alloy powder die casting, low impedance, no lead ends, small parasitic capacitance, unique integrated molding structure, solid and robust construction, precise product thickness, long-lasting rust prevention, small size, large current, and excellent temperature rise current and saturation current characteristics even in high-frequency and high-temperature environments, with a wide operating frequency coverage.

[0030] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. A flat coil thermoformed integral inductor, comprising a flat coil (1), characterized in that, The flat coil (1) includes a base magnet (2) and a winding body (3), and the bottom of the winding body (3) is provided with a bending part (4). The winding body (3) is located inside the bending part (4), and the outside of the flat coil (1) is provided with an inductor-coated insulator (5). The inductor is a flat coil (1) bent and implanted into an I CORE hot-pressing structure, which is then heated by a mold and pressed into an integrated inductor.

2. The flat coil hot-pressed integral inductor according to claim 1, characterized in that, The bending portions (4) are symmetrically distributed, and the bending portions (4) are directly formed on the surface of the base magnet (2) at the lead-out feet of the winding body (3).

3. The flat coil hot-pressed integral inductor according to claim 1, characterized in that, The bottom of the inductor-coated insulator (5) is formed with pins (6) that match the bend (4).

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