Inductor and circuit board assembly

Abstract

The application belongs to the technical field of electronic components, and discloses an inductor and a circuit board assembly. The inductor comprises a magnetic core, and a wire. The wire comprises a main body segment and two electrode segments. The main body segment is arranged in the magnetic core. The main body segment comprises two conductive sheets, an insulating layer and a conductive connecting part. The two conductive sheets are arranged in a spaced manner along the thickness direction of the conductive sheets. The conductive connecting part is connected to one end of the two conductive sheets along the width direction of the conductive sheets, and extends along the conductive sheets. The insulating layer is arranged between the two conductive sheets to separate the two conductive sheets. The two electrode segments are connected to the two ends of the main body segment along the extension direction of the main body segment, and the electrode segments are arranged outside the magnetic core. The embodiment of the application can solve the technical problem of poor heat dissipation effect of the flat copper wire in the integrally-formed inductor.

Description

Technical Field

[0001] This application belongs to the field of electronic component technology, specifically relating to an inductor and circuit board assembly. Background Technology

[0002] The structure of a molded inductor consists of a flat copper wire passing through a cuboid magnetic core. The flat copper wire contacts the magnetic core and can dissipate heat through the magnetic core. However, in existing molded inductors, the contact area between the flat copper wire and the magnetic core is small, resulting in poor heat dissipation. Utility Model Content

[0003] The purpose of this application is to provide an inductor and circuit board assembly to solve the technical problem of poor heat dissipation of flat copper wires in the existing integral molded inductor.

[0004] To achieve the above objectives, an embodiment of the first aspect of this application provides an inductor, comprising: a magnetic core; a conductor, the conductor including a main body segment and two electrode segments, the main body segment being disposed within the magnetic core, the main body segment including two conductive sheets, an insulating layer, and a conductive connection portion, the two conductive sheets being spaced apart along their own thickness direction, the conductive connection portion being connected to one end of the two conductive sheets along their own width direction, and the conductive connection portion extending along the conductive sheets; the insulating layer being disposed between the two conductive sheets to separate the two conductive sheets; the two electrode segments being respectively connected to both ends of the main body segment along their own extension direction, the electrode segments being disposed outside the magnetic core.

[0005] In some embodiments, the two conductive sheets have the same width.

[0006] In some embodiments, the magnetic core has a first surface located at one end of the magnetic core along a direction perpendicular to its own thickness, and the ends of the two electrode segments connected to the main body segment are both disposed on the first surface.

[0007] In some embodiments, each electrode segment includes two first electrode portions, which are connected to two conductive sheets in a one-to-one correspondence; each first electrode portion extends along the thickness direction of the conductive sheet in a direction away from the other first electrode portion.

[0008] In some embodiments, each electrode segment further includes two second electrode portions, which are connected one-to-one with two first electrode portions. The second electrode portions are connected to the end of the first electrode portion away from the conductive sheet. The two ends of the magnetic core along its thickness direction are two second surfaces, and the two second electrode portions are respectively disposed on the two second surfaces.

[0009] In some embodiments, the two conductive sheets, the conductive connection portion, and the two electrode segments are integrated into a conductor, and the wire is formed by folding the conductor and the insulating material coated on the surface of the conductor.

[0010] In some embodiments, the thickness of the conductive sheet is less than or equal to 0.15 mm.

[0011] In some embodiments, the thickness of the insulating layer is 20um-60um.

[0012] In some embodiments, the magnetic core includes a first magnet and a second magnet. The first magnet has a first groove and the second magnet has a second groove. The first groove and the second groove form an installation channel. The main body extends along the installation channel, and the channel wall of the installation channel abuts against the outer surface of the main body.

[0013] An embodiment of the second aspect of this application also provides a circuit board assembly, including a circuit board and an inductor of any one of the embodiments of the first aspect, wherein the inductor is mounted on the circuit board.

[0014] The beneficial effects of the inductor and circuit board assembly provided in this application are as follows: By providing a conductive connection portion in the main body section to electrically connect two conductive sheets, current can flow simultaneously through both conductive sheets and the conductive connection portion. Compared to providing a flat wire in the magnetic core, the two conductive sheets and the conductive connection portion in the main body section have a larger surface area within the magnetic core, resulting in a larger heat dissipation area. The insulating layer prevents the two conductive sheets from electrically connecting and conducts heat from the surfaces of the conductive sheets and the conductive connection portion to the magnetic core, improving the heat dissipation effect of the main body section and increasing the temperature rise current of the inductor. This application solves the technical problem of poor heat dissipation of flat copper wires in integrally molded inductors. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is a schematic diagram of the structure of an inductor provided in some embodiments of this application;

[0017] Figure 2 This application provides schematic diagrams illustrating the connection between the magnetic core and the wire in some embodiments.

[0018] Figure 3 This application provides structural schematic diagrams of the main body segments for some embodiments;

[0019] Figure 4 A schematic diagram of the exploded state structure of a magnetic core provided in some embodiments of this application;

[0020] Figure 5 Flowcharts illustrating the fabrication process of inductors provided in some embodiments of this application;

[0021] Figure 6 This is a schematic diagram of a structure for coating an insulating material onto a conductor, provided in some embodiments of this application;

[0022] Figure 7 Schematic diagrams of the wire structure provided in some embodiments of this application;

[0023] Figure 8 This is a schematic diagram of the structure of placing a wire into a first magnet according to some embodiments of this application;

[0024] Figure 9 This application provides schematic diagrams of the structure for attaching a second magnetic core onto a first magnet, based on some embodiments of the present application.

[0025] Figure 10 This is a schematic diagram of the structure of the cut electrode segment provided in some embodiments of this application;

[0026] Figure 11 A schematic diagram of the inductor in an upright state provided in some embodiments of this application;

[0027] Figure 12 Top view of a conventional copper-iron co-fired inductor provided for some embodiments of this application;

[0028] Figure 13 A front view of a conventional copper-iron co-fired inductor provided for some embodiments of this application.

[0029] The following are the labeling elements in the figure:

[0030] 100. Inductors;

[0031] 10. Magnetic core; 11. First magnet; 111. First groove; 12. Second magnet; 121. Second groove; 13. First surface; 14. Second surface;

[0032] 20. Wire; 21. Main body section; 211. Conductive sheet; 212. Conductive connection part; 213. Insulating layer; 22. Electrode section; 221. First electrode part; 222. Second electrode part; 201. Conductor; 2011. Crease; 2012. Folded part; 202. Insulating material;

[0033] 200. Copper-iron co-fired inductor; 210. Flat copper wire. Detailed Implementation

[0034] To make the technical problems, technical solutions, and beneficial effects to be solved by this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and are not intended to limit the scope of this application.

[0035] It should be noted that when a component is referred to as being "fixed to" or "set on" another component, it can be directly on or indirectly on that other component. When a component is referred to as being "connected to" another component, it can be directly connected to or indirectly connected to that other component.

[0036] It should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0037] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0038] An embodiment of the first aspect of this application provides an inductor for impeding changes in current in a circuit.

[0039] Please refer to Figures 1 to 3 The inductor 100 of this embodiment includes a magnetic core 10 and a conductor 20. The conductor 20 includes a main body segment 21 and two electrode segments 22. The main body segment 21 is disposed within the magnetic core 10 and includes two conductive sheets 211, an insulating layer 213, and a conductive connection portion 212. The two conductive sheets 211 are spaced apart along their thickness direction, and the conductive connection portion 212 is connected to one end of the two conductive sheets 211 along their width direction and extends along the conductive sheets 211. The insulating layer 213 is disposed between the two conductive sheets 211 to separate them. The two electrode segments 22 are respectively connected to both ends of the main body segment 21 along its extension direction and are disposed outside the magnetic core 10.

[0040] The magnetic core 10 is used to store or release magnetic field energy. The magnetic core 10 can be made of insulating material, or it can be insulated to prevent the magnetic core 10 from being electrically connected to the wire 20. Optionally, the magnetic core 10 can be made of materials such as iron-silicon-chromium, iron-silicon-aluminum, or manganese-zinc ferrite, which have high magnetic permeability.

[0041] When the conductor 20 transmits current, it can generate a magnetic field around the conductor 20. Since the main body section 21 is inside the magnetic core 10, the main body section 21 can generate a magnetic field inside the magnetic core 10.

[0042] The two conductive sheets 211 are spaced apart along their own thickness direction, meaning that the thickness directions of the two conductive sheets 211 are consistent. Figure 2 The Z-direction in the diagram indicates the thickness direction of the conductive sheet 211. The thickness of the conductive sheet 211 is less than its width. The two conductive sheets 211 extend in the same direction and have the same width. A conductive connection portion 212 connects to the same end of both conductive sheets 211 along their width direction, and is positioned between them. The conductive connection portion 212 extends along the conductive sheet 211, that is, it extends from one end of the conductive sheet 211 to the other along its extension direction. The length of the conductive connection portion 212 is equal to or nearly equal to the length of the two conductive sheets 211. Optionally, the conductive sheet 211 and the conductive connection portion 212 can be copper wire, which has lower resistance.

[0043] An insulating layer 213 separates the two conductive sheets 211, preventing them from being directly electrically connected. The insulating layer 213 is disposed between the two conductive sheets 211 and fills the gap between them. In the thickness direction of the conductive sheets 211, both ends of the insulating layer 213 contact the outer surfaces of the two conductive sheets 211, respectively. In the width direction of the conductive sheets 211, both ends of the insulating layer 213 contact the outer surface of the conductive connection portion 212 and the magnetic core 10, respectively. The insulating layer 213 can conduct heat from the conductive sheets 211 and the conductive connection portion 212 to the magnetic core 10. Optionally, the insulating layer 213 can be made of materials such as silicon dioxide or boron nitride, which have good thermal conductivity.

[0044] Electrode segment 22 is disposed outside the magnetic core 10 and can be electrically connected to an external circuit of the inductor 100. The extending direction of the main body segment 21 is also the extending direction of the conductive sheet 211, and electrode segment 22 can be connected to one or more of the two conductive sheets 211 and conductive connection portion 212 of the main body segment 21. Optionally, electrode segment 22 can be made of materials such as copper or copper-tin alloy.

[0045] In use, the two electrode segments 22 are connected to the circuit, and the current flows sequentially from one electrode segment 22 to the main body segment 21 and the other electrode segment 22. When the current flows through the main body segment 21, a magnetic field is generated in the magnetic core 10 surrounding the main body segment 21. When the current increases, the magnetic field in the magnetic core 10 increases and generates a reverse electromotive force that opposes the increase in current; when the current decreases, the magnetic field in the magnetic core 10 decreases and generates a positive electromotive force that opposes the decrease in current, thus reducing current fluctuations.

[0046] The beneficial effects of this application embodiment are as follows: By providing a conductive connection portion 212 in the main body segment 21 to electrically connect two conductive sheets 211, current can flow simultaneously through both conductive sheets 211 and the conductive connection portion 212. Compared to providing a flat wire in the magnetic core 10, the two conductive sheets 211 and the conductive connection portion 212 in the main body segment 21 have a larger surface area within the magnetic core 10, resulting in a larger heat dissipation area. The insulating layer 213 prevents the two conductive sheets 211 from being electrically connected and can conduct heat from the surfaces of the conductive sheets 211 and the conductive connection portion 212 to the magnetic core 10, thereby improving the heat dissipation effect of the main body segment 21 and increasing the temperature rise current of the inductor. This application embodiment can solve the technical problem of poor heat dissipation effect of flat copper wire in integrally molded inductors.

[0047] In some embodiments, please refer to Figure 3 The two conductive sheets 211 have equal widths. With the width of the main body segment 21 remaining constant, the equal widths of the two conductive sheets 211 mean that both conductive sheets 211 reach their maximum width, resulting in a larger surface area and better heat dissipation. Furthermore, the two conductive sheets 211 occupy the same space within the magnetic core 10 along their width direction, thus fully utilizing the space within the magnetic core 10.

[0048] In some embodiments, please refer to Figure 1 and Figure 2 The magnetic core 10 has a first surface 13, which is located at one end of the magnetic core 10 along the direction perpendicular to its own thickness Z. The ends of the two electrode segments 22 connected to the main body segment 21 are both located on the first surface 13.

[0049] The main body segment 21 is located inside the magnetic core 10, and the electrode segment 22 is located outside the magnetic core 10. Therefore, both ends of the main body segment 21 along its extension direction are located on the outer surface of the magnetic core 10, and the ends of the electrode segment 22 connected to the main body segment 21 are also located on the outer surface of the magnetic core 10. A first surface 13 is defined as being located at one end of the magnetic core 10 along a first direction. There are multiple directions perpendicular to the thickness direction Z of the magnetic core 10, and the first direction can be any direction perpendicular to the thickness direction Z of the magnetic core 10. For example, the magnetic core 10 is cuboid in shape, the thickness direction Z of the magnetic core 10 is the height direction, and the first direction can be the length direction of the magnetic core 10 or the width direction of the magnetic core 10.

[0050] The main body segment 21 extends from the first surface 13 into the magnetic core 10, then bends from the magnetic core 10 and extends back to the first surface 13. Optionally, the main body segment 21 has a "U" shaped structure.

[0051] The thickness of the magnetic core 10 is less than its length and width. The surface area of ​​the magnetic core 10 along its own thickness direction Z is the largest, while the surface area of ​​the magnetic core 10 along its own length or width direction is smaller. The first surface 13 is located at one end of the magnetic core 10 along the direction perpendicular to its own thickness Z, which means that the area of ​​the first surface 13 is smaller.

[0052] Please refer to Figure 12 and Figure 13 The existing co-fired copper-iron inductor 200 has two electrodes located on one surface of the magnetic core along its thickness direction. When connecting the two electrodes of the co-fired copper-iron inductor 200 to a circuit board, one surface of the magnetic core along the thickness direction Z is attached to the circuit board, resulting in a large area occupied by the co-fired copper-iron inductor 200 on the circuit board. Nowadays, servers have high power density, and a single Graphics Processing Unit (GPU) requires a very large number of inductors, to the point that inductors fill the entire perimeter of the GPU. Further increasing the number of inductors would cause a problem in their arrangement. To solve this problem, some researchers have developed co-fired copper-iron inductor arrays and integrated co-fired copper-iron inductors. These solutions combine several co-fired copper-iron inductors together, reducing the gap between each inductor and increasing the mounting density, thus saving some mounting area. However, planar integration only reduces the gap between inductors; the mounting area of ​​a single inductor is not reduced. After integration, the absence of gaps increases the difficulty of heat dissipation, leading to a decrease in current due to temperature rise.

[0053] In this embodiment of the application, when the two electrode segments 22 of the inductor 100 are connected to the circuit board, the first surface 13 is attached to the circuit board. The area occupied by the inductor 100 on the circuit board is the area of ​​the first surface 13. That is to say, the area occupied by the inductor 100 on the circuit board is small, the gap between the inductor 100 and adjacent components is large, more inductors can be installed around the graphics processor, and the exposed area of ​​the inductor 100 is larger, the inductor 100 dissipates heat faster, and the temperature rise current is higher.

[0054] In other embodiments, the two electrode segments 22 may also be connected to the main body segment 21 on two different outer surfaces of the magnetic core 10.

[0055] In other embodiments, the main body segment 21 may extend in a direction perpendicular to the thickness direction Z of the magnetic core 10.

[0056] In some embodiments, please refer to Figure 1 Each electrode segment 22 includes two first electrode portions 221, and the two first electrode portions 221 in the same electrode segment 22 are connected to two conductive sheets 211 in a one-to-one correspondence; any first electrode portion 221 extends along the thickness direction of the conductive sheet 211 in a direction away from the other first electrode portion 221.

[0057] In the same electrode segment 22, the first electrode portion 221 extends away from the other first electrode portion 221 along the thickness direction of the conductive sheet 211, that is, the two first electrode portions 221 extend from the conductive sheet 211 in opposite directions. The conductive sheet 211 and the electrode segment 22 are connected on the first surface 13, and the thickness direction of the conductive sheet 211 is substantially parallel to the first surface 13. The first electrode portion 221 extends along the thickness direction of the conductive sheet 211, that is, the first electrode portion 221 extends along the first surface 13.

[0058] The beneficial effects of the embodiments of this application are as follows: each electrode segment 22 includes two first electrode portions 221, so the inductor 100 can be connected to other devices at different positions through multiple first electrode portions 221; the two first electrode portions 221 extend in opposite directions on the first surface 13, and the first surface 13 is attached to other devices, so the contact area between the first electrode portions 221 and other devices is larger, and the inductor 100 is more stable when connected to other devices.

[0059] In some embodiments, please refer to Figure 1 Each electrode segment 22 also includes two second electrode portions 222, which are connected one-to-one with two first electrode portions 221. The second electrode portions 222 are connected to the end of the first electrode portion 221 away from the conductive sheet 211. The two ends of the magnetic core 10 along its thickness direction Z are two second surfaces 14, and the two second electrode portions 222 are respectively disposed on the two second surfaces 14.

[0060] The two second electrode portions 222 in the same electrode segment 22 are connected one-to-one with the two first electrode portions 221 in the same electrode segment 22.

[0061] The second electrode portion 222 is connected to the end of the first electrode portion 221 away from the conductive sheet 211. That is, the first electrode portion 221 extends from the conductive sheet 211 to the second electrode portion 222 along the thickness direction of the conductive sheet 211. Since the second electrode portion 222 is provided on the second surface 14 of the magnetic core 10 along its own thickness direction Z, the extension direction of the first electrode portion 221 is consistent with the thickness direction Z of the magnetic core 10. That is, the thickness direction Z of the magnetic core 10 is consistent with the thickness direction of the conductive sheet 211. The conductive sheet 211 occupies a small space in the thickness direction Z of the magnetic core 10, and the magnetic core 10 can be provided with a smaller thickness.

[0062] By providing two second connecting portions on the two second surfaces 14, the two ends of the inductor 100 along the thickness direction Z of the magnetic core 10 can be connected to other devices, making the connection between the inductor 100 and other devices more secure. Moreover, the second connecting portions increase the contact area between the electrode segment 22 and the magnetic core 10, making the connection between the electrode segment 22 and the magnetic core 10 more stable.

[0063] In some embodiments, please refer to Figure 1 as well as Figures 6 to 8 The conductor 201 is an integral unit comprising two conductive sheets 211, a conductive connection portion 212, and two electrode segments 22. The wire 20 is formed by folding the conductor 201 and an insulating material 202 coated on the surface of the conductor 201. Optionally, the conductor 201 has a sheet-like structure. Before folding the conductor 201, an insulating material 202 is coated on one side of the conductor 201 along its thickness direction. The thickness of the conductor 201 is less than the width and length of the conductor 201.

[0064] Folding the conductor 201 creates a crease 2011, dividing it into two folded portions 2012. The portion of the folded portion 2012 within the magnetic core 10 forms a conductive sheet 211, and the insulating material 202 between the two conductive sheets 211 forms an insulating layer 213. The portion of the crease 2011 within the magnetic core 10 forms a conductive connection portion 212, and the portions of the folded portion 2012 and the crease 2011 outside the magnetic core 10 constitute an electrode segment 22. Since the conductive sheet 211, the conductive connection portion 212, and the two electrode segments 22 are integrated into a single structure, the connection between the electrode segment 22 and the main body segment 21 is more robust. Furthermore, fabricating the two conductive sheets 211 by folding the conductor 201 is more efficient.

[0065] In some embodiments, please refer to Figure 3 The thickness B of the conductive sheet 211 is less than or equal to 0.15 mm. This means that when a flat conductor 201 is bent to form the conductive sheet 211, the thickness of the conductor 201 is less than or equal to 0.15 mm. The smaller the thickness of the conductor 201, the easier it is to bend. Optionally, the thickness B of the conductive sheet 211 can be 0.15 mm. Optionally, the thickness B of the conductive sheet 211 can also be 0.1 mm.

[0066] In some embodiments, the thickness A of the insulating layer 213 is 20um-60um.

[0067] When bending a flat conductor 201 to form a conductive sheet 211, an insulating material can be coated onto the conductor 201 first, and then the conductor 201 can be bent. After bending the conductor 201, the thickness of the insulating layer 213 is twice the thickness of the insulating material 202 before bending the conductor 201. If the thickness of the insulating layer 213 is too large, it will increase the difficulty of bending the conductor 201; if the thickness of the insulating layer 213 is too small, it will reduce the insulation effect. Setting the thickness A of the insulating layer 213 within the above range can ensure the insulation effect and facilitate bending the flat conductor 201 to form the conductive sheet 211.

[0068] Optionally, the thickness A of the insulating layer 213 can be 20µm, facilitating the bending of the conductor 201. Optionally, the thickness A of the insulating layer 213 can also be 60µm, providing better insulation. Optionally, the thickness A of the insulating layer 213 can also be 40µm.

[0069] In some embodiments, please refer to Figure 1 , Figure 2 and Figure 4 The magnetic core 10 includes a first magnet 11 and a second magnet 12. The first magnet 11 is provided with a first groove 111 and the second magnet 12 is provided with a second groove 121. The first groove 111 and the second groove 121 form an installation channel. The main body segment 21 extends along the installation channel, and the channel wall of the installation channel abuts against the outer surface of the main body segment 21.

[0070] The opening of the first groove 111 along its depth direction is directly opposite to the opening of the second groove 121 along its depth direction. The groove walls of the first groove 111 and the second groove 121 form the channel wall of the mounting channel. The main body segment 21 extends along the mounting channel, that is, the main body segment 21 extends along the first groove 111 and the second groove 121. The two openings of the first groove 111 along its extension direction are respectively located at the connection positions of the two electrode segments 22 and the main body segment 21. The two openings of the second groove 121 along its extension direction are respectively located at the connection positions of the two electrode segments 22 and the main body segment 21. The channel wall of the mounting channel is a closed loop, and the channel wall of the mounting channel abuts against multiple outer surfaces of the main body segment 21 within the magnetic core 10, which can locate the position of the main body segment 21 within the magnetic core 10.

[0071] Optionally, the first magnet 11 and the second magnet 12 are symmetrically arranged and can be manufactured using the same device. Optionally, when the main body segment 21 has a "U" shaped structure, both the first groove 111 and the second groove 121 are "U" shaped grooves.

[0072] The advantages of this embodiment are: the first magnet 11 and the second magnet 12 form a magnetic core 10, which facilitates the installation of the main body segment 21 into the magnetic core 10. The first groove 111 and the second groove 121 can locate the installation position of the main body segment 21, and can accurately install the main body segment 21 into the preset position in the magnetic core 10.

[0073] In some embodiments, please refer to Figures 1 to 3The inductor 100 includes a magnetic core 10 and a conductor 20. The conductor 20 includes a main body segment 21 and two electrode segments 22. The main body segment 21 is disposed within the magnetic core 10 and includes two conductive sheets 211, an insulating layer 213, and a conductive connection portion 212. The two conductive sheets 211 are spaced apart along their thickness direction. The conductive connection portion 212 is connected to one end of the two conductive sheets 211 along their width direction and extends along the conductive sheets 211. The insulating layer 213 is disposed between the two conductive sheets 211 to separate them. The two electrode segments 22 are respectively connected to both ends of the main body segment 21 along its extension direction and are disposed outside the magnetic core 10. The magnetic core 10 has a first surface 13 located at one end of the magnetic core 10 perpendicular to its thickness direction Z. Both electrode segments 22 are connected to the main body segment 21 on the first surface 13.

[0074] This application also provides a method for manufacturing an inductor, capable of manufacturing the inductor 100 in the first aspect embodiment. Please refer to [link / reference]. Figures 5 to 11 Inductor manufacturing methods include:

[0075] S1, please refer to Figure 6 First, an insulating material 202 is coated on one side of the conductor 201 along its thickness direction. Then, the insulating material 202 is dried, and the thickness of the dried insulating material 202 is controlled to be between 10µm and 30µm. Optionally, the conductor 201 can be a flat copper wire, etc. Optionally, the insulating material 202 can be silicone resin, etc.

[0076] S2, Fold conductor 201 along its central axis. The crease 2011 formed on conductor 201 divides conductor 201 into two strip-shaped folded portions 2012; please refer to... Figure 7 Two folds 2012 sandwich the insulating material 202 in the middle to form a conductor 20, and the crease 2011 extends along the length of the conductor 201.

[0077] S3, please refer to Figure 4 The first magnet 11 and the second magnet 12 are pressed using high-temperature resistant magnetic powder and resin, and a first groove 111 and a second groove 121 are left on the first magnet 11 and the second magnet 12. The depth of the first groove 111 and the second groove 121 is the same as the thickness of the conductor 201 before it is folded.

[0078] S4, please refer to Figure 8 and Figure 9The wire 20 is placed into the first groove 111, and then the second groove 121 is aligned with the wire 20. The second magnet 12 is placed on the first magnet 11. The first magnet 11 and the second magnet 12 form the magnetic core 10. The part of the wire 20 inside the magnetic core 10 is the main body segment 21, and the part of the wire 20 outside the magnetic core 10 is the electrode segment 22. When the first groove 111 and the second groove 121 are "U" shaped grooves, the wire 20 is bent into a "U" shaped structure.

[0079] S5, the magnetic core 10 and the wire 20 are placed into the mold cavity and held under pressure of 200MPa-600MPa and temperature of 180℃ for 70-100 seconds to fix the first magnet 11, the second magnet 12 and the main body segment 21.

[0080] S6. The pressed magnetic core 10 blank is placed in an atmosphere furnace and protected with hydrogen or nitrogen gas. It is held at 650℃-800℃ for 20-60 minutes, then allowed to cool naturally. This results in a more secure connection between the first magnet 11, the second magnet 12, and the main body segment 21. When the insulating material 202 is silicone resin, the silicone resin forms a silicon dioxide insulating layer after sintering, which has good thermal conductivity and insulation properties.

[0081] S7, please refer to Figure 10 Cut the electrode segment 22 along the crease 2011, and bend the cut electrode segment 22 against the two adjacent surfaces of the magnetic core 10 toward both sides of the main body segment 21. The portions of the electrode segment 22 on the two adjacent surfaces are the first electrode portion 221 and the second electrode portion 222, respectively. Then, grind away the insulating material 202 on the electrode segment 22.

[0082] S8, tin plating is performed on the electrode segment 22 exposed outside the magnetic core 10.

[0083] Please refer to Figure 11 When in use, the first electrode part 221 should face down so that the inductor 100 is mounted upright on the circuit board.

[0084] Existing molded inductors are formed by integrally pressing magnetic powder and metal electrodes within a mold cavity, with the metal electrodes embedded within the magnetic powder. These inductors typically use metal powder as the magnetic material and feature high saturation current and good shielding performance. Co-fired copper-iron inductors are a type of molded inductor. The most representative co-fired copper-iron inductor 200 has the following structure... Figure 12 and Figure 13As shown, its structure consists of a flat copper wire 210 passing through a cuboid magnetic core. To improve the operating current and temperature of ordinary molded inductors, this embodiment uses a high-temperature resistant metal magnetic powder and resin formulation. The inductor 100 is sintered at high temperature in a reducing atmosphere. Compared to ordinary molded inductors that rely on resin bonding, the metal magnetic powder in the inductor 100 of this embodiment is bonded together by inorganic grain boundaries, resulting in significantly stronger high-temperature resistance. It can operate for extended periods in environments approaching 200°C, which is superior to ordinary molded inductors.

[0085] In some embodiments, please refer to Table 1 to compare the inductor 100 of this application embodiment with the existing copper-iron co-fired inductor 200. Embodiments 1 to 3 show the parameters of the inductor 100 of this application embodiment, and Comparative Examples 1 to 3 show the parameters of the existing copper-iron co-fired inductor 200. The magnetic cores of both embodiments and comparative examples are made of the same magnetic powder material, iron-silicon-chromium, with a permeability of 29 H / m. The relevant parameters for manufacturing the inductor 100 of this application embodiment are as follows: In S1, the silicone resin coating thickness is 20 μm. In S5, the pressure is maintained at 400 MPa and 180°C for 80 seconds. In S6, hydrogen gas is introduced into an atmosphere furnace, and the temperature is maintained at 680°C for 40 minutes. In this application embodiment, both electrode segments 22 are located on a first surface 13 of the magnetic core 10. Please refer to... Figure 12 and Figure 13 In Comparative Examples 1 to 3, the copper-iron co-fired inductor 200 is formed by passing a flat copper wire 210 through a magnetic core, and both electrodes are on a surface of the magnetic core along its thickness direction Z.

[0086] Table 1. Parameters of inductors provided in some embodiments of this application and existing copper-iron co-fired inductors.

[0087]

[0088] In Example 1 and Comparative Example 1, the inductance of both inductors is 120 nH, and the cross-sectional area of ​​conductor 201 and flat copper wire 210 is 0.42 mm². 2 The magnetic core has dimensions of 9.0mm × 4.0mm × 2.8mm (length × width × thickness), and the inductor mounting area in Example 1 is 25.2mm². 2 The inductor in Comparative Example 1 has a mounting area of ​​36 mm². 2 In Example 1, the inductor 100 has a temperature rise current of 70A at 40°C, while in Comparative Example 1, the copper-iron co-fired inductor 200 has a temperature rise current of 50A at 40°C. The inductor mounting area refers to the area of ​​the same mounting surface where the two electrodes are located. The cross-sectional area of ​​conductor 201 is the overall cross-sectional area of ​​the two conductive sheets 211 and the conductive connection portion 212.

[0089] In Example 2 and Comparative Example 2, the inductance of both inductors is 200 nH, and the cross-sectional area of ​​conductor 201 and flat copper wire 210 is 0.56 mm². 2 The magnetic core has dimensions of 12.0mm × 5.5mm × 3.0mm (length × width × thickness), and the inductor mounting area in Example 2 is 36mm². 2 The inductor mounting area of ​​Comparative Example 2 is 66 mm². 2 In Example 2, the inductor 100 has a temperature rise current of 55A at 40°C, while in Comparative Example 2, the copper-iron co-fired inductor 200 has a temperature rise current of 40A at 40°C.

[0090] In Example 3 and Comparative Example 3, the inductance of both inductors is 270 nH, and the cross-sectional area of ​​conductor 201 and flat copper wire 210 is 0.3 mm². 2 The magnetic core has dimensions of 14.2mm × 5.0mm × 3.0mm (length × width × thickness), and the inductor mounting area in Example 3 is 42.6mm². 2 The inductor in Comparative Example 3 has a mounting area of ​​71 mm². 2 In Example 3, the inductor 100 has a temperature rise current of 40A at 40°C, while in Comparative Example 3, the copper-iron co-fired inductor 200 has a temperature rise current of 30A at 40°C.

[0091] As can be seen from the above embodiments and comparative examples, while keeping the inductance value of the inductor the same, the cross-sectional area of ​​the conductor 201 inside the magnetic core and the cross-sectional area of ​​the flat copper wire 210 the same, and the length × width × thickness of the magnetic core the same, compared with the existing copper-iron co-fired inductor 200, the inductor 100 of this application embodiment has a smaller mounting area and a larger temperature rise current.

[0092] The second aspect of this application also provides a circuit board assembly, which includes a circuit board and an inductor 100 of any one of the first aspect embodiments, wherein the inductor 100 is mounted on the circuit board.

[0093] The beneficial effects of the embodiments of this application are as follows: the circuit board assembly implemented in this application includes the inductor 100 of the first aspect embodiment, which can improve the heat dissipation effect of the flat wires in the integrally molded inductor and has all the effects of the inductor 100.

[0094] In some embodiments, the two electrode segments 22 of the inductor 100 are connected to a circuit board, the thickness direction Z of the inductor 100 is perpendicular to the thickness direction of the circuit board, and the inductor 100 stands upright on the circuit board. The inductor 100 occupies a small area on the circuit board, the gap between the inductor 100 and adjacent components is large, and the exposed area of ​​the inductor 100 is larger, resulting in faster heat dissipation and higher temperature rise current.

[0095] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. An inductor, characterized in that, include: magnetic core; A conductor, comprising a main body segment and two electrode segments, wherein the main body segment is disposed within the magnetic core, and the main body segment includes two conductive sheets, an insulating layer, and a conductive connection portion. The two conductive sheets are spaced apart along their thickness direction, and the conductive connection portion is connected to one end of the two conductive sheets along their width direction and extends along the conductive sheets. The insulating layer is disposed between the two conductive sheets to separate them. The two electrode segments are respectively connected to both ends of the main body segment along its extension direction and are disposed outside the magnetic core.

2. The inductor as described in claim 1, characterized in that, The two conductive sheets have the same width.

3. The inductor as described in claim 1, characterized in that, The magnetic core has a first surface located at one end of the magnetic core perpendicular to its own thickness direction, and the ends of the two electrode segments that connect to the main body segment are both located on the first surface.

4. The inductor as described in claim 3, characterized in that, Each of the electrode segments includes two first electrode portions, which are connected one-to-one with the two conductive sheets; each of the first electrode portions extends along the thickness direction of the conductive sheet in a direction away from the other first electrode portion.

5. The inductor as described in claim 4, characterized in that, Each of the electrode segments further includes two second electrode portions, which are connected one-to-one with the two first electrode portions. The second electrode portions are connected to the end of the first electrode portion away from the conductive sheet. The magnetic core has two second surfaces at its two ends along its thickness direction, and the two second electrode portions are respectively disposed on the two second surfaces.

6. The inductor as described in any one of claims 1-5, characterized in that, The two conductive sheets, the conductive connection portion, and the two electrode segments are integrated into a conductor, and the wire is formed by folding the conductor and the insulating material coated on the surface of the conductor.

7. The inductor as described in claim 6, characterized in that, The thickness of the conductive sheet is less than or equal to 0.15 mm.

8. The inductor as claimed in claim 6, characterized in that, The thickness of the insulating layer is 20um-60um.

9. The inductor as described in any one of claims 1-5, characterized in that, The magnetic core includes a first magnet and a second magnet. The first magnet has a first groove and the second magnet has a second groove. The first groove and the second groove form an installation channel. The main body extends along the installation channel, and the channel wall of the installation channel abuts against the outer surface of the main body.

10. A circuit board assembly, characterized in that, The device includes a circuit board and an inductor as described in any one of claims 1-9, wherein the inductor is mounted on the circuit board.

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