Inductor

Abstract

The utility model provides an inductor. The inductor comprises a sintered magnet, a copper coil sleeved on the surface of the sintered magnet, a first bonding layer between the sintered magnet and the copper coil, and a shielding layer coated on the surface of the copper coil, the distance between the side surface of the sintered magnet and the inner side wall of the copper coil is 0.1-0.2 mm; the length of the sintered magnet is smaller than that of the copper coil, and the distance between the end faces of the two ends of the sintered magnet and the end face, close to the end faces, of the copper coil ranges from 0.1 mm to 0.2 mm. The distance between every two adjacent coils on the copper coil ranges from 0.01 mm to 5 mm. The copper coil is obtained through laser etching of a copper pipe, and electrode areas are arranged at the two ends of the copper pipe. Compared with an existing integrated inductor, under the condition of the same inductance value, the inductor has the advantages that the number of turns is smaller, the temperature rise rated current is higher, the direct-current resistance is lower, and therefore the inductor has higher rated power.

Description

Technical Field

[0001] This utility model relates to the field of inductor technology, and more specifically, to an inductor. Background Technology

[0002] Currently, the mainstream integrated molded inductors fall into two categories. One type uses a block material made by thoroughly mixing and kneading atomized alloy powder, carbonyl iron powder, or amorphous powder with thermosetting or thermoplastic epoxy resin, then granulating, pressing, and baking to cure. This block material serves as the magnetic material, with round or flat copper wire as the electrode. The magnetic permeability of this type of inductor is not high, ranging from 30 to 50, and the pressing process requires very high pressure, reaching several hundred MPa. This causes the magnetic powder and electrodes to rub against each other under high pressure, damaging their respective insulation layers and leading to short circuits. The other type is the copper-iron co-fired inductor. The copper electrode is integrally pressed with atomized alloy powder, carbonyl iron powder, or amorphous powder and then sintered together under a protective atmosphere. The magnetic material of this type of inductor is a sintered magnet with a higher permeability, ranging from 60 to 80. However, because the problem of high-temperature resistant insulation layer on the surface of the copper wire has not yet been solved, multi-turn designs cannot be adopted, limiting the development of high-inductance models. Utility Model Content

[0003] This invention provides an inductor that is formed by etching a copper tube onto the surface of a sintered iron core to create a coil. This inductor structure can achieve an inductance of 1.2 to 2 times that of inductors of the same volume obtained by existing technology.

[0004] To achieve the above objectives, the technical solution of this utility model is as follows:

[0005] An inductor includes a sintered magnet, a copper coil sleeved on the surface of the sintered magnet, a first adhesive layer between the sintered magnet and the copper coil, and a shielding layer covering the surface of the copper coil; the distance between the side of the sintered magnet and the inner wall of the copper coil is 0.1-0.2 mm; the length of the sintered magnet is less than the length of the copper coil, and the distance between the end faces of the two ends of the sintered magnet and the end faces of the copper coils near those end faces is 0.1-0.2 mm; the distance between any two adjacent coils on the copper coil is 0.01-5 mm; the copper coil is obtained by laser etching of a copper tube, and electrode areas are provided at both ends of the copper tube.

[0006] In some embodiments, a second adhesive layer is provided between the copper coil and the shielding layer; the first and second adhesive layers are respectively obtained by coating silicone resin on the inner and outer surfaces of the copper tube and curing it at room temperature.

[0007] In some embodiments, the thickness of the copper tube is 0.03-0.2 mm.

[0008] In some implementations, each coil has the same width along the inductor axis, which is 0.5-5 mm.

[0009] In some embodiments, a nickel layer is also provided on the electrode region.

[0010] In some embodiments, the nickel layer has a thickness of 30-40 μm.

[0011] In some embodiments, a tin layer is also provided on the surface of the nickel layer.

[0012] In some embodiments, the tin layer thickness is 35-40 μm.

[0013] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0014] The inductor of this invention comprises, from the inside out, a sintered iron core, a first bonding layer, a copper coil, and a shielding layer. The copper coil is obtained by laser etching of a copper tube. The electrode area is located at both ends of the copper tube. Compared with existing integrated inductors, the inductance of this structure can reach 1.2-2 times that of existing inductors of the same volume. With the same inductance value, it has fewer turns, higher rated current with temperature rise, and lower DC resistance, thus having a larger rated power. In addition, this inductor does not require pressing during the manufacturing process, which can effectively reduce the risk of inductor short circuit. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of the copper tube after laser etching in an embodiment of this utility model;

[0016] Figure 2 This is a schematic diagram of the structure of the copper tube and sintered iron core after laser etching in an embodiment of this utility model;

[0017] Figure 3 This is a partial cross-sectional view of the inductor in an embodiment of this utility model;

[0018] Figure 4 for Figure 3 AA view in the middle;

[0019] Among them, 1-sintered magnet, 2-copper coil, 21-first coil, 22-second coil, 3-first bonding layer, 4-shielding layer, 5-electrode area, 51-nickel layer, 52-tin layer, 6-second bonding layer. Detailed Implementation

[0020] Many specific details are set forth in the following description to provide a full understanding of the present invention. However, the present invention can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0021] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. Example 1

[0022] like Figures 1-4 As shown, an inductor comprises, from the inside out, a sintered magnet 1, a first bonding layer 3, a copper coil 2, and a shielding layer 4. The distance between the side of the sintered magnet 1 and the inner wall of the copper coil 2 is 0.1-0.2 mm. The length of the sintered magnet 1 is less than the length of the copper coil 2. The distance between the end faces of the two ends of the sintered magnet 1 and the end faces of the copper coil 2 near those end faces is 0.1-0.2 mm. The distance between any two adjacent coils on the copper coil is 0.01-5 mm (e.g., the distance between the first coil 21 and the second coil 22 is between 0.01-5 mm). The copper coil 2 is obtained by laser etching of a copper tube, and electrode areas 5 are respectively provided at both ends of the copper tube.

[0023] In this invention, the copper coil 2 is obtained by laser etching of a copper tube. Each coil has the same width along the inductance axis, ranging from 0.5 to 5 mm. The copper coil 2 is fixedly connected to the sintered magnet 1 and the copper tube through a first adhesive layer 3, and then a shielding layer 5 is wrapped around its surface. Compared with the inductors of the prior art, the inductance of the inductor of the same volume can reach 1.2 to 2 times that of the prior art inductors. With the same inductance value, fewer turns are required, the rated current with temperature rise is higher, and the DC resistance is lower, thus achieving a higher rated power. In addition, this structure of the inductor does not require pressing during the manufacturing process, reducing the risk of inductor short circuits.

[0024] Furthermore, a second adhesive layer 6 is provided between the copper coil 2 and the shielding layer 4 to further improve the structural stability of the inductor.

[0025] Specifically, in this embodiment, the first adhesive layer 3 and the second adhesive layer 6 are obtained by curing silicone rubber at room temperature.

[0026] Furthermore, the thickness of the copper tube is 0.03-0.2mm.

[0027] Furthermore, a nickel layer 51 with a thickness of 30-40 μm is provided on the electrode region 5; a tin layer 52 with a thickness of 35-40 μm is also provided on the surface of the nickel layer 51.

[0028] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0029] The embodiments described above are merely illustrative of several implementations of this utility model, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these all fall within the protection scope of this utility model. Therefore, the protection scope of this utility model patent should be determined by the appended claims.

Claims

1. An inductor, characterized by The sintered magnet, the copper coil, the first adhesive layer and the shielding layer; the distance between the side of the sintered magnet and the inner side wall of the copper coil is 0.1-0.2mm; the length of the sintered magnet is less than the length of the copper coil, the distance between the end face of the sintered magnet and the end face of the copper coil near the end face is 0.1-0.2mm; the distance between every two adjacent copper coils is 0.01-5mm; the copper coil is obtained by laser etching of a copper tube, and the copper tube is provided with electrode areas at both ends.

2. The inductor of claim 1, wherein, The second adhesive layer is further arranged between the copper coil and the shielding layer.

3. The inductor of claim 1, wherein, The thickness of the copper tube is 0.03-0.2mm.

4. The inductor of claim 1, wherein, The width of each coil in the inductance axial direction is the same, and is 0.5-5mm.

5. The inductor of claim 1, wherein, The nickel layer is further arranged on the electrode area.

6. The inductor of claim 5, wherein, The thickness of the nickel layer is 0.1-10μm.

7. The inductor of claim 6, wherein, The tin layer is further arranged on the surface of the nickel layer.

8. The inductor of claim 7, wherein, The thickness of the tin layer is 0.1-10μm.

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