Laminated power inductance coil

Abstract

The utility model relates to the technical field of high-saturation power inductors, in particular to a laminated power inductance coil. A laminated power inductance coil comprises an identification layer, a conductive coil, a first external electrode, an insulating layer, a filling layer and a second external electrode, the identification layer is located on a second surface, the first external electrode is located on a first surface or extends from the first surface to a fifth surface, and the second external electrode is located on the first surface or extends from the first surface to a sixth surface. The length of the insulating layer is consistent with that of the external electrode on the first surface, the insulating layer is provided with at least one conductor hole which is connected with the upper and lower conductive coils, the lead-in electrode is connected with the first external electrode, and the lead-out electrode is connected with the second external electrode. According to the utility model, the iron-nickel material and the iron-silicon-chromium material are innovatively combined, so that the problem of poor insulativity of the nickel soft magnetic material is solved, and meanwhile, the situation of magnetic leakage is prevented.

Description

Technical Field

[0001] This utility model relates to the field of high saturation power inductor technology, and more specifically to a multilayer power inductor coil. Background Technology

[0002] In recent years, due to the rapid development of information technology, electronic components made of magnetic materials have been widely used in electronics, mechanics, communications, and new energy fields because of their functional characteristics such as information conversion, transmission, processing, and energy storage. At the same time, electronic components have presented new requirements and challenges for high precision, high sensitivity, miniaturization, large capacity, and fast transmission. Especially with the development of AI technology, the AI ​​functions integrated into wearable technology require compact and efficient power solutions. The demand for miniaturized power inductors is particularly urgent. While multilayer molding processes have significant advantages in miniaturization, currently miniaturized power inductors generally suffer from poor saturation current.

[0003] Due to their limited space, multilayer products present significant challenges in optimizing core design. While iron-nickel soft magnetic materials offer better magnetic saturation characteristics, their insulation is poor. To manufacture inductors, they require coating their surface with insulating resin. However, the presence of organic materials in the resin-coated iron-nickel material can lead to magnetic leakage.

[0004] Therefore, there is an urgent need to develop a miniaturized power inductor with high saturation current. Utility Model Content

[0005] To address the aforementioned problems, a miniaturized, high-saturation-current multilayer power inductor coil is provided. This invention employs the following technical solution.

[0006] A multilayer power inductor coil includes a marking layer, a conductive coil, a first external electrode, an insulating layer, a filling layer, and a second external electrode. The marking layer is located on a second surface. The first external electrode is located on a first surface or extends from the first surface to a fifth surface. The second external electrode is located on a first surface or extends from the first surface to a sixth surface, with its length consistent with that of the external electrode located on the first surface. The insulating layer has at least one conductive hole connecting the upper and lower conductive coil layers. It also includes an inlet electrode and an outlet electrode. The inlet electrode is connected to the first external electrode, and the outlet electrode is connected to the second external electrode.

[0007] Preferably, the thickness of the lower protective cover of the multilayer power inductor is greater than 75µm and less than 150µm, and the thickness of the upper protective cover is greater than or equal to 75µm.

[0008] Preferably, the final density of the multilayer power inductor is between 6.0 g / cm³ and 6.7 g / cm³.

[0009] Preferably, the dimensions of the multilayer power inductor are between 1.0mm*0.5mm*0.5mm and 2.0mm*1.6mm*1.0mm.

[0010] The advantages of this utility model are that the overall structure is highly integrated and has the advantage of miniaturization. It is equipped with lead-in electrodes and lead-out electrodes or adopts full-terminal electrodes, which improves the saturation current and can meet market demands. Attached Figure Description

[0011] Figure 1 This is a schematic diagram of a structure in Example 1;

[0012] Figure 2 This is a cross-sectional view of Example 1;

[0013] Figure 3 This is an exploded view of Example 1;

[0014] Figure 4 This is a schematic diagram of a structure in Example 2;

[0015] Figure 5 This is a cross-sectional view of Example 2;

[0016] Figure 6 This is an exploded view of Example 2. Detailed Implementation

[0017] Example 1.

[0018] A multilayer power inductor coil includes a marking layer m, a conductive coil n, an insulating layer f, a filling layer tc, and a first external electrode a1 and a second external electrode a2. The marking layer is located on a second surface 2, and the external electrodes a1 and a2 are located on a first surface 1. Each insulating layer has at least one conductive hole nk connecting the upper and lower conductive coils n, and an inlet electrode ia connected to the first external electrode, as well as an outlet electrode aoa and a second external electrode. The component also contains two soft magnetic alloy materials: iron-silicon-chromium and iron-nickel. The iron-silicon-chromium material is distributed on the upper and lower sides of the conductive coil, while the iron-nickel material is distributed on the same side of the conductive coil and on the conductive coil protective cover. The soft magnetic material FeSiCr contains 89%~94% iron, 3%~6% silicon, and 1.5%~6% chromium. The iron-nickel material contains 45%~55% iron and 45%~55% nickel. The particle size D50 of the iron-nickel material is between 2~7µm. The D50 of the iron-silicon-chromium material is between 1µm and 3µm. The thickness of the lower protective cover of the multilayer power inductor is greater than 75µm and less than 150µm, and the thickness of the upper protective cover is greater than or equal to 75µm. The final density of the multilayer power inductor is between 6.0g / cm³ and 6.7g / cm³. The dimensions of the multilayer power inductor are 1.0mm * 0.5mm * 0.5mm.

[0019] This embodiment also provides a fabrication process for a multilayer power inductor coil, including the following steps:

[0020] Step 1: Use conductive paste to prepare the first external electrode a1 and the second external electrode a2.

[0021] Step 2: Use soft magnetic material FeNi to make a lower protective cover fn1 with 50% iron and 50% nickel. Make connection holes ifn1 and ofn1 on the lower protective cover fn1 to connect to the external electrode. The thickness of the lower protective cover is greater than 75um and less than 150um.

[0022] Step 3: Fabricate the lead-in electrode ia1 and the lead-out electrode oa1 on the lower protective cover. Steps 2 and 3 can be repeated more than twice until the design is satisfied.

[0023] Step 4: Fabricate conductive coil n1 and lead-out electrode oa2 on the lower protective cover after the lead-in and lead-out electrodes have been fabricated;

[0024] Step 5: Fabricate a filling layer TC1 on the completed conductive coil n1 and lead electrode oa2 components. The filling layer TC1 is made of soft magnetic material FeNi, with an iron content of 55% and a nickel content of 45%. The FeNi filling layer TC1 has a particle size D50 of 5µm.

[0025] Step 6: Fabricate an insulating layer f1 on the completed TC1 component. The insulating layer is made of a soft magnetic material FeSiCr with an iron content of 92%, a silicon content of 3.5%, and a Cr content of 4.5%. The FeSiCr soft magnetic material has a particle size D50 of 2 μm. A via nk1 and a via of1 for connecting the lead-out electrodes are fabricated on the insulating layer f1.

[0026] Step 7: Fabricate conductive coil n2 and lead-out electrode oa3 on the component where the insulating layer f1 has been fabricated.

[0027] Step 8: Repeat steps 5 to 7 until the design is complete. Fabricate a filling layer TC2 on the completed conductive coil n2 and lead-out electrode OA3 components. Fabricate an insulating layer F2 on the completed TC2 components. Form a via NK2 and a via OF2 connecting the lead-out electrode on the insulating layer F2. Fabricate a conductive coil n3 and lead-out electrode OA4 on the completed insulating layer F2 components. Then, fabricate a filling layer TC3 on the completed conductive coil n3 and lead-out electrode OA4 components. Fabricate an insulating layer F3 on the completed TC3 components. Form a via NK3 and a via OF3 connecting the lead-out electrode on the insulating layer F3. Fabricate conductive wires on the completed insulating layer F3 components. The process involves fabricating coil n4 and lead-out electrode OA5, followed by fabricating a filling layer TC4 on the coil n4 and lead-out electrode OA5 components. An insulating layer F4 is then fabricated on the completed TC4 component, with vias NK4 and OF4 connecting the lead-out electrode formed on the insulating layer F4. A conductive coil n5 and lead-out electrode OA6 are then fabricated on the completed insulating layer F4 component. Finally, a filling layer TC5 is fabricated on the coil n5 and lead-out electrode OA6 component, followed by an insulating layer F5 on the completed TC5 component. A via NK5 and OF5 connecting the lead-out electrode are formed on the insulating layer F5. A conductive coil n6 is then fabricated on the completed insulating layer F5 component, and the filling layer TC6 is fabricated.

[0028] Step 9: Use soft magnetic material FeNi to make the upper protective cover fn2. The soft magnetic material has an iron content of 45%~55% and a nickel content of 45%~55%. The FeNi particle size D50 is between 2~7um. The thickness of the upper protective cover is greater than 75um.

[0029] Step 10: Create an identifier m1 on the ni2 component of the completed upper protective cover. The color of the identifier m1 should have a large contrast with the ni2 component of the upper protective cover, preferably white.

[0030] Step 11: Press the completed m1 component in a pressure vessel with a pressure of 550 MPa or higher and a temperature of 70°C or higher to obtain a density of 6 g / cm³.3 Multilayer power inductor coils.

[0031] Step 11: Anneal the pressed multilayer power inductor coil under a nitrogen or hydrogen atmosphere, preferably at a temperature of 750°C for 2 hours.

[0032] Step 12: The annealed multilayer power inductor coil is electroplated with nickel and tin layers to finally form a multilayer power inductor coil with welding characteristics.

[0033] Example 2.

[0034] A multilayer power inductor coil includes a marking layer, a conductive coil, an insulating layer, a filling layer, and a first external electrode a1 and a second external electrode a2. The first external electrode is located on a first surface and extends from the first surface 1 to a second surface 2, a third surface 3, a fourth surface 4, and a fifth surface 5. The second external electrode is located on the first surface and extends from the first surface to a second surface 2, a third surface 3, a fourth surface 4, and a sixth surface 6. The insulating layer has at least one conductive hole connecting the upper and lower conductive coil layers. The filling layer is located on the same plane as the conductive coil, and in this embodiment, no lead-out electrodes or lead-in electrodes are provided.

[0035] The rest is the same as in Example 1.

[0036] Example 3.

[0037] The dimensions of the multilayer power inductor coil are 1.6mm*0.8mm*0.8mm.

[0038] The rest is the same as in Example 1.

[0039] Example 4.

[0040] The dimensions of the multilayer power inductor coil are 1.6mm*0.8mm*0.8mm.

[0041] The rest is the same as in Example 2.

[0042] Example 5.

[0043] The dimensions of the multilayer power inductor are 1.4mm*1.2mm*0.8mm.

[0044] The rest is the same as in Example 1.

[0045] Example 6.

[0046] The dimensions of the multilayer power inductor are 1.4mm*1.2mm*0.8mm.

[0047] The rest is the same as in Example 2.

[0048] The comparative case is a full-end electrode made solely of iron-nickel soft magnetic alloy material.

[0049] The test results are as follows:

[0050]

Claims

1. A laminated power inductor coil, characterized by: The device includes an identification layer, a conductive coil, a first external electrode, an insulating layer, a filling layer, and a second external electrode. The identification layer is located on a second surface, and the external electrode is located on a first surface. The first external electrode is located on the first surface or extends from the first surface to a fifth surface, and the second external electrode is located on the first surface or extends from the first surface to a sixth surface, with its length consistent with that of the external electrode located on the first surface. The insulating layer has at least one conductive hole connecting the upper and lower conductive coils. The device also includes an inlet electrode and an outlet electrode. The inlet electrode is connected to the first external electrode, and the outlet electrode is connected to the second external electrode.

2. A laminated power inductor coil according to claim 1, wherein: The thickness of the lower protective cover of the multilayer power inductor coil is greater than 75µm and less than 150µm, and the thickness of the upper protective cover is greater than or equal to 75µm.

3. A laminated power inductor coil according to claim 2, wherein: The final density of the stacked power inductor coil is between 6.0 g / cm 3 6.7 g / cm 3 .

4. A laminated power inductor coil according to claim 3, wherein: The dimensions of the multilayer power inductor coil are between 1.0mm*0.5mm*0.5mm and 2.0mm*1.6mm*1.0mm.

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