Method for manufacturing magnetic device, and magnetic device

Abstract

To improve magnetic properties of a magnetic device (e.g., inductor).SOLUTION: Provided are a magnetic device and a method for manufacturing the device. The magnetic device manufactured by the method includes an integrally formed main body. The method includes a preparing step, a coil assembly step, an arranging step, and a forming step. The preparing step is executed by producing a bottom sheet and a lid. The coil assembly step is executed by fixing a coil to the bottom seat in order to form a first semi-finished product. The arranging step is executed by arranging the first semi-finished product into a metal mold, and arranging the lid onto the first semi-finished product in order to form a second semi-finished product. The forming step is executed by applying pressure to the second semi-finished product such that the bottom seat and the lid are melted and connected to each other to form the main body. The coil is surrounded by the main body correspondingly.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to methods of making magnetic devices and magnetic devices, and more particularly to methods of making magnetic devices and magnetic devices applicable as inductors. [Background technology]

[0002] Generally, in the conventional inductor manufacturing method, the coil is placed in a mold, then the magnetic powder is filled into the mold, and finally the magnetic powder is molded into a magnetic body by heating and pressing. The magnetic body manufactured in this way easily has the problem that the density of some areas is obviously higher or lower than that of other areas, which may directly affect the magnetic properties of the inductor. Summary of the Invention [Problem to be solved by the invention]

[0003] The present invention provides a method for manufacturing a magnetic device and a magnetic device that are primarily configured to address the above-mentioned technical deficiencies and improve the poor magnetic properties of existing magnetic devices (e.g., inductors) caused by excessive density differences in different regions of the magnetic body of an inductor manufactured by a conventional method. [Means for solving the problem]

[0004] In order to solve the above problems, one of the technical aspects adopted by the present invention is to provide a method for manufacturing a magnetic device. The magnetic device includes an integrally formed main body. The manufacturing method for the magnetic device includes a preparation step, a coil assembly step, a placement step, and a molding step. The preparation step is carried out to manufacture a bottom sheet and a lid body using at least one magnetic mixture. One side of the lid body is recessed to form a groove, and the lid body includes a column body disposed in the groove. The coil assembly step is carried out to fix the coil to the bottom sheet to form a first semi-finished product. The coil includes a winding part, a first end, and a second end, one end of the first end is connected to an upper part of the winding part, and one end of the second end is connected to a lower part of the winding part. The outer diameter of the winding part is smaller than the width of the bottom sheet, the outer diameter of the winding part is smaller than the length of the bottom sheet, the outer diameter of the winding part is smaller than the inner diameter of the groove, the inner diameter of the central hole of the winding part is larger than the outer diameter of the column body, and the depth of the groove is equal to or greater than the height of the winding part. In the placing step, the first semi-finished product is placed in a mold, and the lid body is placed on the first semi-finished product to form a second semi-finished product. A part of the end surface of the lid body of the second semi-finished product in which the groove is formed is abutted corresponding to a part adjacent to the upper part of the winding part at the first end. The lid body is supported by a partial section of the first end, the column body is placed corresponding to the upper part of the central hole of the winding part, and the winding part is placed corresponding to the lower part of the groove. In the molding step, the second semi-finished product is pressed to melt and connect the lid body and the bottom sheet included in the second semi-finished product to each other to form a main body part. The winding part is placed correspondingly in the main body part, and a part of the end of the first end and a part of the end of the second end are exposed from the main body part.

[0005] In order to solve the above-mentioned problems, another technical aspect adopted by the present invention is to provide a method for manufacturing a magnetic device. The magnetic device includes a main body portion configured as a monolithic structure. The method for manufacturing the magnetic device includes a preparation step, a coil assembly step, an arrangement step, and a molding step. The preparation step is performed to generate a bottom sheet and a lid body using at least one magnetic mixture. One side of the lid body is formed with a recessed groove and an avoidance groove, and the avoidance groove and the recessed groove are communicated with each other. The lid body includes a column body arranged in the recessed groove. The coil assembly step is performed to fix the coil to the bottom sheet to form a first semi-finished product. The coil includes a winding portion, a first end, and a second end, one end of the first end being connected to an upper portion of the winding portion, the other end of the first end being bent from the first side to the second side of the bottom sheet, and a portion of the other end of the first end being flush with the bottom surface of the bottom sheet. One end of the second end is connected to the lower part of the winding part, and the other end of the second end is bent from the first side to the second side. A part of the other end of the second end is made flush with the bottom surface of the bottom sheet. The outer diameter of the winding part is smaller than the width of the bottom sheet, the outer diameter of the winding part is smaller than the length of the bottom sheet, the outer diameter of the winding part is smaller than the inner diameter of the groove, the inner diameter of the central hole of the winding part is larger than the outer diameter of the column body, and the depth of the groove is equal to or greater than the height of the winding part. The arranging step is performed to arrange the first semi-finished product in a mold and arrange the lid body on the first semi-finished product to form a second semi-finished product. The winding part of the second semi-finished product is arranged corresponding to the groove, the part connected to the upper part of the winding part at the first end is arranged corresponding to the avoidance groove, and the column body is arranged corresponding to the central hole. The molding step is performed to pressurize the second semi-finished product to melt and connect the lid body and the bottom sheet included in the second semi-finished product to each other to form a main body part. The winding portion is correspondingly disposed within the body portion, and a terminal portion of the first end portion and a terminal portion of the second end portion are exposed from the body portion.

[0006] One embodiment of the present invention provides a magnetic device manufactured by the method for manufacturing a magnetic device described above.

[0007] A magnetic device provided in a specific embodiment of the present invention includes a cover, a bottom sheet, and a coil. One side of the cover is recessed to form a groove, and a column body is disposed in the groove. The coil includes a winding portion, a first end, and a second end. One end of the first end is connected to an upper portion of the winding portion, and one end of the second end is connected to a lower portion of the winding portion. The winding portion is disposed on one side of the base, and an outer diameter of the winding portion is smaller than a width of the bottom sheet, an outer diameter of the winding portion is smaller than a length of the bottom sheet, an outer diameter of the winding portion is smaller than an inner diameter of the groove, an inner diameter of a central hole of the winding portion is larger than an outer diameter of the column body, and a depth of the groove is equal to or greater than a height of the winding portion. The cover is configured to be disposed on the side of the base where the coil is disposed. Effect of the Invention

[0008] Therefore, in the magnetic device manufacturing method and magnetic device of the present invention, the problems of the inductor manufactured by the conventional inductor manufacturing method can be effectively improved through the design of the preparation step, the coil assembly step, the arrangement step and the formation step. In the magnetic device manufactured by the magnetic device manufacturing method of the present invention, the density in each region of the main body is substantially uniform. Compared with the magnetic device manufactured by the conventional method, the magnetic device of the present invention has better magnetic properties and reliability.

[0009] These and other aspects of the present invention will become apparent with reference to the following description of the embodiments and the following drawings and their captions, although changes and modifications therein may be made without departing from the spirit and scope of the novel concepts of the present invention. [Brief description of the drawings]

[0010] [Figure 1] 4 is a flowchart of a method for manufacturing a magnetic device according to a first embodiment of the present invention. [Diagram 2] 3A to 3C are schematic diagrams of a bottom sheet and a lid manufactured in a preparation step of a manufacturing method of a magnetic device according to a first embodiment of the present invention. [Diagram 3]3A to 3C are schematic diagrams of a bottom sheet and a lid manufactured in a preparation step of a manufacturing method of a magnetic device according to a first embodiment of the present invention. [Figure 4] 5A to 5C are schematic cross-sectional views of a lid manufactured in a preparation step of the manufacturing method of the magnetic device according to the first embodiment of the present invention. [Diagram 5] 3A to 3C are schematic views from different perspectives of a first semi-finished product manufactured in a coil assembly step of the manufacturing method for a magnetic device according to the first embodiment of the present invention. [Figure 6] 3A to 3C are schematic views from different perspectives of a first semi-finished product manufactured in a coil assembly step of the manufacturing method for a magnetic device according to the first embodiment of the present invention. [Figure 7] 3A to 3C are schematic views from different perspectives of a first semi-finished product manufactured in a coil assembly step of the manufacturing method for a magnetic device according to the first embodiment of the present invention. [Figure 8] 2A-2D are schematic diagrams of a placement step of a method for manufacturing a magnetic device according to a first embodiment of the present invention; [Figure 9] FIG. 2 is a schematic diagram of a method for manufacturing a magnetic device according to a first embodiment of the present invention, prior to a molding step. [Figure 10] 2 is a partial schematic cross-sectional view of a magnetic device according to a first embodiment of the present disclosure, prior to a molding step of the method for manufacturing the magnetic device. [Figure 11] 10 is a schematic cross-sectional view taken along line XI-XI in FIG. 9. [Figure 12] FIG. 10 is a schematic cross-sectional view taken along line XII-XII in FIG. 9. [Figure 13] 4 is a schematic cross-sectional view showing a tilted lid before a molding step in the method for manufacturing the magnetic device according to the first embodiment of the present specification. FIG. [Figure 14] 3A-3C are schematic cross-sectional views of a magnetic device according to a first embodiment of the present disclosure after a molding step of the method for manufacturing the magnetic device. [Figure 15] 1 is a schematic diagram of a magnetic device manufactured by a method for manufacturing a magnetic device according to a first embodiment of the present specification; [Figure 16]5 is a flow chart of a method for manufacturing a magnetic device according to a second embodiment of the present specification. [Figure 17] 5 is a schematic cross-sectional view of a lid manufactured in a preparatory step of a method for manufacturing a magnetic device according to a second embodiment of the present specification. FIG. [Figure 18] 5A-5C are schematic diagrams of a placement step of a method for manufacturing a magnetic device according to a second embodiment of the present disclosure. [Figure 19] FIG. 4 is a schematic diagram of a method for manufacturing a magnetic device according to a second embodiment of the present disclosure prior to a molding step. [Figure 20] 5 is a partial schematic cross-sectional view of a method for manufacturing a magnetic device according to a second embodiment of the present disclosure, prior to a molding step. [Figure 21] FIG. 20 is a schematic cross-sectional view taken along line XXI-XXI in FIG. 19. [Figure 22] FIG. 22 is a schematic cross-sectional view taken along line XXII-XXII in FIG. 19. [Diagram 23] 4 is a schematic diagram of a first semi-finished product produced in a coil assembly step of a method for manufacturing a magnetic device according to another embodiment of the present disclosure. FIG. [Figure 24] 4 is a schematic diagram of a first semi-finished product produced in a coil assembly step of a method for manufacturing a magnetic device according to another embodiment of the present disclosure. FIG. [Diagram 25] 4 is a schematic diagram of a first semi-finished product produced in a coil assembly step of a method for manufacturing a magnetic device according to another embodiment of the present disclosure. FIG. [Figure 26] 4 is a schematic diagram of a first semi-finished product produced in a coil assembly step of a method for manufacturing a magnetic device according to another embodiment of the present disclosure. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] In the following description, references to a particular drawing or as shown in a particular drawing are used only to emphasize that in the following description, most of the relevant content referenced appears in the particular drawing, but are not intended to limit the following description to only references to the particular drawing.

[0012] Referring to Fig. 1, Fig. 1 is a schematic flow chart of a method for manufacturing a magnetic device according to a first embodiment of the present invention. The method of the present invention is configured to manufacture a magnetic device Z (as shown in Fig. 15), which includes an integrally molded body part Z1. The method for manufacturing the magnetic device includes a preparation step S11, a coil assembly step S12, a placement step S13, and a molding step S14.

[0013] The preparation step S11 is carried out to manufacture the bottom sheet 1 and the cover 2 using at least one magnetic mixture. In practical applications, the same magnetic mixture can be used to manufacture the bottom sheet 1 and the cover 2 by a molding method, and the body part Z1 of the finally formed magnetic device Z can be made from the same magnetic powder, but the present invention is not limited thereto. In other embodiments, the bottom sheet 1 and the cover 2 can be manufactured by different magnetic mixtures, respectively. For example, the magnetic mixture can include an adhesive, and the magnetic mixture can further include at least one of a crystalline magnetic metal powder and an amorphous magnetic metal powder. The crystalline magnetic metal powder may be, for example, ferrosilicon (Fe-Si), ferrosilicon chromium (Fe-Si-Cr), ferrosilicon aluminum (Fe-Si-Al), ferronickel (Fe-Ni), carbonyl iron powder (i.e., CIP), iron powder, ferronickel molybdenum (Fe-Ni-Mo) powder, and ferrocobalt vanadium (Fe-Co-V), but the present invention is not limited thereto. The amorphous magnetic metal powder may be, for example, iron-based amorphous magnetic metal power, such as iron, silicon, boron, carbon (Fe, Si, B, C) and iron, silicon, chromium, boron, phosphorus, carbon (Fe, Si, Cr, B, P, C), but the present invention is not limited thereto.

[0014] 2 and 3, which are schematic diagrams of a bottom sheet and a lid manufactured in a preparation step of the method for manufacturing a magnetic device according to the first embodiment of the present invention. As shown in FIG. 2, the bottom sheet 1 can have a base 11 and a protrusion 12. The protrusion 12 is connected to one side of the base 11, and the width 12W of the protrusion 12 is smaller than the width 11W of the base 11. Furthermore, on the one side of the base 11, the protrusion 12 and the base 11 together define a first notch 13 and a second notch 14. The sum of the length 11L of the base 11 and the length 12L of the protrusion 12 is equal to or greater than the length 2L of the lid 2, and the width 11W of the base 11 is equal to or greater than the width 2W of the lid 2. In other words, in the top view of the bottom sheet 1, the bottom sheet 1 is formed in a substantially convex shape. In another embodiment, the bottom sheet 1 only has the base 11 and does not have the protrusion 12, and the overall structure of the bottom sheet 1 is substantially a rectangular plate.

[0015] 3 and 4, the cover 2 may include a bottom wall 21, an annular side wall 22, and a column body 23. The annular side wall 22 is disposed around the bottom wall 21, one end of the column body 23 is disposed on the bottom wall 21, and the bottom wall 21, the annular side wall 22, and the column body 23 together define a groove 24. The groove 24 is disposed on one side of the cover 2. In a top view of the cover 2, the periphery of the groove 24 is substantially circular, but the present invention is not limited thereto. In other embodiments, the periphery of the groove 24 may be substantially elliptical or rectangular. The groove 24 is annular, and the column body 23 is disposed substantially at the center of the groove 24, but the present invention is not limited thereto. The column body 23 may be cylindrical or rectangular cubic, but the present invention is not limited thereto. In practical applications, the height 23H of the column body 23 is equal to or less than the height 22H of the annular side wall 22, in order to facilitate the manufacture of the cover 2. Of course, in other embodiments, the height 23H of the column body 23 may be greater than the height 22H of the annular side wall 22, and a portion of the column body 23 may protrude outside the recessed groove 24.

[0016] Please refer to Figures 1, 4 and 5. Figures 4 and 5 are schematic diagrams of a first semi-finished product manufactured in a coil assembly step of the method for manufacturing a magnetic device according to a first embodiment of the present invention. The coil assembly step S12 is performed by fixing a coil 3 to a bottom sheet 1 to form a first semi-finished product A.

[0017] The coil 3 includes a winding portion 31, a first end 32, and a second end 33. One end of the first end 32 is connected to an upper portion 31A of the winding portion 31, and the other end of the first end 32 is bent from a first side 1A of the bottom sheet 1 to a second side 1B of the bottom sheet 1. One end of the second end 33 is connected to a lower portion 31B of the winding portion 31, and the other end of the second end 33 is bent from the first side 1A to the second side 1B. An outer diameter 31D of the winding portion 31 is smaller than a width 11W of the bottom sheet 1, and the outer diameter 31D of the winding portion 31 is smaller than a length of the bottom sheet 1 (i.e., a sum of a length 11L of a base 11 and a length 12L of a protruding portion 12). The coil 3 can be made of flat enameled wire (usually known as flat wire), but the present invention is not limited thereto. In other embodiments, the coil 3 may be made of non-flat enameled wire (commonly known as round wire).

[0018] In the coil assembling step S12, a partial section of the first end 32 is bent toward the second side 1B of the bottom sheet 1 via the first notch 13, and a partial section of the second end 33 is bent toward the second side 1B of the bottom sheet 1 via the second notch 14. Then, the coil 3 is fixed to the bottom sheet 1 by a configuration in which it is bent from the first side 1A to the second side 1B via the partial section of the first end 32 and the partial section of the second end.

[0019] 3 to 6. It should be noted that the outer diameter 31D of the winding portion 31 is smaller than the inner diameter 24D of the groove 24, the inner diameter 311D of the central hole 311 of the winding portion 31 is larger than the outer diameter 23D of the column body 23, and the depth of the groove 24 (i.e., the height 22H of the annular side wall 22) is equal to or greater than the height 31H of the winding portion 31.

[0020] In the drawings of the present invention, the end of the first end 32 and the end of the second end 33 are disposed on the second side 1B of the bottom sheet 1 as an example, but the positions of the end of the first end 32 and the end of the second end 33 relative to the bottom sheet 1 are not limited thereto. For example, in another embodiment, the end of the first end 32 and the end of the second end 33 can be disposed on the narrow side of the bottom sheet 1. In yet another embodiment, the end of the first end 32 and the end of the second end 33 can be bent from the second side 1B of the bottom sheet 1 to the first side 1A.

[0021] Referring to Figures 1 and 6 to 9, Figures 5 to 7 are schematic views from different perspectives of a first semi-finished product manufactured in the coil assembly step of the method for manufacturing a magnetic device according to the first embodiment of the present invention, Figure 8 is a schematic view of the arrangement step of the method for manufacturing a magnetic device according to the first embodiment of the present invention, and Figure 9 is a schematic view before the molding step of the method for manufacturing a magnetic device according to the first embodiment of the present invention.

[0022] The arrangement step S13 is performed by arranging the first semi-finished product A in the mold Q and arranging the lid body 2 on the first semi-finished product A to form the second semi-finished product B. A portion of the end surface 2M in which the groove 24 is formed in the lid body 2 of the second semi-finished product B abuts against a portion adjacent to the upper part of the winding part 31 at the first end part 32, the lid body 2 is supported by the partial section 321 of the first end part, the column body 23 is arranged corresponding to the upper part of the central hole 311 of the winding part 31, and the winding part 31 is arranged corresponding to the lower part of the groove 24. The first notch 13 and the partial section 321 of the first end part that bends to the second side 1B via the first notch 13 are arranged corresponding to the lower part of the lid body 2, and the second notch 14 and the partial section of the second end part 33 that bends to the second side 1B via the second notch 14 are arranged corresponding to the lower part of the lid body 2.

[0023] In this embodiment, in the positioning step S13, the end of the column body 23 remote from the bottom wall 21 does not extend into the central hole 311. Through this configuration, the manufacture of the lid body 2 can be facilitated, but the present invention is not limited thereto. In one embodiment in which the height 23H of the column body 23 of the lid body 2 is greater than the height 22H of the annular side wall 22, in the positioning step S13, a part of the end of the column body 23 remote from the bottom wall 21 can extend into the central hole 311.

[0024] Referring to FIG. 12, it is a schematic diagram of a cross section of a tilted cover body before the molding step of the first embodiment of the manufacturing method of the magnetic device of the present invention. The predetermined gap Q1 between the outer periphery of the cover body 2 and the inner wall of the mold Q is smaller than a predetermined value. Furthermore, the cover body 2 cannot be tilted by more than θ degrees in the mold Q, and θ can be in the range of, for example, 3 to 30 degrees. The predetermined value is, for example, 0.2 mm, and 0.05 mm is preferable. In other words, the predetermined gap Q1 between the outer periphery of the cover body 2 and the inner wall of the mold Q in the arrangement step S13 can be 0.08 mm or less. Preferably, the predetermined gap Q1 is 0.05 mm or less.

[0025] The molding step S14 is carried out by pressing the second semi-finished product B (for example, by using a stamping device Y to press in the opposite direction from the lid body 2 to the bottom sheet 1). As a result, the lid body 2 and the bottom sheet 1 included in the second semi-finished product B are melted and bonded to form the body part Z1. The winding part 31 is correspondingly arranged in the body part Z1, and the end of the first end 32 and the end of the second end 33 are exposed from the body part Z1. In practical application, in the molding step S14, the mold Q is heated at the same time. In other words, the second semi-finished product B is heated and pressed at the same time. Of course, the molding step S14 can also be carried out without heating the second semi-finished product B at the same time, in which case the second semi-finished product B is pressed at room temperature (for example, 20°C to 25°C, which is commonly known as cold pressing).

[0026] In practical application, if the end of the first end 32 and the end of the second end 33 are not correspondingly exposed from the body portion Z1 after the molding step S14, the body portion Z1 is partially removed in a post-processing manner so that at least a portion of the end of the first end 32 and at least a portion of the end of the second end 33 are exposed from the body portion Z1.

[0027] In practical application, in the preparation step S11, the bottom sheet 1 and the cover 2 can be produced by the same magnetic mixture. In the process of heating and pressing the bottom sheet 1 and the cover 2 in the molding step S14, the magnetic mixture that originally formed the bottom sheet 1 and the cover 2 is transformed into a nearly liquid state and flows around the coil 3. Finally, the magnetic mixture that originally formed the bottom sheet 1 and the cover 2 melts to form the main body Z1, and the coil 3 is enclosed in the main body Z1.

[0028] Naturally, in the preparation step S11, the bottom sheet 1 and the cover body 2 are produced with different magnetic mixtures. In step S14, the magnetic mixture that originally formed the bottom sheet 1 may be mainly disposed at the bottom of the mold Q, and the magnetic mixture that originally formed the cover body 2 may be mainly disposed on the outer periphery of the coil 3. From a cross-sectional view of the main body part Z1 of the finally produced magnetic device Z, a boundary line between the two magnetic mixtures may be observed.

[0029] Referring to FIG. 15, FIG. 15 is a schematic diagram of a magnetic device manufactured by the manufacturing method of a magnetic device of the present invention. The magnetic device Z manufactured by the method of the present invention can be used as an inductor. The magnetic device Z includes the body part Z1 and a coil 3. The coil 3 is contained by the body part Z1. An end 322 of the first end 32 and an end 331 of the second end 33 of the coil 3 are exposed from the side of the body part Z1, and the end 322 of the first end 32 and the end of the second end 33 can be used as electrodes of the magnetic device Z.

[0030] Referring to Fig. 16, Fig. 16 is a schematic flow chart of a method for manufacturing a magnetic device according to a second embodiment of the present invention. The method of this embodiment is configured to manufacture a magnetic device including a main body configured as a monolithic structure. The method for manufacturing the magnetic device of this embodiment includes a preparation step S21, a coil assembly step S22, a placement step S23, and a molding step S24.

[0031] 16 and 17, FIG. 17 is a schematic cross-sectional view of a cover manufactured in a preparation step of the manufacturing method of a magnetic device according to the second embodiment of the present invention. The preparation step S21 is carried out to manufacture a bottom sheet 1 and a cover 2A using at least one magnetic mixture. One side of the cover 2A is recessed to form a groove 24 and an avoidance groove 25 spatially communicating with the groove 24, and the cover 2A includes a column body 23 disposed in the groove 24. The only difference between the cover 2A described here and the cover 2 of the previous embodiment is that the cover 2A of this embodiment further includes an avoidance groove 25, and other parts of the cover 2A of this embodiment are the same as the cover 2 of the previous embodiment and will not be repeated here. The structure of the avoidance groove 25 can be designed based on the structure of the first end 32 disposed in the upper portion 31A of the winding portion 31.

[0032] A coil assembly step S22 is carried out to form a first semi-finished product A by fixing the coil 3 to the bottom sheet 1. The first semi-finished product A described here is the same as the first semi-finished product A in the previous embodiment, and its detailed description can be found in the previous embodiment and will not be repeated here.

[0033] Referring to Figures 18 to 22, Figure 18 is a schematic diagram of the arrangement step of the method for manufacturing a magnetic device according to the second embodiment of the present invention, Figure 19 is a schematic diagram before the molding step of the method for manufacturing a magnetic device according to the second embodiment of the present invention, Figure 20 is a schematic partial cross-sectional view before the molding step of the method for manufacturing a magnetic device according to the second embodiment of the present invention, and Figures 21 and 22 are schematic cross-sectional views taken along lines XXI-XXI and XXII-XXII, respectively, of Figure 19.

[0034] The arrangement step S23 is performed to form a second semi-finished product C by arranging the first semi-finished product A in the mold Q and arranging the cover body 2A on the first semi-finished product A. The winding part 31 of the second semi-finished product C is arranged corresponding to the recessed groove 24, and the section connected to the upper part 31A of the winding part 31 at the first end part 32 is arranged corresponding to the avoidance groove 25. The column body 23 is arranged corresponding to the central hole 311, and the other end part of the column body 23 remote from the bottom wall 21 can abut corresponding to the first side of the lower part 31B, and the end face 2M of the annular side wall 22 of the cover body 2A can abut corresponding to the first side of the lower part 31B. In other words, the avoidance groove 25 is configured to accommodate the part connected to the upper part 31A of the winding part 31 at the first end part 32. In this way, a part of the coil 3 of the second semi-finished product C is disposed on the first side of the bottom sheet 1 and can be accommodated in the recessed groove 24 and the clearance groove 25 of the lid body 2A.

[0035] In the molding step S24, the semi-finished product C is pressed, so that the lid body 2A and the bottom sheet 1 included in the second semi-finished product C are melted and connected to form the main body part Z1 (shown in FIG. 15). The winding part 31 is arranged corresponding to the main body part Z1, and another end 322 (shown in FIG. 15) of the first end part 32 and another end 331 (shown in FIG. 15) of the second end part 33 are exposed from the main body part Z1. Except for the second semi-finished product C arranged in the mold Q, the molding step S24 of this embodiment is the same as the molding step S14 of the previous embodiment, and will not be repeated here. In practical application, in the molding step S24, the mold Q is heated at the same time. In other words, the second semi-finished product C is heated and pressed. Of course, the molding step S24 can be performed without heating the second semi-finished product C at the same time, so that the second semi-finished product C is pressed at room temperature (e.g., 20°C to 25°C, which is usually known as cold pressing).

[0036] It should be noted that in the practical application of any of the above-mentioned embodiments, the relevant personnel can appropriately adjust the overall height of the lid according to the difference of the magnetic mixture forming the bottom sheet and the lid, thereby ensuring that the magnetic mixture originally forming the lid and the bottom sheet in the molding step effectively contains the coil. In other words, the overall height of the lid can be changed according to the difference of the magnetic mixture. Similarly, the relevant personnel can adjust the structure of the lid, the overall thickness of the bottom sheet, and the structure of the bottom sheet according to different types of coils, thereby ensuring that the magnetic mixture originally forming the lid and the bottom sheet in the molding step effectively contains the coil.

[0037] 23 to 26, which are schematic diagrams of a first semi-finished product produced by the coil assembly step of the manufacturing method of the magnetic device according to another embodiment of the present invention. As shown in FIG. 23, in a different embodiment, the end of the first end 32 of the coil 3 of the first semi-finished product A1 remote from the end connected to the winding portion 31 is bent through the first notch 13 from the first side 1A to the second side 1B of the bottom sheet 1, but the end 322 of the first end 32 is not bent to the second side 1B of the bottom sheet 1. Furthermore, the end of the first end 32 remote from the end connected to the winding portion 31 is flush with the bottom surface of the bottom sheet 1. The end of the second end 33 of the coil 3 remote from the end connected to the winding portion 31 is bent through the second notch 14 from the first side 1A to the second side 1B of the bottom sheet 1, but the end 331 of the second end 33 is not bent to the second side 1B of the bottom sheet 1. Additionally, the end of the second end 33 remote from the end connected to the winding portion 31 was made flush with the bottom surface of the bottom sheet 1. After the molding step, the portion of the first end 32 that is flush with the bottom surface of the bottom sheet 1 and the portion of the second end 33 that is flush with the bottom surface of the bottom sheet 1 are exposed from the main body portion Z1 (see FIG. 15).

[0038] 24, in a different embodiment, the end of the first end 32 of the coil 3 of the first semi-finished product A2 remote from the end connected to the winding 31 is bent through the first notch 13 from the first side 1A to the second side 1B of the bottom sheet 1, but the end 322 of the first end 32 is not bent to the second side 1B of the bottom sheet 1. The end 322 of the first end 32 is bent in a direction away from the winding 31 to form a first end bend 323, a portion of which is coincident with the bottom surface of the bottom sheet 1. The end of the second end 33 of the coil 3 remote from the end connected to the winding 31 is bent through the second notch 14 from the first side 1A to the second side 1B of the bottom sheet 1, but the end 331 of the second end 33 is not bent to the second side 1B of the bottom sheet 1. The end 331 of the second end portion 33 is bent away from the windings 31 to form a second end bend 332, with a portion of the second end bend 332 being flush with the bottom surface of the bottom sheet 1. After the forming step, the portion of the first end bend 323 that is flush with the bottom surface of the bottom sheet 1 and the portion of the second end bend 332 that is flush with the bottom surface of the bottom sheet 1 are exposed from the main body portion Z1 (see FIG. 15).

[0039] Referring to FIG. 25, in a different embodiment, the winding method of the winding portion 31 of the first semi-finished product A3 is as follows. The wide side of the flat enameled wire is placed toward the central axis and rotated about the central axis, and the resulting winding state is as shown in FIG. 25. In FIG. 25, it is taken as an example that the ends of the first end 32 and the second end 33 included in the coil 3 are respectively placed on the second side 1B of the bottom sheet 1 after bending. However, in actual application, the ends of the first end 32 and the second end 33 are not necessarily placed on the second side 1B of the bottom sheet 1 after bending. For example, in one configuration of this embodiment, the ends of the first end 32 and the second end 33 can be the same as the structures of the ends of the first end 32 and the second end 33 shown in FIG. 23 or FIG. 24.

[0040] The main differences between the first semi-finished product A4 shown in FIG. 26 and the first semi-finished product A shown in FIG. 5 are as follows. The coil 3 in this embodiment is a round wire (i.e., the cross section of the coil 3 is approximately circular), whereas the coil 3 in the embodiment shown in FIG. 5 is a flat wire. In FIG. 26, the end of the first end 32 and the end of the second end 33 included in the coil 3 are respectively disposed on the second side 1B of the bottom sheet 1 after bending, as an example. However, in actual applications, the end of the first end 32 and the end of the second end 33 are not necessarily disposed on the second side 1B of the bottom sheet 1 after bending. For example, in one configuration of this embodiment, the end of the first end 32 and the end of the second end 33 can be the same as the structure of the end of the first end 32 and the end of the second end 33 shown in FIG. 23 or FIG. 24.

[0041] In a preferred embodiment, after the above-mentioned molding step of the manufacturing method of the magnetic device, an insulating layer (e.g., black paint) is formed on the structure of the body (e.g., by a coating method). As a result, the insulating layer completely surrounds the first end and the second end exposed from the body. Then, the insulating layer of the first end and the second end exposed from the body and the insulating paint of the coil are removed by a laser method, exposing the conductive structures of the first end and the second end. Finally, a metal layer is formed on the conductive structures of the first end and the second end to function as electrodes.

[0042] It should be noted that the above steps of the manufacturing method of the magnetic device do not include the step of filling the mold with magnetic powder. Through the design of the above steps, the method of the present invention can effectively solve the potential problems caused by using magnetic powder to form the body of the magnetic device during the traditional production process.

[0043] Specifically, in a conventional method for manufacturing an inductor (i.e., a magnetic device), a mold is placed on a coil, magnetic powder is filled, and the magnetic powder is formed into a magnetic body of the inductor by a heating and pressing method. In an inductor manufactured by this method, the area density of the magnetic body at the center position of the coil and the area density of the magnetic body at the outer position of the coil are relatively low compared to the area density of the magnetic body at other positions. The uneven density of the magnetic body as a whole directly causes the inductor to have poor magnetic properties and reliability.

[0044] In another conventional inductor manufacturing method, a coil is placed on the inverted T-shaped bottom sheet, and the coil and the inverted T-shaped bottom sheet are placed together in the mold. Then, magnetic powder is filled into the mold, and the inverted T-shaped bottom sheet and the magnetic powder are formed together into the magnetic body part of the inductor by a heating and pressing method. The overall uniformity of the magnetic body part of the inductor manufactured by this method is better than that of the magnetic body part of the inductor manufactured by the above conventional method. However, in the magnetic body part manufactured by this method, the difference between the density of the outer region of the coil and the density of the magnetic body part in other regions is still too large, so the magnetic properties of the finally formed inductor still need to be improved. Furthermore, in the inductors manufactured by the above two conventional methods, the problem of the coil moving and not being located at the center position of the magnetic body part may easily occur.

[0045] In contrast, in the magnetic device manufacturing method provided by the present invention, through the design of the preparation step, coil assembly step, placement step and molding step, the problems of the inductors manufactured by the above two conventional methods can be effectively improved. In the magnetic device manufactured by the method of the present invention, the density of the body part in each region is substantially uniform. Compared with the magnetic devices manufactured by the above two conventional methods, the magnetic device of the present invention has better magnetic properties and reliability.

[0046] It is worth mentioning that the uniformity of density of the body part of each magnetic device manufactured in the two embodiments of the present invention is better than that of the magnetic body part manufactured by magnetic powder filling, and the uniformity of density of the body part and the magnetic properties of the magnetic device manufactured in the first embodiment are better than those of the second embodiment.

[0047] Furthermore, in the inductors manufactured by the above two conventional methods, the coil is not easily positioned at the approximate center of the magnetic body, or the coil is easily tilted. As a result, the inductors have poor magnetic properties. In contrast, the winding of the coil included in the magnetic device manufactured by the method of the present invention is effectively positioned at the approximate center of the body, the winding is not easily tilted, and the magnetic device can have better magnetic properties.

[0048] The contents disclosed above are merely preferred possible embodiments of the present invention, and do not limit the scope of the claims of the present invention. Therefore, all equivalent technical modifications made based on the contents of the specification and accompanying drawings of the present invention are intended to be included in the scope of the claims of the present invention. [Explanation of symbols]

[0049] 1: Bottom sheet 11: Bass 11W:Width 11L:Length 12: Convex 13: First notch 14: Second notch 1A: First side 1B: Second side 2: Lid 2M: End face 21: Bottom wall 22: Annular side wall 23: Column type 23D:Outer diameter 24: Groove 24D: Inner diameter 25: Ditch 3: Coil 31: Winding section 31A: Upper part 31B: Bottom 311: Central hole central hole 32: First end 321: Partial section 322: Terminal 323: First end bend 33: Second end 332: Second end bend A: The first semi-finished product B: The second semi-finished product Y: Stamping device Z: Magnetic device Z1: Main body Q:Mold Q1:Prescribed gap S11~S14: Step

Claims

1. 1. A method of manufacturing a magnetic device including a body configured as a monolithic structure, comprising: A preparation step of manufacturing a bottom sheet and a lid body using at least one magnetic mixture, the lid body having a groove formed on one side thereof, the lid body having a column body, and the column body being positioned in the groove; a coil assembly step for fixing a coil to the bottom sheet to form a first semi-finished product, the coil including a winding portion, a first end, and a second end, one end of the first end being connected to an upper portion of the winding portion and one end of the second end being connected to a lower portion of the winding portion, an outer diameter of the winding portion being smaller than a width of the bottom sheet, an outer diameter of the winding portion being smaller than a length of the bottom sheet, an outer diameter of the winding portion being smaller than an inner diameter of the groove, an inner diameter of a central hole of the winding portion being larger than an outer diameter of the column body, and a depth of the groove being equal to or greater than a height of the winding portion; a placement step for placing the first semi-finished product in a mold and placing the lid on the first semi-finished product to form a second semi-finished product, wherein a portion of an end surface of the lid of the second semi-finished product in which the groove is formed corresponds to and abuts against a section adjacent to an upper portion of the winding portion at the first end portion, the lid is supported by a partial section of the first end portion, the column body is placed corresponding to an upper portion of a central hole of the winding portion, and the winding portion is placed corresponding to a lower portion of the groove; a molding step performed by pressing the second semi-finished product to melt and connect the lid and the bottom sheet included in the second semi-finished product to each other to form the body portion, the winding portion being correspondingly disposed within the body portion, and a portion of an end of the first end portion and a portion of an end of the second end portion being exposed from the body portion; A method for manufacturing a magnetic device.

2. 2. The method for manufacturing a magnetic device according to claim 1, wherein in said positioning step, a predetermined gap between an outer periphery of said lid body and an inner wall of said mold is 0.2 mm or less.

3. 2. The method for manufacturing a magnetic device according to claim 1, wherein in the preparing step, the cover body includes a bottom wall, an annular side wall, and the column body, the annular side wall is disposed around the bottom wall, one end of the column body is disposed on the bottom wall, the bottom wall, the annular side wall, and the column body together define the groove, and a height of the column body is equal to or less than a height of the annular side wall, and in the disposing step, an end of the column body remote from the bottom wall does not extend into the central hole.

4. 2. The method for manufacturing a magnetic device according to claim 1, wherein the bottom sheet produced in the preparation step has a base and a convex portion, the convex portion is connected to a first side of the base, the width of the convex portion is narrower than the width of the base, the convex portion and the base together define a first notch and a second notch on one side of the base, a sum of a length of the base and a length of the convex portion is greater than or equal to a length of the lid body, and a width of the base is greater than or equal to a width of the lid body, and in the coil assembly step, a partial section of the first end is arranged in the first notch and a partial section of the second end is arranged in the second notch, and in the arrangement step, the first notch and the partial section of the first end that bends to the second side via the first notch are arranged corresponding to a lower portion of the lid body, and the second notch and the partial section of the second end that bends to the second side via the second notch are arranged corresponding to a lower portion of the lid body.

5. 5. The method for manufacturing a magnetic device as described in claim 4, wherein, in the coil assembly step, a partial section of the first end is bent toward the second side via the first notch and an end of the first end is disposed on the second side of the bottom sheet, and a partial section of the second end is bent toward the second side via the second notch and an end of the second end is disposed on the second side of the bottom sheet.

6. 2. The method for manufacturing a magnetic device as described in claim 1, wherein in the preparation step, the magnetic mixture used to manufacture the bottom sheet is the same as the magnetic mixture used to manufacture the lid body, the main body is made of the same magnetic mixture, and during the placement step and the molding step, the magnetic mixture is not filled into the mold.

7. 2. The method for manufacturing a magnetic device as described in claim 1, wherein in the preparing step, the magnetic mixture used to manufacture the bottom sheet is different from the magnetic mixture used to manufacture the lid body, the main body portion is made of a different magnetic mixture, and during the placing step and the molding step, no magnetic mixture is filled into the mold.

8. A magnetic device manufactured by the method for manufacturing a magnetic device according to any one of claims 1 to 7.

9. 1. A method of manufacturing a magnetic device including a body configured as a monolithic structure, comprising: A preparation step of manufacturing a bottom sheet and a lid body using at least one magnetic mixture, the lid body having a recessed groove and a clearance groove communicating with the recessed groove formed on one side thereof, the lid body having a column body, and the column body being positioned in the recessed groove; a coil assembly step for fixing a coil to the bottom sheet to form a first semi-finished product, the coil including a winding portion, a first end, and a second end, one end of the first end being connected to an upper portion of the winding portion, the other end of the first end being bent from a first side to a second side of the bottom sheet, one end of the second end being connected to a lower portion of the winding portion, the other end of the second end being bent from a first side to a second side of the bottom sheet, an outer diameter of the winding portion being smaller than a width of the bottom sheet, an outer diameter of the winding portion being smaller than a length of the bottom sheet, an outer diameter of the winding portion being smaller than an inner diameter of the groove, an inner diameter of a central hole of the winding portion being larger than an outer diameter of the column body, and a depth of the groove being equal to or greater than a height of the winding portion; a positioning step of positioning the first semi-finished product in a mold and positioning the cover body on the first semi-finished product to form a second semi-finished product, in which a winding portion of the second semi-finished product is positioned in the recessed groove, a partial section connected to an upper portion of the winding portion at the first end portion is positioned in the avoidance groove, and the column body is positioned in the central hole; a molding step performed by pressing the second semi-finished product to melt and connect the lid and the bottom sheet included in the second semi-finished product to each other to form the body portion, the winding portion being correspondingly disposed within the body portion, and a portion of an end of the first end portion and a portion of an end of the second end portion being exposed from the body portion; A method for manufacturing a magnetic device.

10. 10. The method for manufacturing a magnetic device according to claim 9, wherein in the preparation step, the cover body includes a bottom wall, an annular side wall, and the column body, the annular side wall is disposed around the bottom wall, one end of the column body is disposed on the bottom wall, the bottom wall, the annular side wall, and the column body together define the groove, and a height of the column body is smaller than a height of the annular side wall.

11. The bottom sheet produced in the preparation step has a base and a protrusion, the protrusion is connected to a first side of the base, the width of the protrusion is narrower than the width of the base, on one side of the base, the protrusion and the base together define a first notch and a second notch, the sum of the length of the base and the length of the protrusion is equal to or greater than the length of the lid, and the width of the base is equal to or greater than the width of the lid, and in the coil assembly step, a partial section of the first end bends to the second side via the first notch, and an end of the first end is connected to the bottom sheet.

10. The method for manufacturing a magnetic device of claim 9, wherein a partial section of the second end is disposed on the second side of the bottom sheet, a partial section of the second end is bent to the second side via the second notch, and an end of the second end is disposed on the second side of the bottom sheet, and in the disposing step, the first notch and the partial section of the first end that is bent to the second side via the first notch are disposed corresponding to below the lid, and the second notch and the partial section of the second end that is bent to the second side via the second notch are disposed corresponding to below the lid.

12. 10. The method for manufacturing a magnetic device according to claim 9, wherein in the preparation step, the magnetic mixture used to manufacture the bottom sheet is the same as the magnetic mixture used to manufacture the lid body, the main body is made of the same magnetic mixture, and during the placement step and the molding step, no magnetic mixture is filled into the mold.

13. 10. The method for manufacturing a magnetic device according to claim 9, wherein in the preparing step, a magnetic mixture used to manufacture the bottom sheet is different from a magnetic mixture used to manufacture the lid body, the main body portion is made of a different magnetic mixture, and during the placing step and the molding step, no magnetic mixture is filled into the mold.

14. A magnetic device manufactured by the method for manufacturing a magnetic device according to any one of claims 9 to 13.

15. A magnetic device including a lid, a bottom sheet, and a coil, The cover has one side recessed to form a groove, and a column body is disposed in the groove. the coil includes a winding portion, a first end, and a second end, one end of the first end being connected to an upper portion of the winding portion and one end of the second end being connected to a lower portion of the winding portion, the winding portion being disposed on one side of the base, an outer diameter of the winding portion being smaller than a width of the bottom sheet, an outer diameter of the winding portion being smaller than a length of the bottom sheet, an outer diameter of the winding portion being smaller than an inner diameter of the groove, an inner diameter of a central hole of the winding portion being larger than an outer diameter of the column body, and a depth of the groove being equal to or greater than a height of the winding portion, A magnetic device, characterized in that the lid is configured to be placed on the side of the base where the coil is arranged.

16. 16. The magnetic device of claim 15, wherein the cover further includes an avoidance hole communicating with the groove, the cover is disposed on a side of the base on which the coil is disposed, the winding portion is disposed corresponding to the groove, a section connected to an upper portion of the winding portion at the first end is disposed corresponding to the avoidance groove, and the column body is disposed corresponding to the central hole.

17. 16. The magnetic device of claim 15, wherein the bottom sheet has a base and a protrusion, the protrusion is connected to one side of the base, the width of the protrusion is smaller than the width of the base, on the one side of the base, the protrusion and the base together define a first notch and a second notch, a sum of a length of the base and a length of the protrusion is greater than or equal to a length of the lid, the width of the base is greater than or equal to a width of the lid, a partial section of the first end is disposed in the first notch, a partial section of the second end is disposed in the second notch, the first notch and a partial section of the first end that bends to the second side via the first notch are disposed corresponding to a lower portion of the lid, and the second notch and a partial section of the second end that bends to the second side via the second notch are disposed corresponding to a lower portion of the lid.

18. 18. The magnetic device of claim 17, wherein a partial section of the first end is bent toward the second side via the first notch, with an end of the first end being disposed on the second side of the bottom sheet, and a partial section of the second end is bent toward the second side via the second notch, with an end of the second end being disposed on the second side of the bottom sheet.

19. 16. The magnetic device of claim 15, wherein the cover includes a bottom wall, an annular side wall, and the column body, the annular side wall is disposed around the bottom wall, one end of the column body is disposed on the bottom wall, the bottom wall, the annular side wall, and the column body together define the groove, and a height of the column body is equal to or less than a height of the annular side wall.

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