Integrated inductor formed by pre-pressing

Abstract

The utility model discloses an integrated inductor formed by pre-pressing, which comprises a shell, a coil, a cover plate and an internal magnetic core, the internal magnetic core is fixedly arranged on the cover plate, the coil is sleeved on the internal magnetic core, the cover plate is covered on the shell, the coil and the internal magnetic core are arranged in the shell, the coil is provided with a first pin and a second pin, and the first pin and the second pin are arranged on the shell. And the first pin and the second pin are arranged at the bottom of the cover plate. Compared with an existing powder filling forming process, the integrally-formed inductor has the advantages that the density distribution of an integrally-formed inductor product of an existing direct magnetic core powder filling process is not uniform, cracks exist in the inductor finished product, and the structural strength and the electrical property of the product are affected. The consistency of the forming density of the integrally-formed inductor can be effectively improved, the cracks in a magnet are reduced, and the production efficiency is improved. And the electrical consistency of the inductor is improved. The preforming process is simple in implementation method and low in cost, and can be widely applied to manufacturing of the integrally-formed inductor.

Description

Technical Field

[0001] This utility model discloses an inductor, particularly a pre-formed integral inductor, belonging to the field of electronic component technology. Background Technology

[0002] An integrated inductor is a component that combines the coil, core, and insulation of an inductor into a single, integrated unit. This design allows for higher integration on circuit boards, saves space, and improves the inductor's performance and stability. Integrated inductors are widely used in modern electronic devices, particularly in mobile devices, communication equipment, power management, and radio frequency circuits, due to their advantages such as miniaturization, high efficiency, stable inductance, and good electromagnetic compatibility.

[0003] The existing integrated inductor molding process usually adopts a direct powder filling molding and pressing process. The disadvantage of this process is that the magnetic powder and the coil are molded at the same time. Due to the huge difference in density between the magnetic powder material and the coil material before molding, the internal stress of molding is large. In particular, the density of the coil column part is low, which can easily lead to internal cracks, thereby affecting the electrical properties of the finished inductor. Summary of the Invention

[0004] To address the drawback of high internal stress in existing integrated inductors that utilize direct powder filling and molding processes, this invention provides a pre-molded integrated inductor. This inductor is assembled using a pre-molded magnetic core and coil, effectively increasing the density of the inductor during secondary molding. Furthermore, the shape and size of the magnetic core can be adjusted through structural design to improve the molding density in areas with lower density, ensuring consistent density in the finished inductor, balancing internal stress, reducing internal cracks, and improving the electrical performance stability of the inductor.

[0005] The technical solution adopted by this utility model to solve its technical problem is: a pre-pressed integral inductor, the inductor includes a shell, a coil, a cover plate and an internal magnetic core, the internal magnetic core is fixedly mounted on the cover plate, the coil is sleeved on the internal magnetic core, the cover plate is mounted on the shell, the coil and the internal magnetic core are set inside the shell, the coil is provided with a first pin and a second pin, and the first pin and the second pin are set at the bottom of the cover plate.

[0006] The technical solution adopted by this utility model to solve its technical problem further includes:

[0007] The outer shell is formed by pre-pressing with magnetic powder.

[0008] The outer shell is a hollow cuboid shape with an opening on one side.

[0009] The internal magnetic core and cover plate are integrated as a single unit.

[0010] The diameter of the internal magnetic core matches the internal diameter of the coil; the length of the internal magnetic core is sufficient to partially or completely cover the coil.

[0011] The coil includes a coil body, a first pin, a second pin, a first connecting part, a second connecting part, a first bent part, and a second bent part. The first pin and the second pin are arranged in parallel. The first pin is connected to one end of the coil body through the first connecting part, and the second pin is connected to one end of the coil body through the second connecting part. One end of the first pin is connected to the first connecting part, and the other end of the first pin is bent to form the first bent part. One end of the second pin is connected to the second connecting part, and the other end of the second pin is bent to form the second bent part.

[0012] The coil body, first pin, second pin, first connecting part, second connecting part, first bending part and second bending part are integrally formed.

[0013] The bottom of the cover plate is provided with a first groove corresponding to the position of the first pin, and the first pin is disposed in the first groove. The bottom of the cover plate is provided with a second groove corresponding to the position of the second pin, and the second pin is disposed in the second groove.

[0014] The cover plate has a protrusion on its side at a position corresponding to the location between the first connecting part and the second connecting part.

[0015] The beneficial effects of this invention are as follows: Compared with existing powder-filling molding processes, the density distribution of integrally molded inductor products produced by existing direct magnetic core powder-filling processes is uneven, leading to internal cracks in the finished inductor and affecting the product's structural strength and electrical properties. This invention can effectively improve the consistency of the molding density of integrally molded inductors, reduce internal cracks in the magnet, and improve the consistency of inductor electrical properties. This pre-forming process is simple to implement, low in cost, and can be widely used in the manufacture of integrally molded inductors.

[0016] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. Attached Figure Description

[0017] Figure 1 This is a three-dimensional structural diagram of the present invention.

[0018] Figure 2 This is a schematic diagram of the exploded state structure of this utility model.

[0019] Figure 3 This is a three-dimensional structural schematic diagram of the present invention from another perspective.

[0020] Figure 4 This is a schematic diagram of the exploded state structure from another perspective of this utility model.

[0021] Figure 5This is a cross-sectional structural diagram of the present invention.

[0022] In the figure, 1-outer shell, 2-coil, 21-coil body, 22-first pin, 23-second pin, 24-first connecting part, 25-second connecting part, 26-first bending part, 27-second bending part, 3-cover plate, 31-protrusion, 32-first groove, 33-second groove, 4-internal magnetic core. Detailed Implementation

[0023] This embodiment is a preferred embodiment of the present invention. All other embodiments that are the same as or similar to this embodiment in principle and basic structure are within the protection scope of the present invention.

[0024] Please refer to the appendix for details. Figure 1 To be continued Figure 5 The present invention mainly includes a shell 1, a coil 2, a cover plate 3 and an internal magnetic core 4. The internal magnetic core 4 is fixedly mounted on the cover plate 3, the coil 2 is fitted on the internal magnetic core 4, the cover plate 3 is mounted on the shell 1, the coil 2 and the internal magnetic core 4 are arranged inside the shell 1, the coil 2 is provided with a first pin 22 and a second pin 23, and the first pin 22 and the second pin 23 are arranged at the bottom of the cover plate 3.

[0025] In this embodiment, the outer shell 1 is pre-pressed with magnetic powder and can be defined as the outer magnetic core or the first magnetic core. The specific shape is set according to actual needs, preferably a hollow cuboid shape with an opening on one side, which can be used to install the coil 2 and the inner magnetic core 4.

[0026] In this embodiment, the internal magnetic core 4 and the cover plate 3 can be pre-pressed using magnetic powder. Preferably, the internal magnetic core 4 and the cover plate 3 are integrally formed, meaning they are pressed together during the pre-pressing process and are thus defined as the internal magnetic core 4 and the cover plate 3. However, in practice, the internal magnetic core 4 and the cover plate 3 can also be separate components, pressed together as a whole during assembly, or bonded together with glue or similar adhesives. The internal magnetic core 4 and the cover plate 3 can be collectively referred to as the second magnetic core. In this embodiment, the diameter of the internal magnetic core 4 is set according to the internal diameter of the coil 2, allowing the coil 2 to be fitted onto the internal magnetic core 4. The length of the internal magnetic core 4 is specifically set according to the length of the coil 2, allowing it to partially or completely cover the coil 2.

[0027] In this embodiment, the first magnetic core and the second magnetic core can be made of granulated powder of ferrite or metal materials or a mixture of both. When pressing and molding, an unheated mold or a heated mold can be used.

[0028] In this embodiment, the coil 2 can be wound according to a set shape and then mounted on the internal magnetic core 4, or it can be directly wound on the second magnetic core to form the coil 2. The coil 2 mainly includes a coil body 21, a first pin 22, a second pin 23, a first connecting part 24, a second connecting part 25, a first bending part 26, and a second bending part 27. The first pin 22 and the second pin 23 are arranged in parallel. The first pin 22 is connected to one end of the coil body 21 through the first connecting part 24, and the second pin 23 is connected to one end of the coil body 21 through the second connecting part 25. One end of the first pin 22 is connected to the first connecting part 24, and the other end of the first pin 22 is bent to form the first bending part 26. One end of the second pin 23 is connected to the second connecting part 25, and the other end of the second pin 23 is bent to form the second bending part 27, which makes assembly easier. The coil body 21, the first pin 22, the second pin 23, the first connecting part 24, the second connecting part 25, the first bending part 26, and the second bending part 27 are all formed by winding the same copper wire. The above parts are defined by human intervention.

[0029] In this embodiment, a first groove 32 is provided at the bottom of the cover plate 3 corresponding to the position of the first pin 22, and the first pin 22 is disposed in the first groove 32. A second groove 33 is provided at the bottom of the cover plate 3 corresponding to the position of the second pin 23, and the second pin 23 is disposed in the second groove 33. A protrusion 31 is provided on the side of the cover plate 3 at the position between the first connecting part 24 and the second connecting part 25. The arrangement of the first groove 32, the second groove 33, and the protrusion 31 can, on the one hand, make the electrical performance of this utility model more stable, and on the other hand, make the magnetic protrusion of the coil 2 less obvious, which is beneficial to assembly.

[0030] In the assembly process of this utility model, coil 2 and the second magnetic core are assembled to form a semi-finished product to be pressed and molded for a second time. The semi-finished product can be inserted into the molding mold for a second molding. The semi-finished product to be pressed and molded for a second time formed by the coil assembly can be inserted into an unheated mold and a heated mold.

[0031] Compared with existing powder-filling molding processes, the density distribution of integrally molded inductors produced by existing direct magnetic core powder-filling processes is uneven, leading to internal cracks in the finished inductor and affecting the product's structural strength and electrical properties. This invention can effectively improve the consistency of the molding density of integrally molded inductors, reduce internal cracks in the magnet, and improve the consistency of inductor electrical properties. This pre-forming process is simple to implement, low in cost, and can be widely used in the manufacture of integrally molded inductors.

[0032] The above description, in conjunction with specific embodiments, provides a further detailed explanation of the utility model and should not be construed as limiting the specific implementation of the utility model to the foregoing description. For those skilled in the art, several equivalent substitutions or obvious modifications can be made without departing from the concept of the utility model, and all such modifications, with the same purpose, should be considered to fall within the protection scope of the utility model.

Claims

1. A pre-formed integral inductor, characterized in that: The inductor includes a housing (1), a coil (2), a cover plate (3), and an internal magnetic core (4). The internal magnetic core (4) is fixedly mounted on the cover plate (3), the coil (2) is fitted onto the internal magnetic core (4), the cover plate (3) is mounted on the housing (1), the coil (2) and the internal magnetic core (4) are located inside the housing (1), and the coil (2) is provided with a first pin (22) and a second pin (23). The first pin (22) and the second pin (23) are located at the bottom of the cover plate (3). The coil (2) includes a coil body (21), a first pin (22), a second pin (23), a first connecting part (24), a second connecting part (25), a first bending part (26), and a second bending part (27). The first pin (22) and the second pin (23) are arranged in parallel. The first pin (22) is connected to one end of the coil body (21) through the first connecting part (24), and the second pin (23) is connected to one end of the coil body (21) through the second connecting part (25). First, one end of the first pin (22) is connected to the first connecting part (24), and the other end of the first pin (22) is bent to form the first bent part (26). One end of the second pin (23) is connected to the second connecting part (25), and the other end of the second pin (23) is bent to form the second bent part (27). The coil body (21), the first pin (22), the second pin (23), the first connecting part (24), the second connecting part (25), the first bent part (26), and the second bent part (27) are integrally formed. The internal magnetic core (4) and the cover plate (3) are integrally formed; the bottom of the cover plate (3) is provided with a first groove (32) corresponding to the position of the first pin (22), and the first pin (22) is located in the first groove (32); the bottom of the cover plate (3) is provided with a second groove (33) corresponding to the position of the second pin (23), and the second pin (23) is located in the second groove (33); the side of the cover plate (3) is provided with a protrusion (31) corresponding to the position between the first connecting part (24) and the second connecting part (25); the outer shell (1) is formed by pre-pressing magnetic powder; the outer shell (1) is a hollow cuboid shape with an opening on one side.

2. The pre-formed integral inductor according to claim 1, characterized in that: The diameter of the inner magnetic core (4) matches the inner diameter of the coil (2); the length of the inner magnetic core (4) is sufficient to partially or completely cover the coil (2).

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