The invention provides an integrated
inductor formed based on a
magnetic composite material and a winding and a manufacturing method of the integrated
inductor. The integrated
inductor comprises a main magnetic ring, iron-based nanocrystalline
powder and composite
powder which are formed in an axial
magnetic field orientation mode under the pressure of 500-700 MPa, the winding and an internal gradient layer. The crushed magnetic particle mixture is of a
chain structure of Fe-Si-B-Cr amorphous crushed magnetic particles which are directionally arranged in a
magnetic field, and the external
coating layer is made of a high-thermal-
conductivity magnetic composite material. According to the invention, a three-stage
magnetic circuit design is formed by the high
saturation magnetic induction intensity of the main magnetic ring, the structural support, the magnetic resistance shunt of the
transition layer, the stress buffer and the
broadband response and thermal management of the
coating layer, so that the
broadband response of DC-5MHz is realized, and the
saturation current is improved; meanwhile, an
epoxy resin-
cyanate ester-
polysulfide rubber
composite matrix is subjected to
triazine ring crosslinking and
elastomer modification, so that the
thermal deformation temperature reaches 200 DEG C or above, meanwhile, the interlayer CTE difference is reduced, and the forming yield is increased.