Co-Fired Inductor Structure to Eliminate Core-Coil Gaps
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Solution Overview
Problem
Conventional inductor manufacturing methods result in large size due to air gaps and insufficient molding precision, leading to increased process costs and reduced yield, with extra gaps between the coil and magnetic core reducing effective magnetic permeability and introducing stress anisotropy.
Innovation Solution
An integrated co-fired inductor preparation method involving sequential filling of different types of magnetic powders into a mold cavity, followed by compression molding and heat treatment to minimize wire deformation, eliminate extra gaps, and enhance material hysteresis loss, using a combination of soft magnetic materials with positive and negative temperature coefficients to improve temperature stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If air gaps are provided to improve saturation current resistance, then saturation current resistance is improved, but device size increases
Solution Approach 1:
The patent combines the magnetic core and coil into a single integrated component manufactured through co-fired sintering, eliminating the need for separate air gaps between discrete components. The magnetic powder core material inherently provides saturation current resistance without requiring additional air gap structures, thus resolving the contradiction between improving saturation current resistance and reducing device size.
Solution Approach 2:
The patent uses magnetic powder core material with specific magnetic properties that provide high saturation magnetic induction intensity. By changing the material parameters (using magnetic powder instead of traditional ferrite), the inductor achieves high saturation current resistance without needing air gaps, thereby reducing device volume while maintaining reliability.
2Reliability
If discrete components with air gaps are used to achieve high saturation superposed current, then saturation current resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent integrates the magnetic core and coil into a single co-fired component, eliminating the need for separate assembly steps and tolerance matching between discrete parts. The magnetic powder core is sintered with the coil embedded within it, creating an integrated structure that simplifies manufacturing while maintaining high saturation current resistance.
Solution Approach 2:
The coil is embedded into the magnetic powder core during the sintering process itself, before final assembly. This preliminary integration of the coil within the magnetic core structure eliminates subsequent assembly steps and tolerance matching requirements, reducing manufacturing complexity while ensuring proper positioning and electrical connection.
3Ease of manufacture
If conventional molding processes are used, then manufacturing is simpler, but molding precision is insufficient leading to extra gaps
Solution Approach 1:
The patent uses co-fired sintering technology with magnetic powder core material that allows for precise dimensional control during the sintering process. By controlling sintering temperature, time, and pressure parameters, the process achieves high molding precision with minimal shrinkage and no extra gaps, while maintaining relative manufacturing simplicity through a single integrated process step.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method reduces material hysteresis loss, eliminates extra gaps between the wire and magnetic core, and improves temperature stability, resulting in a more efficient and reliable inductor with reduced vibration noise and increased saturation magnetic induction intensity.
Implementation Method 1
Metal magnetic powder core materials have developed rapidly in recent years because of their high saturation magnetic induction intensity, high-temperature stability
Implementation Method 2
heat treatment is performed after the integrated molding process, stress is fully released, material hysteresis loss is reduced
Implementation Method 3
heat treatment is performed after the integrated molding process, stress is fully released
Implementation Method 4
sequential filling of different types of magnetic powders into a mold cavity, followed by compression molding
Data Source
AI summary
An integrated co-fired inductor and preparation method therefor, comprising: batch filling a magnetic powder in the mold cavity, embedding at least one wire into one layer of the magnetic powder, the two ends of the wire extending out of the mold cavity, sequentially performing compression molding and heat treatment to obtain a magnetic core, and bending and tinning the wire to obtain the co-fired inductor. The preparation method uses an integrated mold forming process to prepare the inductor to avoid an assembly process involving an excessive number of components; heat treatment is performed after the integral forming process, stress is fully released, material hysteresis loss is reduced, and the loss of the device under light load conditions is reduced; no extra gap exists between the wire and the magnetic core, air gaps are uniformly distributed within the magnetic core, and the vibration noise of eddy current loss is reduced.