CN106449012A - Customized surface-mount power inductor and manufacturing method thereof - Google Patents
Customized surface-mount power inductor and manufacturing method thereof Download PDFInfo
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- CN106449012A CN106449012A CN201510488834.6A CN201510488834A CN106449012A CN 106449012 A CN106449012 A CN 106449012A CN 201510488834 A CN201510488834 A CN 201510488834A CN 106449012 A CN106449012 A CN 106449012A
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Abstract
The invention provides a customized surface-mount power inductor and a manufacturing method thereof. The customized surface-mount power inductor comprises a magnetic substrate, a coil structure, a magnetic coating structure and a terminal electrode structure, wherein the coil structure is arranged on the magnetic substrate and comprises a conductive extension part and an insulated extension part coating the conductive extension part; the magnetic coating structure is arranged on the magnetic substrate to cover the coil structure; the magnetic coating structure comprises a middle coating layer and a top-end coating layer; the middle coating layer is provided with a surrounding part; the magnetic substrate has a first predetermined relative magnetic-conducting coefficient; the surrounding part has a second predetermined relative magnetic-conducting coefficient; the middle coating layer has a third predetermined relative magnetic-conducting coefficient; and the top-end coating layer has a fourth predetermined relative magnetic-conducting coefficient. The electrical characteristics of the customized surface-mount power inductor are adjusted along with different numerical values of the first predetermined relative magnetic-conducting coefficient, the second predetermined relative magnetic-conducting coefficient, the third predetermined relative magnetic-conducting coefficient and the fourth predetermined relative magnetic-conducting coefficient to meet the customized requirements.
Description
Technical field
The present invention relates to a kind of power inductor and preparation method thereof, more particularly, to a kind of customization
SMD LED surface-mount device LED power inductor and preparation method thereof.
Background technology
In general, existing power inductor includes circuit board, coil and housing.Coil quilt
It is attached on circuit board.Extend the first wire and the second wire from housing, and the first wire
Weld with the pad phase on circuit board respectively with the second wire.Coil is then to be using a section
The upright flat wire of square forms a winding body, and its coil becomes helical form and has many
A few, and coil includes medial extremity and outboard end.One lead frame with two end respectively with
The medial extremity of winding body and outboard end are welded into one.Then, it has been welded with the coiling of wire
Body is placed in mold, and injection is preferably gluey said magnetic powder material in mold.Magnetic
Dusty material becomes block after being dried, and after the demoulding, the part cut-out of lead frame is showed
Some power inductors.However, the overall structure of existing power inductor and manufacture method mistake
In numerous and diverse, therefore how to solve the above problems, it has also become those skilled in the art to be solved
One of important topic.
Content of the invention
The technical problem to be solved is, provides a kind of for the deficiencies in the prior art
Customize SMD LED surface-mount device LED power inductor and preparation method thereof.
A kind of customization SMD LED surface-mount device LED power inductance that a present invention wherein embodiment is provided
Device, it includes：One Magnetic Substrate, a loop construction, a magnetic cladding structure and one end electricity
Pole structure.Described loop construction is arranged on described Magnetic Substrate, wherein said loop construction bag
Include a conductive extension and the insulation extension of a described conductive extension of cladding, described conduction is prolonged
Extending portion and described insulation extension extend all along a desired trajectory, and described conductive extension tool
Have one first conductive tips and one with respect to described first conductive tips the second conductive tips；Institute
State magnetic cladding structure to be arranged on described Magnetic Substrate, to cover described loop construction, wherein
Described magnetic cladding structure includes one and is arranged on described Magnetic Substrate and is connected to described insulation prolonging
The middle coating layer of extending portion and one is arranged on the top on described loop construction and described middle coating layer
End coating layer, described conductive extension passes through described insulation extension with described magnetic cladding structure
Isolation to be electrically insulated from, described first conductive tips of described conductive extension and described
Second conductive tips are all exposed and go out from described middle coating layer, and described middle coating layer has one
Surrounding cincture portion；Described end-electrode structure includes the of described first conductive tips in electrical contact
One end electrode portion and one corresponds to described first end electrode portion and the described second conductive end in electrical contact
The second termination electrode portion at end, wherein said first end electrode portion is arranged on described middle coating layer
On wherein one side and coat a portion of described Magnetic Substrate and described top coating layer
A portion, and described second termination electrode portion is arranged on the other side of described middle coating layer
On end and coat other one of the another part of described Magnetic Substrate and described top coating layer
Point；Wherein, described Magnetic Substrate has one first predetermined relative permeability, described surrounding ring
Around portion, there is one second predetermined relative permeability, described middle coating layer has one the 3rd and makes a reservation for
Relative permeability, described top coating layer has one the 4th predetermined relative permeability, described
The described 3rd predetermined relative permeability in central filler portion is more than or equal to described top coating layer
Described 4th predetermined relative permeability, described top coating layer the described 4th predetermined relatively
Magnetic capacity is more than or equal to the described first predetermined relative permeability of described Magnetic Substrate, and
Described first predetermined relative permeability of described Magnetic Substrate is more than or equal to described surrounding cincture
The described second predetermined relative permeability in portion；Wherein, described customization SMD LED surface-mount device LED power
The electrical characteristic of inducer is with the described first predetermined relative permeability, described second predetermined phase
To magnetic capacity, described 3rd predetermined relative permeability and described 4th predetermined magnetic conduction relatively
The difference of the numerical values recited of coefficient and be adjusted.Described middle coating layer has one and seamlessly connects
In described insulation extension and by described insulation extension around central filler portion, described week
Collarette is seamlessly connected to described insulation extension and around described insulation extension around portion, and institute
State top coating layer and be seamlessly connected to described central filler portion, described surrounding cincture portion and institute
State insulation extension, wherein said first predetermined relative permeability, described second predetermined relatively
Magnetic capacity, described 3rd predetermined relative permeability and described 4th predetermined magnetic conduction system relatively
The scope of number is all between 1 to 53.
Described Magnetic Substrate made by one first predetermined soft magnetic materials, described insulation extension by
Made by one second predetermined soft magnetic materials, described middle coating layer is by one the 3rd predetermined soft magnetic materials
Made, described top coating layer made by one the 4th predetermined soft magnetic materials, and described first
Predetermined soft magnetic materials, described second predetermined soft magnetic materials, described 3rd predetermined soft magnetic materials and
Described 4th predetermined soft magnetic materials is complete phase XOR soft magnetic materials partly different each other each other,
Wherein said conductive extension is a conductive metal wire, a conductive metal foil, a conductive printing layer,
And one conductive electroplated layer one of them, and described conductive extension is along a spiral upwards
Shape track or one serpentine shape track upwards is being extended.
A kind of customization SMD LED surface-mount device LED power inductance that the other embodiment of the present invention is provided
Device, it includes：One Magnetic Substrate, a loop construction, a magnetic cladding structure and one end electricity
Pole structure.Described loop construction is arranged on described Magnetic Substrate, wherein said loop construction bag
Include a conductive extension and the insulation extension of a described conductive extension of cladding, described conduction is prolonged
Extending portion and described insulation extension extend all along a desired trajectory, and described conductive extension tool
Have one first conductive tips and one with respect to described first conductive tips the second conductive tips；Institute
State magnetic cladding structure to be arranged on described Magnetic Substrate, to cover described loop construction, wherein
Described magnetic cladding structure includes one and is arranged on described Magnetic Substrate and is connected to described insulation prolonging
The middle coating layer of extending portion and one is arranged on the top on described loop construction and described middle coating layer
End coating layer, described conductive extension passes through described insulation extension with described magnetic cladding structure
Isolation to be electrically insulated from, described first conductive tips of described conductive extension and described
Second conductive tips are all exposed and go out from described middle coating layer, and described middle coating layer has one
Surrounding cincture portion；Described end-electrode structure includes the of described first conductive tips in electrical contact
One end electrode portion and one corresponds to described first end electrode portion and the described second conductive end in electrical contact
The second termination electrode portion at end, wherein said first end electrode portion is arranged on described middle coating layer
On wherein one side and coat a portion of described Magnetic Substrate and described top coating layer
A portion, and described second termination electrode portion is arranged on the other side of described middle coating layer
On end and coat other one of the another part of described Magnetic Substrate and described top coating layer
Point；Wherein, described Magnetic Substrate made by one first predetermined soft magnetic materials, prolong by described insulation
, made by one second predetermined soft magnetic materials, described middle coating layer is predetermined soft by one the 3rd for extending portion
Made by magnetic material, described top coating layer is made by one the 4th predetermined soft magnetic materials, and institute
State the first predetermined soft magnetic materials, described second predetermined soft magnetic materials, described 3rd predetermined soft magnetism material
Material and described 4th predetermined soft magnetic materials are complete phase XOR soft magnetism partly different each other each other
Material；Wherein, the described electrical characteristic customizing SMD LED surface-mount device LED power inductor is with described
First predetermined soft magnetic materials, described second predetermined soft magnetic materials, described 3rd predetermined soft magnetic materials,
And being adjusted using the difference of material of described 4th predetermined soft magnetic materials.
Described middle coating layer has one and is seamlessly connected to described insulation extension and by described exhausted
Edge extension around central filler portion, described surrounding cincture portion be seamlessly connected to described absolutely
Edge extension and around described insulation extension, and described top coating layer is seamlessly connected to institute
State central filler portion, described surrounding cincture portion and described insulation extension, wherein said described
Conductive extension is a conductive metal wire, a conductive metal foil, a conductive printing layer and are led
Electric electrodeposited coating one of them, and described conductive extension is along a spiral trajectory upwards
Or one serpentine shape track upwards being extended.
Described Magnetic Substrate has one first predetermined relative permeability, described surrounding cincture portion tool
There is one second predetermined relative permeability, described middle coating layer has one the 3rd and makes a reservation for relatively lead
Magnetic coefficient, described top coating layer has one the 4th predetermined relative permeability, and described centre is filled out
The described 3rd predetermined relative permeability filling portion is more than or equal to the described of described top coating layer
4th predetermined relative permeability, the described 4th predetermined magnetic conduction system relatively of described top coating layer
Number is more than or equal to the described first predetermined relative permeability of described Magnetic Substrate, and described magnetic
Property substrate the described first predetermined relative permeability be more than or equal to described surrounding cincture portion institute
State the second predetermined relative permeability, wherein said first predetermined relative permeability, described
Two predetermined relative permeabilities, described 3rd predetermined relative permeability and the described 4th make a reservation for
The scope of relative permeability is all between 1 to 53.
A kind of customization SMD LED surface-mount device LED power inductor that the other embodiment of the present invention is provided
Manufacture method, it comprises the following steps：One initial Magnetic Substrate unit is provided, wherein said
Initial Magnetic Substrate unit is made up of multiple Magnetic Substrates；Form an initial magnetic coil unit
On described initial Magnetic Substrate unit, wherein said initial magnetic coil unit is by multiple difference
The loop construction being arranged on multiple described Magnetic Substrates is formed, each described loop construction
Including the insulation extension of a conductive extension and a described conductive extension of cladding, and described lead
Electrically extend portion and described insulation extension extends all along a desired trajectory；Form an initial magnetic
Coating unit on described initial Magnetic Substrate unit, to cover described initial magnetic coil unit,
Wherein said initial magnetic coating unit by multiple be separately positioned on multiple described Magnetic Substrates with
The magnetic cladding structure being covered each by multiple described loop constructions is formed, each described magnetic
Cladding structure includes one and is arranged on described Magnetic Substrate and is connected in described insulation extension
Between coating layer and be arranged on the top coating on described loop construction and described middle coating layer
Layer, described conductive extension and the isolation by described insulation extension for the described magnetic cladding structure
To be electrically insulated from, described middle coating layer has a surrounding cincture portion；Cutting is described initial
Magnetic Substrate unit, described initial magnetic coil unit and described initial magnetic coating unit,
To form multiple granular electronic components, wherein said initial Magnetic Substrate unit is cut to separate
Multiple described Magnetic Substrates, described initial magnetic coil unit is cut to separate multiple described lines
Coil structures, described initial magnetic coating unit is cut to separate multiple described magnetic cladding structures,
And each described granular electronic component is by described Magnetic Substrate, described loop construction and described
Magnetic cladding structure is formed；At a temperature of between 200 DEG C to 900 DEG C, simultaneously by multiple institutes
State granular electronic component and carry out densification；And, in each described granular electronic component
Two opposition side ends on form a first end electrode portion and one second termination electrode portion respectively, to complete
The described making customizing SMD LED surface-mount device LED power inductor, wherein said conductive extension has
One first conductive tips and one with respect to described first conductive tips the second conductive tips, described
Described first conductive tips of conductive extension and described second conductive tips are all draped over one's shoulders from described centre
Coating is exposed and go out, with respectively described first end electrode portion in electrical contact and described second termination electrode
Portion, wherein said first end electrode portion be arranged on wherein one side of described middle coating layer and
Coat a portion of described Magnetic Substrate and a portion of described top coating layer, and
Described second termination electrode portion is arranged on the other side end of described middle coating layer and coats described
The another part of Magnetic Substrate and the another part of described top coating layer.
Described Magnetic Substrate has one first predetermined relative permeability, described surrounding cincture portion tool
There is one second predetermined relative permeability, described middle coating layer has one the 3rd and makes a reservation for relatively lead
Magnetic coefficient, described top coating layer has one the 4th predetermined relative permeability, and described centre is filled out
The described 3rd predetermined relative permeability filling portion is more than or equal to the described of described top coating layer
4th predetermined relative permeability, the described 4th predetermined magnetic conduction system relatively of described top coating layer
Number is more than or equal to the described first predetermined relative permeability of described Magnetic Substrate, and described magnetic
Property substrate the described first predetermined relative permeability be more than or equal to described surrounding cincture portion institute
State the second predetermined relative permeability, wherein said first predetermined relative permeability, described
Two predetermined relative permeabilities, described 3rd predetermined relative permeability and the described 4th make a reservation for
The scope of relative permeability is all between 1 to 53, and described customization SMD LED surface-mount device LED work(
The electrical characteristic of rate inducer with the described first predetermined relative permeability, described second make a reservation for
Relative permeability, described 3rd predetermined relative permeability and the described 4th make a reservation for relatively lead
The difference of the numerical values recited of magnetic coefficient and be adjusted.
Described Magnetic Substrate made by one first predetermined soft magnetic materials, described insulation extension by
Made by one second predetermined soft magnetic materials, described middle coating layer is by one the 3rd predetermined soft magnetic materials
Made, described top coating layer made by one the 4th predetermined soft magnetic materials, and described first
Predetermined soft magnetic materials, described second predetermined soft magnetic materials, described 3rd predetermined soft magnetic materials and
Described 4th predetermined soft magnetic materials is complete phase XOR soft magnetic materials partly different each other each other,
The wherein said electrical characteristic customizing SMD LED surface-mount device LED power inductor makes a reservation for described first
Soft magnetic materials, described second predetermined soft magnetic materials, described 3rd predetermined soft magnetic materials and described
Being adjusted using the difference of material of 4th predetermined soft magnetic materials.
Described middle coating layer has one and is seamlessly connected to described insulation extension and by described exhausted
Edge extension around central filler portion, described surrounding cincture portion be seamlessly connected to described absolutely
Edge extension and around described insulation extension, and described top coating layer is seamlessly connected to institute
State central filler portion, described surrounding cincture portion and described insulation extension, wherein said described
Conductive extension is a conductive metal wire, a conductive metal foil, a conductive printing layer and are led
Electric electrodeposited coating one of them, and described conductive extension is along a spiral trajectory upwards
Or one serpentine shape track upwards being extended.
Beneficial effects of the present invention can be, described customization SMD LED surface-mount device LED power inductor
Electrical characteristic with the described first predetermined relative permeability, the described second predetermined magnetic conduction relatively
Coefficient, described 3rd predetermined relative permeability and described 4th predetermined relative permeability
The difference of numerical values recited and be adjusted.Or, described customization SMD LED surface-mount device LED power inductance
The electrical characteristic of device with the described first predetermined soft magnetic materials, described second predetermined soft magnetic materials,
The difference of the use material of described 3rd predetermined soft magnetic materials and described 4th predetermined soft magnetic materials
And be adjusted.
Be further understood that feature and the technology contents of the present invention for enabling, refer to below in connection with
Detailed description of the invention and accompanying drawing, but appended accompanying drawing only provides and uses with reference to explanation, not
It is used for the present invention is any limitation as.
Brief description
Fig. 1 is that the loop construction of the present invention is arranged on the schematic perspective view on Magnetic Substrate；
Fig. 2 is the vertical of the customization SMD LED surface-mount device LED power inductor of a present invention wherein embodiment
Body schematic diagram；
Fig. 3 is the generalized section of the A-A face line of Fig. 2；
Fig. 4 is the vertical of the customization SMD LED surface-mount device LED power inductor of the other embodiment of the present invention
Body schematic diagram；
Fig. 5 is the flow process of the manufacture method of customization SMD LED surface-mount device LED power inductor of the present invention
Figure；
Fig. 6 is the step of the manufacture method of customization SMD LED surface-mount device LED power inductor of the present invention
The generalized section of S100 and S102；
Fig. 7 is the step of the manufacture method of customization SMD LED surface-mount device LED power inductor of the present invention
The generalized section of S104；
Fig. 8 is the step of the manufacture method of customization SMD LED surface-mount device LED power inductor of the present invention
The generalized section of S106 and S108；
Fig. 9 is the step of the manufacture method of customization SMD LED surface-mount device LED power inductor of the present invention
The generalized section of S110；
Figure 10 customizes SMD LED surface-mount device LED power inductor institute in different embodiments for the present invention
Using different Dc bias (amps) obtained by corresponding inductance value (μ H) curve
Figure.
【Description of reference numerals】
SMD LED surface-mount device LED power inductor Z
Granular electronic component G
Initial Magnetic Substrate unit 1 '
Magnetic Substrate 1
Initial magnetic coil unit 2 '
Loop construction 2 conductive extension 21
First conductive tips 211
Second conductive tips 212
Insulation extension 22
Initial magnetic coating unit 3 '
The middle coating layer 31 of magnetic cladding structure 3
Central filler portion 311
Surrounding cincture portion 312
Top coating layer 32
End-electrode structure 4 first end electrode portion 41
Second termination electrode portion 42
Specific embodiment
The following is and relevant " customization disclosed in this invention is described by specific instantiation
The embodiment of SMD LED surface-mount device LED power inductor and preparation method thereof ", those skilled in the art
Member can understand advantages of the present invention and technique effect by content disclosed in this specification.The present invention
Can be implemented or be applied by other different specific embodiments, every thin in this specification
Section may be based on different viewpoints and application, carries out various modifications under without departing from the spirit
With change.In addition, the accompanying drawing of the present invention is only simply schematically illustrate, not according to actual size
Describe, hereby illustrate.Following embodiment will be explained in further detail the related skill of the present invention
Art content, but disclosure of that is not used for limiting the technology category of the present invention.
Refer to shown in Fig. 1 to Fig. 3, wherein Fig. 3 is that the section of the A-A face line of Fig. 2 shows
It is intended to.The present invention provides a kind of customization SMD LED surface-mount device LED power inductor Z, and it includes：One magnetic
Property substrate 1, a loop construction 2, a magnetic cladding structure 3 and an end-electrode structure 4.
First, in conjunction with shown in Fig. 1 and Fig. 3, loop construction 2 is arranged on Magnetic Substrate 1.
For further, loop construction 2 includes a conductive extension 21 and a coated with conductive extension
21 insulation extension 22, and conductive extension 21 have one first conductive tips 211 and
One with respect to the first conductive tips 211 the second conductive tips 212.For further, conductive
Extension 21 and insulation extension 22 all can be extended along a desired trajectory.For example,
As shown in figure 1, conductive extension 21 and insulation extension 22 all can be along spirals upwards
Shape track is being extended, and conductive extension 21 belongs to the inner ring extension of loop construction 2,
And insulation extension 22 then belongs to the outer ring extension of loop construction 2.In addition, according to different
Design requirement, conductive extension 21 can for a conductive metal wire, a conductive metal foil, one pass through
Conductive printing layer and a conductive plated being formed by electro-plating method that printing process is formed
One of layer, but the present invention is not illustrated with this and is limited.
In addition, combining shown in Fig. 2 and Fig. 3, magnetic cladding structure 3 is arranged on Magnetic Substrate 1
On, to cover loop construction 2.For further, magnetic cladding structure 3 includes one and is arranged on
On Magnetic Substrate 1 and be connected to the middle coating layer 31 of insulation extension 22 and a setting is online
Top coating layer 32, conductive extension 21 and magnetic on coil structures 2 and middle coating layer 31
Cladding structure 3 can be electrically insulated from by the isolation of insulation extension 22, and conduction is prolonged
First conductive tips 211 of extending portion 21 and the second conductive tips 212 all can be from middle coating layers 31
Exposed and go out.For example, middle coating layer 31 has one and is seamlessly connected to insulation extension
22 and by insulation extension 22 around central filler portion 311 and be seamlessly connected to insulation
Extension 22 and the cincture portion of surrounding 312 around insulation extension 22, and top coating layer
32 are seamlessly connected to central filler portion 311, surrounding cincture portion 312 and insulation extension 22.
Whereby, middle coating layer 31 all can seamlessly be connected to insulation extension with top coating layer 32
22 so that do not have between insulation extension 22 and middle coating layer 31 any gap or
Space produces, and there will not be any between insulation extension 22 and top coating layer 32
Gap or space produce.
In addition, combining shown in Fig. 2 and Fig. 3, end-electrode structure 4 includes one in electrical contact first
The first end electrode portion 41 and one of conductive tips 211 is corresponding to first end electrode portion 41 and electrical
Contact the second termination electrode portion 42 of the second conductive tips 212.For example, first end electrode portion
41 are arranged on wherein one side of middle coating layer 31 and wherein one of coated magnetic substrate 1
Point and top coating layer 32 a portion, and the second termination electrode portion 42 is arranged on centre
On the other side end of coating layer 31 and the another part of coated magnetic substrate 1 and top coating
The another part of layer 32.
It should be noted that Magnetic Substrate 1 has one first predetermined relative permeability (relative
Permeability) μ 1, the portion of cincture around 312 has one second predetermined relative permeability μ 2,
Middle coating layer 31 has one the 3rd predetermined relative permeability μ 3, and top coating layer 32 has
One the 4th predetermined relative permeability μ 4.For further, the 3rd of central filler portion 311 the
Predetermined relative permeability μ 3 is more than or equal to the 4th predetermined magnetic conduction relatively of top coating layer 32
Coefficient μ 4, the 4th predetermined relative permeability μ 4 of top coating layer 32 is more than or equal to magnetic
First predetermined relative permeability μ 1 of substrate 1, and the first of Magnetic Substrate 1 makes a reservation for relative leading
Magnetic coefficient μ 1 is more than or equal to the second predetermined relative permeability μ 2 in surrounding cincture portion 312.Lift
For example, the first predetermined relative permeability μ 1, the second predetermined relative permeability μ the 2, the 3rd
The scope of predetermined relative permeability μ 3 and the 4th predetermined relative permeability μ 4 is all between 1
To between 53 (can be for example between 1 to 26, or between 26 to 53), so first is pre-
Determine relative permeability μ 1, the second predetermined relative permeability μ the 2, the 3rd makes a reservation for magnetic conduction system relatively
Relation between number μ 3 and the 4th predetermined relative permeability μ 4 may conform to 53 μ, 3 μ 4 μ 1
The conditional of μ 21, but the present invention is not illustrated with this and is limited.For example, as Figure 10
Shown, Figure 10 display present invention customizes SMD LED surface-mount device LED power inductor Z in different embodiments
Different direct current employed in (as shown in the table, using different relative permeabilities) is inclined
The curve chart of the corresponding inductance value (μ H) obtained by pressure (amps).
| μ1 | μ2 | μ3 | μ4 | Inductance initial value (μ H) | |
| Embodiment 1 | 15 | 15 | 15 | 15 | 0.99 |
| Embodiment 2 | 20 | 15 | 35 | 20 | 1.95 |
| Embodiment 3 | 30 | 20 | 60 | 30 | 4.51 |
| Embodiment 4 | 50 | 30 | 80 | 50 | 6.84 |
Whereby, customize SMD LED surface-mount device LED power inductor Z electrical characteristic (such as inductance value,
Rated current, DC impedance and operating temperature range etc.) can make a reservation for relatively lead with first
Magnetic coefficient μ 1, the second predetermined relative permeability μ 2, the 3rd predetermined relative permeability μ 3 and
The difference of numerical values recited of the 4th predetermined relative permeability μ 4 and be adjusted to and meet different clients
The requirement at end.In other words, designer can by change the first predetermined relative permeability μ 1, the
Two predetermined relative permeability μ 2, the 3rd predetermined relative permeability μ 3 and the 4th are predetermined relative
The numerical values recited of magnetic capacity μ 4 customizes the electric of SMD LED surface-mount device LED power inductor Z to adjust
Characteristic, to meet the requirement of different clients, and then makes the present invention have the excellent of customizable
Gesture.
For further, Magnetic Substrate 1, made by one first predetermined soft magnetic materials, insulate
, made by one second predetermined soft magnetic materials, middle coating layer 31 is pre- by one the 3rd for extension 22
Determine made by soft magnetic materials, top coating layer 32 made by one the 4th predetermined soft magnetic materials, and
And the first predetermined soft magnetic materials, the second predetermined soft magnetic materials, the 3rd predetermined soft magnetic materials and
Four predetermined soft magnetic materials are complete phase XOR soft magnetic materials partly different each other each other.Citing comes
Say, predetermined soft magnetic materials can be iron powder system (Iron based metal), such as carbonyl iron dust (CIP),
Ferrum alusil alloy (FeAlSi alloy, sendust), siderochrome silicon alloy (FeCrSi alloy), ferrum
Silicon alloy (FeSi alloy) etc.；Or, predetermined soft magnetic materials can be brown iron oxide system
(ferrite based oxide), nickel zinc iron powder (Ni-Zn ferrite), ambrose alloy zinc-iron powder (Ni-Cu-Zn
) or MnZn iron powder (Mn-Zn ferrite) etc. ferrite.
Whereby, customize the electrical characteristic of SMD LED surface-mount device LED power inductor Z also with first
Predetermined soft magnetic materials, the second predetermined soft magnetic materials, the 3rd predetermined soft magnetic materials and the 4th make a reservation for
Soft magnetic materials be adjusted to the requirement meeting different clients using the difference of material.Change speech
It, designer also can by change the first predetermined soft magnetic materials, the second predetermined soft magnetic materials, the
The difference using material of three predetermined soft magnetic materials and the 4th predetermined soft magnetic materials is adjusting customization
Change the electrical characteristic of SMD LED surface-mount device LED power inductor Z, to meet the requirement of different clients,
And then make the present invention have the advantage of customizable.
It is noted that as shown in figure 4, conductive extension 21 may be designed as along one to
On serpentine shape track being extended.
Refer to shown in Fig. 5 to Fig. 9, the present invention further provides a kind of surface that customizes to stick
The manufacture method type power inductor Z, it comprises the following steps：
First, in conjunction with shown in Fig. 5 and Fig. 6, providing an initial Magnetic Substrate unit 1 ', such as S 100
Shown, wherein initial Magnetic Substrate unit 1 ' is made up of multiple Magnetic Substrates 1.Then, shape
Become an initial magnetic coil unit 2 ' on initial Magnetic Substrate unit 1 ', as shown in S 102,
Wherein initial magnetic coil unit 2 ' is by multiple coils being separately positioned on multiple Magnetic Substrates 1
Structure 2 is formed.For further, each loop construction 2 includes a conductive extension
21 and one coated with conductive extension 21 insulation extension 22, and conductive extension 21 and absolutely
Edge extension 22 extends all along a desired trajectory.For example, initial Magnetic Substrate unit 1 '
It can be semiconductor wafer.
Then, in conjunction with shown in Fig. 5 and Fig. 7, formation one initial magnetic coating unit 3 ' is in first
On beginning Magnetic Substrate unit 1 ', to cover initial magnetic coil unit 2 ', as shown in S 104,
Wherein initial magnetic coating unit 3 ' is separately positioned on multiple Magnetic Substrates 1 by multiple with respectively
The magnetic cladding structure 3 covering multiple loop constructions 2 is formed.For further, each
Individual magnetic cladding structure 3 includes one and is arranged on Magnetic Substrate 1 and is connected to insulation extension 22
The top that is arranged on loop construction 2 and middle coating layer 31 of middle coating layer 31 and drape over one's shoulders
Coating 32, and conductive extension 21 can pass through insulation extension 22 with magnetic cladding structure 3
Isolation to be electrically insulated from.
Next, combining shown in Fig. 5 and Fig. 8, along the B-B line of cut of Fig. 8, cutting is just
Beginning Magnetic Substrate unit 1 ', initial magnetic coil unit 2 ' and initial magnetic coating unit 3 ',
To form multiple granular electronic component G, (Fig. 8 to be illustrated with any two granular electronic component G
Illustrate), wherein initial Magnetic Substrate unit 1 ' is cut to separate multiple Magnetic Substrates 1, just
Beginning magnetic coil unit 2 ' is cut to separate multiple loop constructions 2, initial magnetic coating unit
3 ' cut to separate multiple magnetic cladding structures 3, and each granular electronic component G by
Magnetic Substrate 1, loop construction 2 and magnetic cladding structure 3 are formed, as shown in S106.
And then, in conjunction with shown in Fig. 5 and Fig. 8, at a temperature of between 200 DEG C to 900 DEG C,
Multiple granular electronic component G are carried out densification (densification treatment) simultaneously,
As shown in S108.For example, when loop construction 2 has the conduction of insulation material cladding for surface
During metal wire, densification temperature can be between 150 DEG C to 300 DEG C.When loop construction 2 is many
When individual conductive metal foil and multiple insulating barriers are stacked with, densification temperature can between 150 DEG C extremely
Between 300 DEG C.When loop construction 2 is that multiple conduction printing layers are stacked with multiple insulating barriers,
Densification temperature can be between 600 DEG C to 750 DEG C.When loop construction 2 is multiple conductive plated
When layer and multiple insulating barriers are stacked with, densification temperature can be between 150 DEG C to 300 DEG C.
Finally, in conjunction with shown in Fig. 5 and Fig. 9, two in each granular electronic component G are contrary
One first end electrode portion 41 and one second termination electrode portion 42 are formed on side, to complete to customize respectively
Change the making of SMD LED surface-mount device LED power inductor Z, as shown in S110.For further, lead
Electrically extend portion 21 and there are one first conductive tips 211 and with respect to the first conductive tips 211
Second conductive tips 212, the first conductive tips 211 of conductive extension 21 and the second conductive end
End 212 is all exposed and go out from middle coating layer 31, with first end electrode portion 41 in electrical contact respectively
And the second termination electrode portion 42.In addition, first end electrode portion 41 is arranged on middle coating layer 31
On wherein one side and a portion of coated magnetic substrate 1 and top coating layer 32 wherein
A part, and the second termination electrode portion 42 is arranged on the other side end of middle coating layer 31
And the another part of the another part of coated magnetic substrate 1 and top coating layer 32.
In sum, beneficial effects of the present invention can be, wherein in an embodiment, fixed
The electrical characteristic of inhibition and generation SMD LED surface-mount device LED power inductor Z can be with the first predetermined magnetic conduction system relatively
Number μ 1, the second predetermined relative permeability μ 2, the 3rd predetermined relative permeability μ 3 and the 4th
The difference of numerical values recited of predetermined relative permeability μ 4 and be adjusted to and meet different clients
Require.Or, in an other embodiment, customize SMD LED surface-mount device LED power inductor Z
Electrical characteristic also with the first predetermined soft magnetic materials, the second predetermined soft magnetic materials, the 3rd pre-
Determine being adjusted to and meet using the difference of material of soft magnetic materials and the 4th predetermined soft magnetic materials
The requirement of different clients.
The foregoing is only the preferable possible embodiments of the present invention, the non-guarantor therefore limiting to the present invention
The equivalence techniques change that shield scope, therefore every utilization description of the invention and accompanying drawing content are done,
It is both contained in protection scope of the present invention.
Claims (10)
1. a kind of customize SMD LED surface-mount device LED power inductor it is characterised in that described customization
SMD LED surface-mount device LED power inductor includes：
One Magnetic Substrate；
One loop construction, described loop construction is arranged on described Magnetic Substrate, wherein said line
Coil structures include a conductive extension and the insulation extension of a described conductive extension of cladding, institute
State conductive extension and described insulation extension extends all along a desired trajectory, and described conduction
Extension has one first conductive tips and conductive with respect to the second of described first conductive tips
End；
One magnetic cladding structure, described magnetic cladding structure is arranged on described Magnetic Substrate, with
Cover described loop construction, wherein said magnetic cladding structure includes one and is arranged on described magnetic base
On plate and be connected to the middle coating layer and of described insulation extension and be arranged on described loop construction
And the top coating layer on described middle coating layer, described conductive extension and described magnetic coating
Structure is electrically insulated from by the isolation of described insulation extension, described conductive extension
Described first conductive tips and described second conductive tips all from described middle coating layer exposed and
Go out, described middle coating layer has a surrounding cincture portion；And
One end-electrode structure, described end-electrode structure includes a described first conductive end in electrical contact
The first end electrode portion at end and one corresponds to described first end electrode portion and in electrical contact described second
Second termination electrode portion of conductive tips, wherein said first end electrode portion is arranged on described centre and drapes over one's shoulders
On wherein one side of coating and a portion of the described Magnetic Substrate of cladding and described top is draped over one's shoulders
A portion of coating, and described second termination electrode portion is arranged on the another of described middle coating layer
On an outer side and coat the another of the another part of described Magnetic Substrate and described top coating layer
An outer part；
Wherein, described Magnetic Substrate has one first predetermined relative permeability, described surrounding ring
Around portion, there is one second predetermined relative permeability, described middle coating layer has one the 3rd and makes a reservation for
Relative permeability, described top coating layer has one the 4th predetermined relative permeability, described
The described 3rd predetermined relative permeability in central filler portion is more than or equal to described top coating layer
Described 4th predetermined relative permeability, described top coating layer the described 4th predetermined relatively
Magnetic capacity is more than or equal to the described first predetermined relative permeability of described Magnetic Substrate, and
Described first predetermined relative permeability of described Magnetic Substrate is more than or equal to described surrounding cincture
The described second predetermined relative permeability in portion；
Wherein, the described electrical characteristic customizing SMD LED surface-mount device LED power inductor is with described the
One predetermined relative permeability, described second predetermined relative permeability, described 3rd predetermined phase
The difference of magnetic capacity and the numerical values recited of described 4th predetermined relative permeability is adjusted
Whole.
2. customization SMD LED surface-mount device LED power inductor as claimed in claim 1, its feature exists
In described middle coating layer has one and is seamlessly connected to described insulation extension and by described exhausted
Edge extension around central filler portion, described surrounding cincture portion be seamlessly connected to described absolutely
Edge extension and around described insulation extension, and described top coating layer is seamlessly connected to institute
State central filler portion, described surrounding cincture portion and described insulation extension, wherein said first
Predetermined relative permeability, described second predetermined relative permeability, the described 3rd predetermined relatively
The scope of magnetic capacity and described 4th predetermined relative permeability is all between 1 to 53.
3. customization SMD LED surface-mount device LED power inductor as claimed in claim 1, its feature exists
In, described Magnetic Substrate made by one first predetermined soft magnetic materials, described insulation extension by
Made by one second predetermined soft magnetic materials, described middle coating layer is by one the 3rd predetermined soft magnetic materials
Made, described top coating layer made by one the 4th predetermined soft magnetic materials, and described first
Predetermined soft magnetic materials, described second predetermined soft magnetic materials, described 3rd predetermined soft magnetic materials and
Described 4th predetermined soft magnetic materials is complete phase XOR soft magnetic materials partly different each other each other,
Wherein said conductive extension is a conductive metal wire, a conductive metal foil, a conductive printing layer,
And one conductive electroplated layer one of them, and described conductive extension is along a spiral upwards
Shape track or one serpentine shape track upwards is being extended.
4. a kind of customize SMD LED surface-mount device LED power inductor it is characterised in that described customization
SMD LED surface-mount device LED power inductor includes：
One Magnetic Substrate；
One loop construction, described loop construction is arranged on described Magnetic Substrate, wherein said line
Coil structures include a conductive extension and the insulation extension of a described conductive extension of cladding, institute
State conductive extension and described insulation extension extends all along a desired trajectory, and described conduction
Extension has one first conductive tips and conductive with respect to the second of described first conductive tips
End；
One magnetic cladding structure, described magnetic cladding structure is arranged on described Magnetic Substrate, with
Cover described loop construction, wherein said magnetic cladding structure includes one and is arranged on described magnetic base
On plate and be connected to the middle coating layer and of described insulation extension and be arranged on described loop construction
And the top coating layer on described middle coating layer, described conductive extension and described magnetic coating
Structure is electrically insulated from by the isolation of described insulation extension, described conductive extension
Described first conductive tips and described second conductive tips all from described middle coating layer exposed and
Go out, described middle coating layer has a surrounding cincture portion；And
One end-electrode structure, described end-electrode structure includes a described first conductive end in electrical contact
The first end electrode portion at end and one corresponds to described first end electrode portion and in electrical contact described second
Second termination electrode portion of conductive tips, wherein said first end electrode portion is arranged on described centre and drapes over one's shoulders
On wherein one side of coating and a portion of the described Magnetic Substrate of cladding and described top is draped over one's shoulders
A portion of coating, and described second termination electrode portion is arranged on the another of described middle coating layer
On an outer side and coat the another of the another part of described Magnetic Substrate and described top coating layer
An outer part；
Wherein, described Magnetic Substrate made by one first predetermined soft magnetic materials, prolong by described insulation
, made by one second predetermined soft magnetic materials, described middle coating layer is predetermined soft by one the 3rd for extending portion
Made by magnetic material, described top coating layer is made by one the 4th predetermined soft magnetic materials, and institute
State the first predetermined soft magnetic materials, described second predetermined soft magnetic materials, described 3rd predetermined soft magnetism material
Material and described 4th predetermined soft magnetic materials are complete phase XOR soft magnetism partly different each other each other
Material；
Wherein, the described electrical characteristic customizing SMD LED surface-mount device LED power inductor is with described the
One predetermined soft magnetic materials, described second predetermined soft magnetic materials, described 3rd predetermined soft magnetic materials,
And being adjusted using the difference of material of described 4th predetermined soft magnetic materials.
5. customization SMD LED surface-mount device LED power inductor as claimed in claim 4, its feature exists
In described middle coating layer has one and is seamlessly connected to described insulation extension and by described exhausted
Edge extension around central filler portion, described surrounding cincture portion be seamlessly connected to described absolutely
Edge extension and around described insulation extension, and described top coating layer is seamlessly connected to institute
State central filler portion, described surrounding cincture portion and described insulation extension, wherein said described
Conductive extension is a conductive metal wire, a conductive metal foil, a conductive printing layer and are led
Electric electrodeposited coating one of them, and described conductive extension is along a spiral trajectory upwards
Or one serpentine shape track upwards being extended.
6. customization SMD LED surface-mount device LED power inductor as claimed in claim 4, its feature exists
In described Magnetic Substrate has one first predetermined relative permeability, described surrounding cincture portion tool
There is one second predetermined relative permeability, described middle coating layer has one the 3rd and makes a reservation for relatively lead
Magnetic coefficient, described top coating layer has one the 4th predetermined relative permeability, and described centre is filled out
The described 3rd predetermined relative permeability filling portion is more than or equal to the described of described top coating layer
4th predetermined relative permeability, the described 4th predetermined magnetic conduction system relatively of described top coating layer
Number is more than or equal to the described first predetermined relative permeability of described Magnetic Substrate, and described magnetic
Property substrate the described first predetermined relative permeability be more than or equal to described surrounding cincture portion institute
State the second predetermined relative permeability, wherein said first predetermined relative permeability, described
Two predetermined relative permeabilities, described 3rd predetermined relative permeability and the described 4th make a reservation for
The scope of relative permeability is all between 1 to 53.
7. a kind of customize SMD LED surface-mount device LED power inductor manufacture method it is characterised in that
The described manufacture method customizing SMD LED surface-mount device LED power inductor comprises the following steps：
There is provided an initial Magnetic Substrate unit, wherein said initial Magnetic Substrate unit is by multiple magnetic
Property substrate is formed；
Form an initial magnetic coil unit on described initial Magnetic Substrate unit, wherein said
Initial magnetic coil unit is by multiple loop constructions being separately positioned on multiple described Magnetic Substrates
Formed, each described loop construction includes a conductive extension and a described conduction of cladding is prolonged
The insulation extension of extending portion, and described conductive extension and described insulation extension pre- all along one
Fixed track extends；
Form an initial magnetic coating unit on described initial Magnetic Substrate unit, to cover
State initial magnetic coil unit, wherein said initial magnetic coating unit is separately positioned on by multiple
To be covered each by the magnetic cladding structure institute of multiple described loop constructions on multiple described Magnetic Substrates
Composition, each described magnetic cladding structure includes one and is arranged on described Magnetic Substrate and connects
Middle coating layer and one in described insulation extension is arranged on described loop construction and described centre
Top coating layer on coating layer, described conductive extension passes through institute with described magnetic cladding structure
To be electrically insulated from, described middle coating layer has a surrounding ring for the isolation stating insulation extension
Around portion；
Cut described initial Magnetic Substrate unit, described initial magnetic coil unit and described just
Beginning magnetic coating unit, to form multiple granular electronic components, wherein said initial Magnetic Substrate
Unit is cut to separate multiple described Magnetic Substrates, and described initial magnetic coil unit is cut
To separate multiple described loop constructions, described initial magnetic coating unit is cut multiple to separate
Described magnetic cladding structure, and each described granular electronic component is by described Magnetic Substrate, institute
State loop construction and described magnetic cladding structure is formed；
At a temperature of between 200 DEG C to 900 DEG C, multiple described granular electronic components are entered simultaneously
Row densification；And
One first end electricity is formed respectively on two opposition side ends of each described granular electronic component
Pole portion and one second termination electrode portion, to complete described customization SMD LED surface-mount device LED power inductor
Make, wherein said conductive extension has one first conductive tips and with respect to described first
Second conductive tips of conductive tips, described first conductive tips of described conductive extension and institute
State the second conductive tips all exposed and go out from described middle coating layer, with electrical contact described respectively
First end electrode portion and described second termination electrode portion, wherein said first end electrode portion is arranged on institute
State on wherein one side of middle coating layer and coat a portion and the institute of described Magnetic Substrate
State a portion of top coating layer, and described second termination electrode portion is arranged on described centre and drapes over one's shoulders
On the other side end of the coating and another part of the described Magnetic Substrate of cladding and described top is draped over one's shoulders
The another part of coating.
8. the making side customizing SMD LED surface-mount device LED power inductor as claimed in claim 7
Method is it is characterised in that described Magnetic Substrate has one first predetermined relative permeability, described
Around cincture portion there is one second predetermined relative permeability, described middle coating layer has one the
Three predetermined relative permeabilities, described top coating layer has one the 4th predetermined relative permeability,
The described 3rd predetermined relative permeability in described central filler portion drapes over one's shoulders more than or equal to described top
The described 4th predetermined relative permeability of coating, the described 4th of described top coating layer makes a reservation for
Relative permeability is more than or equal to the described first predetermined magnetic conduction system relatively of described Magnetic Substrate
Number, and the described first predetermined relative permeability of described Magnetic Substrate is more than or equal to described week
Around the described second predetermined relative permeability in portion, wherein said first makes a reservation for magnetic conduction relatively to collarette
Coefficient, described second predetermined relative permeability, described 3rd predetermined relative permeability and
The scope of described 4th predetermined relative permeability is all between 1 to 53, and described customization
The electrical characteristic of SMD LED surface-mount device LED power inductor with the described first predetermined relative permeability,
Described second predetermined relative permeability, described 3rd predetermined relative permeability and described
The difference of numerical values recited of four predetermined relative permeabilities and be adjusted.
9. the making side customizing SMD LED surface-mount device LED power inductor as claimed in claim 7
Method is it is characterised in that described Magnetic Substrate is made by one first predetermined soft magnetic materials, described
, made by one second predetermined soft magnetic materials, described middle coating layer is by one the 3rd for insulation extension
Made by predetermined soft magnetic materials, described top coating layer made by one the 4th predetermined soft magnetic materials,
And it is described first predetermined soft magnetic materials, described second predetermined soft magnetic materials, the described 3rd predetermined soft
Magnetic material and described 4th predetermined soft magnetic materials are that phase XOR completely is partly different each other each other
Soft magnetic materials, the electrical characteristic of wherein said customization SMD LED surface-mount device LED power inductor is with institute
State the first predetermined soft magnetic materials, described second predetermined soft magnetic materials, described 3rd predetermined soft magnetism material
Material and being adjusted using the difference of material of described 4th predetermined soft magnetic materials.
10. the making side customizing SMD LED surface-mount device LED power inductor as claimed in claim 7
Method is seamlessly connected to described insulation extension it is characterised in that described middle coating layer has one
Portion and by described insulation extension around central filler portion, described surrounding cincture portion is seamlessly
It is connected to described insulation extension and around described insulation extension, and described top coating layer is no
It is connected to described central filler portion, described surrounding cincture portion and described insulation extension seam,
Wherein said described conductive extension is a conductive metal wire, a conductive metal foil, a conductive print
One of brush layer and a conductive electroplated layer, and described conductive extension is along one upwards
Spiral trajectory or serpentine shape track upwards being extended.
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| US20140167897A1 (en) * | 2012-12-14 | 2014-06-19 | Samsung Electro-Mechanics Co., Ltd. | Power inductor and method of manufacturing the same |
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| US3068433A (en) * | 1954-04-15 | 1962-12-11 | Sylvania Electric Prod | Electromagnetic coils |
| CN1343996A (en) * | 2000-09-08 | 2002-04-10 | 株式会社村田制作所 | Inductor and method of mfg. same |
| CN101615490A (en) * | 2007-06-26 | 2009-12-30 | 胜美达集团株式会社 | Coil component |
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| CN106449012B (en) | 2018-09-18 |
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