CN216597243U - Inductor - Google Patents

Abstract

The utility model belongs to the technical field of inductors, and discloses an inductor, wherein an enameled flat copper wire is adopted to manufacture a first coil and a second coil, so that on one hand, the thickness-width ratio of the coil can be improved, and meanwhile, the production processes of vacuum coating, photoetching, electroplating copper deposition and the like are omitted, the production process is effectively simplified, and the production cost is reduced; on the other hand copper line adopts the enameled wire structure, the insulating effect of coil has directly been realized, make an end face of first coil can set up with an end face laminating of second coil, and another end face of first coil can hold the inner wall laminating setting in chamber with the base plate, another end face of second coil also can hold the inner wall laminating setting in chamber with the base plate, the setting of insulating substrate and insulating film has been saved, the structure of inductor has effectively been simplified, production technology has also been simplified simultaneously and manufacturing cost has been reduced.

Description

Inductor

Technical Field

The utility model relates to the technical field of inductors, in particular to an inductor.

Background

The inductor is a component capable of converting electric energy into magnetic energy and storing the magnetic energy, and with the continuous development of electronic power technology and the diversified use requirements of people for inductor products, inductor products with high current, low loss and low cost are gradually favored by the market. The larger the aspect ratio of the inductor coil, the lower the resistance of the coil, i.e., the lower the loss.

In order to improve the thickness-to-width ratio of the coil, the prior art discloses an inductor, which includes a first coil and a second coil, each coil is formed by at least two layers of wire patterns, and each coil is provided with a surface coating covering the conductive patterns, and the outer side of the surface coating is provided with a plating layer, so as to achieve the effect of increasing the thickness-to-width ratio of the coil. In addition, in order to achieve an insulating effect between the two coils and between each coil and the substrate, it is necessary to provide an insulating substrate between the two coils and to lay an insulating film between each coil and the substrate.

The coil is manufactured by adopting the processes of vacuum coating, photoetching, electroplating and copper deposition, the insulating film is manufactured by screen printing, photoresist exposure, development or spraying application, and the like, and the insulating substrate is manufactured by adopting materials such as a polypropylene glycol substrate or a ferrite substrate, so that the manufacturing process is complex and the production cost is high. Therefore, how to make the coil have a higher thickness-to-width ratio, simplify the production process and reduce the production cost is a technical problem that needs to be solved by those skilled in the art.

SUMMERY OF THE UTILITY MODEL

An object of the present invention is to provide an inductor, which can improve the thickness-to-width ratio of a coil and simplify the manufacturing process to reduce the manufacturing cost.

In order to achieve the purpose, the utility model adopts the following technical scheme:

the utility model provides an inductor, includes base plate, first coil and second coil, and the base plate is equipped with and holds the chamber, and first coil and second coil are all arranged in and are held the intracavity, and a side end face of first coil and a side end face laminating of second coil, the opposite side end face of first coil and the inner wall laminating that holds the chamber, the opposite side end face of second coil and the inner wall laminating that holds the chamber, first coil and second coil are made by enameled rectangular copper wire.

Optionally, the substrate is provided with a first notch and a second notch, the winding end of the first coil is connected to the first outer electrode through the first notch, and the winding end of the second coil is connected to the second outer electrode through the second notch.

Optionally, the substrates include a first substrate, a second substrate, and a third substrate, the first substrate, the second substrate, and the third substrate are stacked in sequence, the second substrate is provided with a through hole, and the through hole, the first substrate, and the third substrate form an accommodating cavity.

Optionally, the first notch and the second notch are both opened on the second substrate.

Optionally, the first substrate, the second substrate and the third substrate are equal in thickness.

Optionally, the substrate is made of amorphous soft magnetic alloy powder.

Optionally, a gap between the substrate and the first and second coils is filled with a slurry made of amorphous soft magnetic alloy powder.

Optionally, the amorphous soft magnetic alloy powder has two or more kinds of particle sizes.

Has the advantages that:

according to the inductor provided by the utility model, the first coil and the second coil are made of the enameled flat copper wire, so that on one hand, the production processes of vacuum coating, photoetching, electroplating and copper deposition and the like can be saved while the thickness-width ratio of the coil is improved, the production flow is effectively simplified, and the production cost is reduced; on the other hand copper line adopts the enameled wire structure, the insulating effect of coil has directly been realized, make an end face of first coil can set up with an end face laminating of second coil, and another end face of first coil can hold the inner wall laminating setting in chamber with the base plate, another end face of second coil also can hold the inner wall laminating setting in chamber with the base plate, the setting of insulating substrate and insulating film has been saved, the structure of inductor has effectively been simplified, production technology has also been simplified simultaneously and manufacturing cost has been reduced.

Drawings

Fig. 1 is an exploded view of an inductor product according to the present invention;

fig. 2 is a schematic diagram of an assembly structure of an inductance product provided by the present invention;

fig. 3 is a cross-sectional view in the a-a direction of fig. 2 not showing the first and second external electrodes.

In the figure:

100. a substrate; 110. a first substrate; 120. a second substrate; 121. a first cut; 122. a second cut; 130. a third substrate; 200. a first coil; 300. a second coil; 400. a first external electrode; 500. And a second external electrode.

Detailed Description

The present invention will be described in further detail with reference to the accompanying drawings and examples. It is to be understood that the specific embodiments described herein are merely illustrative of the utility model and are not limiting of the utility model. It should be further noted that, for the convenience of description, only some of the structures related to the present invention are shown in the drawings, not all of the structures.

In the description of the present invention, unless expressly stated or limited otherwise, the terms "connected," "connected," and "fixed" are to be construed broadly, e.g., as meaning permanently connected, removably connected, or integral to one another; can be mechanically or electrically connected; either directly or indirectly through intervening media, either internally or in any other relationship. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art.

In the present invention, unless otherwise expressly stated or limited, "above" or "below" a first feature means that the first and second features are in direct contact, or that the first and second features are not in direct contact but are in contact with each other via another feature therebetween. Also, the first feature being "on," "above" and "over" the second feature includes the first feature being directly on and obliquely above the second feature, or merely indicating that the first feature is at a higher level than the second feature. A first feature being "under," "below," and "beneath" a second feature includes the first feature being directly under and obliquely below the second feature, or simply meaning that the first feature is at a lesser elevation than the second feature.

In the description of the present embodiment, the terms "upper", "lower", "right", etc. are used in an orientation or positional relationship based on that shown in the drawings only for convenience of description and simplicity of operation, and do not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and thus, should not be construed as limiting the present invention. Furthermore, the terms "first" and "second" are used only for descriptive purposes and are not intended to have a special meaning.

The embodiment provides an inductor, which can achieve the technical effects of improving the thickness-width ratio of a coil, simplifying the production process and reducing the production cost.

Specifically, as shown in fig. 1 and 2, this inductor includes base plate 100, first coil 200 and second coil 300, base plate 100 is equipped with and holds the chamber, first coil 200 and second coil 300 are all arranged in and are held the intracavity, and a side end face of first coil 200 and a side end face laminating of second coil 300, the opposite side end face of first coil 200 and the inner wall laminating that holds the chamber, the opposite side end face of second coil 300 and the inner wall laminating that holds the chamber, first coil 200 and second coil 300 are made by the enameled rectangular copper wire. The first coil 200 and the second coil 300 are made of the enameled flat copper wire, so that the coils have a high thickness-to-width ratio, processes of vacuum coating, photoetching, electroplating and copper deposition and the like for making the coils with the high thickness-to-width ratio are omitted, the production flow is effectively simplified, and the production cost is reduced; on the other hand, the coils have an insulation effect, so that the effect that one side end face of the first coil 200 is directly attached to one side end face of the second coil 300, the other side end face of the first coil 200 is directly attached to the inner wall of the accommodating cavity, and the other side end face of the second coil 300 is directly attached to the inner wall of the accommodating cavity can be realized in the structure of the inductor, the production processes of arranging the insulation substrate 100 between the two coils and arranging the insulation film between the coils and the accommodating cavity are omitted, the production process of the inductor is further simplified, the production cost is reduced, and the overall dimension of the inductor product is reduced.

Optionally, as shown in fig. 1 and 2, the inductor further includes a first external electrode 400 and a second external electrode 500, the substrate 100 is provided with a first notch 121 and a second notch 122, the winding end of the first coil 200 is connected to the first external electrode 400 through the first notch 121, the winding end of the second coil 300 is connected to the second external electrode 500 through the second notch 122, and the first external electrode 400 and the second external electrode 500 are used to electrically connect the coils to the outside.

Optionally, with continued reference to fig. 1 and fig. 2, the substrate 100 includes a first substrate 110, a second substrate 120, and a third substrate 130, the first substrate 110, the second substrate 120, and the third substrate 130 are stacked in sequence, and the second substrate 120 is provided with a through hole, which forms the accommodating cavity with the first substrate 110 and the third substrate 130. The above-mentioned structural form of the substrate 100 can effectively simplify the production process when producing the substrate 100, for example, cutting the same piece of raw magnetic tape to form three substrates 100, forming a through hole on one of the substrates 100, stacking the substrate 100 with the through hole on one substrate 100 without the through hole, placing a coil at the through hole, and then stacking the other substrate 100 without the through hole on the substrate 100 with the through hole to complete the assembly of the inductor product.

Furthermore, the first notch 121 and the second notch 122 are both formed on the second substrate 120, and a through hole, the first notch 121 and the second notch 122 are simultaneously formed on the same substrate 100, thereby further simplifying the production process of the substrate 100.

Optionally, the thicknesses of the first substrate 110, the second substrate 120, and the third substrate 130 are equal, so that a process of cutting the substrates 100 with different thicknesses is omitted, and the manufacturing process of the substrates 100 is further simplified.

Optionally, the substrate 100 is made of amorphous soft magnetic alloy powder, and the magnetic saturation of the amorphous soft magnetic alloy powder is higher, so that the saturation current of the inductor can be effectively improved, and the characteristics of the inductor product with high current and low loss are further realized.

Further, the amorphous soft magnetic alloy powder is subjected to insulation coating treatment to improve the insulation performance of the substrate 100.

Further, the gaps between the substrate 100 and the first and second coils 200 and 300 are filled with a slurry made of amorphous soft magnetic alloy powder, thereby further increasing the saturation current of the inductor. Preferably, as shown in fig. 3, the gap-filling paste is the same material as the material of the substrate 100, which further simplifies the production process of the inductor product.

Specifically, the substrate 100 and the slurry are prepared by mixing amorphous soft magnetic alloy powder, a plasticizer, a binder, a curing agent, a dispersant and an organic solvent according to a certain ratio, that is, the substrate 100 is formed by curing the slurry. The substrate 100 can be prepared by mixing the amorphous soft magnetic alloy powder and the thermosetting adhesive through high-temperature baking and curing, so that the processes of glue discharging, sintering and the like are omitted, the production cost is effectively reduced, and the production process is simplified. In addition, in the traditional substrate manufacturing process, the colloid is discharged after the substrate is sintered, the resistivity of the magnet is greatly reduced, the eddy current loss is increased, and the outer electrode is very easy to creep and plate when the outer electrode is processed. Thirdly, in the traditional process, the combination and connection of a plurality of substrates are realized through a die pressing process, and in the die pressing process, the problem of damage of a coating film on the outer layer of a coil is very easy to occur in high-pressure die pressing, so that the problem of short circuit of an inductor product is caused; according to the process method provided by the embodiment, the amorphous soft magnetic alloy powder is mixed with solvents such as the plasticizer, the adhesive, the curing agent and the like to prepare the substrate 100, so that the assembly process of the plurality of substrates 100 can be realized through a simple low-pressure pressing process, the breakage rate of the coil enameled wire is reduced, and the risk of short circuit of an inductor product is further reduced.

Alternatively, the amorphous soft magnetic alloy powder may be one or a mixture of two or more of fesicrir, FeSiAl, FeNi, and nanocrystals.

Optionally, the amorphous soft magnetic alloy powder has two or more types of particle sizes, and the smaller powder particles can fill gaps between the larger powder particles, so as to improve the density of the substrate 100 and the filling slurry, and improve the magnetic permeability of the inductor product. In the technical solution provided in this embodiment, the amorphous soft magnetic alloy powder with two particle sizes is selected, so that the density of the substrate 100 is improved, and the production process is simplified. Preferably, the D50 value for large particle size: the D50 value of the small particle size is more than or equal to 2.5, so that the effect of better magnetic permeability of the inductance product can be realized. Preferably, the specific gravity of the large particle diameter to the small particle diameter is 75 to 90%: 25-10%, thereby also realizing the effect of better magnetic permeability of the inductance product. Preferably, the large-particle-diameter powder D50 is 35 μm or less, and inductor loss can be reduced while ensuring extremely poor accuracy of the thickness of the substrate 100.

According to the inductor provided by the embodiment, the first coil 200 and the second coil 300 are made of the enameled flat copper wire, so that the coils have a high thickness-to-width ratio, processes such as vacuum coating, photoetching and electroplating copper deposition for making the coils with the high thickness-to-width ratio are omitted, the production flow is effectively simplified, and the production cost is reduced; on the other hand, the coils have an insulation effect, so that the effect that one side end face of the first coil 200 is directly attached to one side end face of the second coil 300, the other side end face of the first coil 200 is directly attached to the inner wall of the accommodating cavity, and the other side end face of the second coil 300 is directly attached to the inner wall of the accommodating cavity can be realized in the structure of the inductor, the production processes of arranging the insulation substrate 100 between the two coils and arranging the insulation film between the coils and the accommodating cavity are omitted, the production process of the inductor is further simplified, the production cost is effectively reduced, and the overall dimension of an inductor product is also reduced.

The embodiment also provides a manufacturing method of the inductor, which comprises the following steps:

1) manufacturing a raw magnetic tape;

2) slicing: slicing the raw tape to form a first substrate 110, a third substrate 130 and a second substrate semi-finished product;

3) punching: punching a through hole in the middle of the second substrate semi-finished product, and forming a first notch 121 and a second notch 122 on two opposite side walls of the through hole to manufacture a second substrate 120; of course, in other embodiments, the through hole, the first notch 121 and the second notch 122 may be formed at other positions;

4) first stacking: stacking a second substrate 120 on the first substrate 110, the through holes of the second substrate 120 forming open cavities with the first substrate 110;

5) coil implantation: placing a first coil 200 and a second coil 300 into the open cavity, attaching one side end face of the first coil 200 to one side end face of the second coil 300, placing the winding end part of the first coil 200 into the first notch 121, and placing the winding end part of the second coil 300 into the second notch 122, wherein the first coil 200 and the second coil 300 are both made of enameled flat copper wires;

6) filling slurry: pouring slurry into gaps among the first coil 200, the second coil 300 and the open cavity to fill and level the pits, and drying;

7) and (3) second stacking: stacking the third substrate 130 on the second substrate 120 and performing a first press-fitting to form a bar;

8) and (3) second pressing: carrying out second pressing on the blocks;

9) cutting: cutting the barblock subjected to the second pressing to obtain a single product;

10) baking and curing: baking the single product;

11) processing an outer electrode: the first notch 121 and the second notch 122 are coated with silver paste to make an external electrode.

According to the manufacturing method of the inductor, the first coil 200 and the second coil 300 are manufactured by using the enameled flat copper wire, so that the coils have a high thickness-to-width ratio, processes of vacuum coating, photoetching, electroplating and copper deposition and the like for manufacturing the coils with the high thickness-to-width ratio are omitted, the production flow is effectively simplified, and the production cost is reduced; on the other hand, the coils have an insulation effect, so that the effect that one side end face of the first coil 200 is directly attached to one side end face of the second coil 300, the other side end face of the first coil 200 is directly attached to the inner wall of the accommodating cavity, and the other side end face of the second coil 300 is directly attached to the inner wall of the accommodating cavity can be realized in the structure of the inductor, the production process that the insulating substrate 100 is arranged between the two coils and the insulating film is arranged between the coils and the accommodating cavity is omitted, the production process of the inductor is further simplified, and the production cost is effectively reduced. In addition, the first substrate 110, the third substrate 130 and the second substrate semi-finished product are manufactured by slicing the raw magnetic sheets, and the second substrate 120 is manufactured by directly punching holes on the second substrate semi-finished product, so that the three substrates 100 are stacked and coils are implanted to complete the assembly of the substrates 100 and the coils, thereby further simplifying the production process and reducing the production cost.

Before the step 1), optionally, a batching process can also be adopted, specifically, amorphous soft magnetic alloy powder, an adhesive and a curing agent are mixed to prepare slurry, and the slurry is utilized to prepare the raw magnetic sheet. The amorphous soft magnetic alloy powder has higher magnetic saturation, so that the saturation current of the inductor can be effectively improved, and the characteristics of high current and low loss of the inductor product are further realized. In addition, the substrate 100 can be manufactured by adopting a method of mixing the amorphous soft magnetic alloy powder and the thermosetting adhesive and baking and curing at high temperature, so that the processes of glue discharging, sintering and the like are omitted, the production cost is effectively reduced, and the production process is simplified. In addition, in the traditional substrate manufacturing process, the colloid is discharged after the substrate is sintered, the resistivity of the magnet is greatly reduced, the eddy current loss is increased, and the outer electrode is very easy to creep and plate when the outer electrode is processed. Thirdly, in the traditional process, the assembly of a plurality of substrates is realized through a die pressing process, and in the die pressing process, the problem of short circuit of an inductor product caused by the breakage of a coating film on the outer layer of a coil is very easy to occur in high-pressure die pressing; according to the process method provided by the embodiment, the amorphous soft magnetic alloy powder, the adhesive, the curing agent and other solvents are mixed to prepare the substrate 100, so that the assembly process of the plurality of substrates 100 can be realized through a simple low-pressure pressing process, the probability of damage of the coil enameled wire is reduced, and the risk of short circuit of an inductor product is further reduced.

Further, the slurry in the step 6) includes amorphous soft magnetic alloy powder, an adhesive and a curing agent, that is, the slurry filled in the gap in the step 6) is the same as the slurry for manufacturing the raw magnetic tape in the step 1), so that the saturation current of the inductor is further improved, and further, the characteristics of the inductor product with high current and low loss are realized.

The curing temperature of the material sheet prepared by mixing the adhesive and the curing agent is required to be higher than 150 ℃, and optionally, the adhesive and the curing agent can be epoxy resin or high-temperature curing glue prepared by mixing polyimide and polycyanamine according to a certain proportion.

Further, the amorphous soft magnetic alloy powder may be one or a mixture of two or more of fesicrib, fesai, FeNi, and nanocrystals. The amorphous soft magnetic alloy powder has more than two types of particle sizes, and the smaller powder particles can fill gaps among the larger powder particles, so that the density of the substrate 100 and the slurry is improved, and the magnetic conductivity of an inductance product is improved. In the technical solution provided in this embodiment, the amorphous soft magnetic alloy powder with two particle sizes is selected, so that the density of the substrate 100 is improved, and the production process is simplified. Preferably, the large particle size: the D50 value of the small particle size is more than or equal to 2.5, so that the effect of better magnetic permeability of the inductance product can be realized. Preferably, the specific gravity of the large particle diameter to the small particle diameter is 75 to 90%: 25-10%, thereby also realizing the effect of better magnetic permeability of the inductance product. Preferably, the large-particle-diameter powder D50 is 35 μm or less, and inductor loss can be reduced while ensuring extremely poor accuracy of the thickness of the substrate 100.

Optionally, the amorphous soft magnetic alloy powder is processed by insulation coating to improve the insulation performance of the substrate 100.

Further, in the step 1) and the step 6), the raw magnetic tape and the slurry further comprise a plasticizer, a dispersing agent and an organic solvent, so that the overall strength of the inductor product is improved, and the amorphous soft magnetic alloy powder is dispersed in the slurry more uniformly.

Alternatively, in step 1), a casting machine may be selected to uniformly coat the mixed slurry on the PET film, and the PET film is dried to form a raw tape. The thickness range of the magnetic generating tape can be 100-300 mu m, and the tape casting preparation can be carried out according to different thickness requirements.

Optionally, in the step 2), the size of the cut pieces of the first substrate 110, the third substrate 130, and the second substrate semi-finished product may be determined according to the requirement, and is preferably 6 to 10 inches, and preferably, the size of the cut pieces of the first substrate 110, the third substrate 130, and the second substrate semi-finished product is the same, so as to simplify the cutting process.

Optionally, in step 3), a hole punching machine may be used to punch holes on the second substrate semi-finished product according to the product design requirements. After the punching is finished, the alignment mark required by the cutting in the step 9) can be carved by utilizing laser.

Optionally, in the step 5), the first coil 200 and the second coil 300 may be made by winding an enameled flat copper wire by using a winding machine, a ratio of a thickness of the copper wire to a wire width of the copper wire is greater than 2 to improve a thickness-to-width ratio of the coil, a thickness of the enameled film wrapping the copper wire is preferably 3 to 8 μm, and lead wires of the two coils are led out in an outer layer manner to simplify an implantation process of the coil.

Optionally, in the step 6), the gap may be filled with the slurry by means of squeegee printing, and the drying temperature is 80-100 ℃ and the time is 30-60 min.

Optionally, in the step 7), the pressure of the first pressing is 15 to 20 tons, and the dwell time is 20 to 50 s.

Optionally, the second pressing in the step 8) is performed on the bar blocks by using an isostatic pressing machine, and the uniformity of pressing on the bar blocks can be effectively improved by using the isostatic pressing machine; the pressure of the second pressing is 25-40MPa, the time is 15-30min, the temperature is 60-90 ℃, the pressing in the temperature range can enable the substrate 100 and the adhesive in the gap filling slurry to be softened appropriately, gaps of the blocks are filled under the action of the pressure, and the density of the blocks is improved.

Optionally, the cutting process in step 9) may employ a dicing saw to cut the bar.

Optionally, in the step 10), the baking and curing temperature is controlled at 160-.

Optionally, in the step 11), the silver paste is a low-temperature cured silver paste, so that a silver firing process can be omitted, the curing temperature is 120-.

After the step 11), optionally, there may be a step 12) of an external electrode electroplating process, specifically, electroplating a nickel layer and a tin layer on the terminal silver, where the nickel layer has a thickness of 1-5 μm and the tin layer has a thickness of 5-12 μm, so as to protect the terminal silver.

After the step 12), optionally, there may be a step 13) of an electrical property testing process for the inductor product, so as to improve the factory yield of the inductor product.

The method for manufacturing the inductor provided in this embodiment first uses the enameled rectangular copper wire to manufacture the first coil 200 and the second coil 300, the coil has higher thickness-width ratio, simultaneously, the processes of vacuum coating, photoetching, electroplating and copper deposition and the like are saved, the production flow is effectively simplified, the production cost is reduced, when the inductor is assembled, the effects that one side end face of the first coil 200 is directly attached to one side end face of the second coil 300, the other side end face of the first coil 200 is directly attached to the inner wall of the accommodating cavity, and the other side end face of the second coil 300 is directly attached to the inner wall of the accommodating cavity can be achieved, the production process that the insulating substrate 100 is arranged between the two coils and the insulating film is arranged between the coils and the accommodating cavity is omitted, the production process of the inductor is further simplified, and the production cost is effectively reduced. Secondly, the first substrate 110, the third substrate 130 and the second substrate semi-finished product are manufactured by slicing the green magnetic sheets in the manufacturing of the substrate 100, and the second substrate 120 is manufactured by directly punching holes on the second substrate semi-finished product, so that the three substrates 100 are stacked and coils are implanted to complete the assembly of the substrate 100 and the coils, the production process is further simplified, and the production cost is reduced. Thirdly, the substrate 100 and the slurry filled between the substrate 100 and the coil are made of the slurry mixed by the amorphous soft magnetic alloy powder, the adhesive and the curing agent, so that the saturation current of the inductor is effectively improved, and the characteristics of the inductor product with high current and low loss are realized; the colloid is baked and cured and then is filled in the grain gaps of the amorphous soft magnetic alloy powder, so that the insulating property of the inductor product is effectively improved; the assembly process of the plurality of substrates 100 can be realized by a simple low-voltage pressing process, so that the probability of damage of the coil enameled wire is reduced, and the risk of short circuit of the inductor product is further reduced.

The following describes the inductor manufacturing method provided in this embodiment by taking several specific sets of parameters as examples:

first example

The design size of the inductor is as follows: the manufacturing method of the inductor comprises the following steps of 1.2mm of L, 1.0mm of W, less than 0.6mm of H, 100nH of inductance, less than or equal to 40 mOmega of RDC, rated current greater than 1A, 45 mu m of designed electrode line width and 100 mu m of line thickness, and 200 mu m of first substrate 110, second substrate 120 and third substrate 130, wherein the manufacturing method of the inductor comprises the following steps:

1) preparing materials: the amorphous soft magnetic alloy powder is prepared by uniformly mixing amorphous soft magnetic alloy powder, a plasticizer, an adhesive, a curing agent, a dispersing agent and an organic solvent according to a certain proportion to form slurry with a certain viscosity, wherein the coarse powder is FeSiCr, the particle size D50 is 20 micrometers, the fine powder is FeNi, the particle size D50 is 3.6 micrometers, the mass ratio of the coarse powder to the fine powder is 8:2, the amorphous soft magnetic alloy powder is subjected to insulation coating treatment, the curing temperature of a tablet prepared by mixing the adhesive and the curing agent is 180 ℃, and the tablet is high-temperature curing glue prepared by mixing epoxy resin and polycyanamine according to a certain proportion.

2) Manufacturing a raw magnetic tape: uniformly coating the mixed slurry on a PET film with the thickness of 50 mu m by using a casting machine, and drying to form a magnetic tape with the thickness of 200 mu m, wherein the stripping force is 10-25 g/inch, the drying parameter is 60-90 ℃, and the speed is 3-5 m/min.

3) Slicing: cutting the green tape into a first substrate 110, a third substrate 130 and a second substrate semi-finished product, wherein the length and the width of the first substrate semi-finished product are 6 inches;

4) punching: the second substrate 120 is manufactured by punching a through hole in a designated position (usually, a center position) of the second substrate semi-finished product according to design requirements, and forming a first notch 121 and a second notch 122 in two opposite sidewalls of the through hole. Then, engraving a registration mark required by cutting in the subsequent step by using laser;

5) first stacking: stacking a second substrate 120 on the first substrate 110, the through holes of the second substrate 120 forming open cavities with the first substrate 110;

6) implanting a coil: the first coil 200 and the second coil 300 are placed into the open cavity, one side end face of the first coil 200 is attached to one side end face of the second coil 300, the winding end portion of the first coil 200 is placed into the first notch 121, the winding end portion of the second coil 300 is placed into the second notch 122, the first coil 200 and the second coil 300 are both made of enameled flat copper wires wound by a winding machine, the wire width of the enameled flat copper wires is 45 micrometers, the wire thickness is 100 micrometers, the thickness of the enameled film wrapping the copper wires is 4 micrometers, and lead leading-out modes of the two coils are outer layer leading-out.

7) Filling slurry: pouring the slurry prepared in the step 1) into gaps among the first coil 200, the second coil 300 and the open cavity in a scraper printing mode to fill and level the pits, and drying at the temperature of 90 ℃ for 50 min;

8) and (3) second stacking: stacking the third substrate 130 on the second substrate 120, and performing a first pressing process to form a bar block, wherein the pressing pressure is 20 tons, and the pressure maintaining time is 30 s;

9) and (3) second pressing: putting the blocks into an isostatic pressing machine for secondary pressing, wherein the pressing pressure is 25MPa, the time is 30min, and the temperature is 85 ℃;

10) cutting: cutting the barblock subjected to the second pressing by using a dicing saw according to the mark carved by the laser in the step 4) to obtain a single product;

11) baking and curing: baking the cut single product at the baking temperature of 200 ℃ for 3 hours to solidify the colloid;

12) processing an outer electrode: and coating the low-temperature cured silver paste on the outer sides of the first notch 121 and the second notch 122 to be used as an outer electrode led out by the inner electrode, and then baking at 175 ℃ for 60 min. 13) Electroplating of an external electrode: electroplating a nickel layer and a tin layer on the terminal silver, wherein the thickness of the nickel layer is 1-5 mu m, and the thickness of the tin layer is 5-12 mu m;

14) and (5) testing the electrical property.

Second example

Design size of inductor appearance: the manufacturing method of the inductor comprises the following steps of (1) setting L to 2mm, W to 1.2mm, H to less than 0.8mm, inductance to 1 muH, RDC to less than or equal to 90m omega, rated current to more than 2.5A, design electrode line width to be 55 muM, line thickness to be 130 muM, and thicknesses of the first substrate 110, the second substrate 120 and the third substrate 130 to be 260 muM:

1) preparing materials: the preparation method comprises the steps of uniformly mixing amorphous soft magnetic alloy powder, a plasticizer, an adhesive, a curing agent, a dispersing agent and an organic solvent according to a certain proportion to form slurry with certain viscosity, wherein in the amorphous soft magnetic alloy powder, coarse powder is nanocrystalline, the particle size D50 is 18 microns, fine powder is FeSiAl, the particle size D50 is 4 microns, the mass ratio of the coarse powder to the fine powder is 75:25, the amorphous soft magnetic alloy powder is subjected to insulation coating treatment, the curing temperature of a tablet prepared by mixing the adhesive and the curing agent is 180 ℃, and the tablet is high-temperature curing adhesive prepared by mixing epoxy resin and polycyanamine according to a certain proportion.

2) Manufacturing a raw magnetic tape: uniformly coating the mixed slurry on a PET film with the thickness of 50 mu m by using a casting machine, and drying to form a green magnetic tape with the thickness of 260 mu m, wherein the stripping force is 10-25 g/inch, the drying parameter is 60-90 ℃, and the speed is 3-5 m/min.

3) Slicing: cutting the green magnetic tape into a first substrate 110, a third substrate 130 and a second substrate semi-finished product, wherein the length and the width of the first substrate semi-finished product are 6 inches;

4) punching: the second substrate 120 is manufactured by punching a through hole in a designated position (usually, a center position) of the second substrate semi-finished product according to design requirements, and forming a first notch 121 and a second notch 122 in two opposite sidewalls of the through hole. Then, engraving a registration mark required by cutting in the subsequent step by using laser;

5) first stacking: stacking a second substrate 120 on the first substrate 110, the through holes of the second substrate 120 forming open cavities with the first substrate 110;

6) implanting a coil: the first coil 200 and the second coil 300 are placed into the open cavity, one side end face of the first coil 200 is attached to one side end face of the second coil 300, the winding end portion of the first coil 200 is placed into the first notch 121, the winding end portion of the second coil 300 is placed into the second notch 122, the first coil 200 and the second coil 300 are both made of enameled flat copper wires wound by a winding machine, the wire width of the enameled flat copper wires is 55 micrometers, the wire thickness is 130 micrometers, the thickness of the enameled film wrapping the copper wires is 4 micrometers, and lead leading-out modes of the two coils are outer layer leading-out.

7) Filling slurry: pouring the slurry prepared in the step 1) into gaps among the first coil 200, the second coil 300 and the open cavity in a scraper printing mode to fill and level the pits, and drying at the temperature of 90 ℃ for 50 min;

8) and (3) second stacking: stacking the third substrate 130 on the second substrate 120 and performing a first pressing to form a bar block, wherein the pressing pressure is 15 tons, and the pressure maintaining time is 50 s;

9) and (3) second pressing: putting the blocks into an isostatic pressing machine for secondary pressing, wherein the pressing pressure is 40MPa, the time is 20min, and the temperature is 85 ℃;

10) cutting: cutting the barblock subjected to the secondary pressing by using a dicing saw according to the mark carved by the laser in the step 4) to obtain a single product;

11) baking and curing: baking the cut single product at 180 ℃ for 4h to solidify the colloid;

12) processing an outer electrode: and coating the low-temperature cured silver paste on the outer sides of the first notch 121 and the second notch 122 to be used as an outer electrode led out by the inner electrode, and then baking at the baking temperature of 180 ℃ for 60 min.

13) Electroplating of an external electrode: electroplating a nickel layer and a tin layer on the terminal silver, wherein the thickness of the nickel layer is 1-5 mu m, and the thickness of the tin layer is 5-12 mu m;

14) and (5) testing the electrical property.

Third example

Design size of inductor appearance: the manufacturing method of the inductor comprises the following steps of 1.2mm for L, 1.0mm for W, less than 0.6mm for H, 1 muH for inductance, less than or equal to 190 mOmega for RDC, more than 1.0A for rated current, 35 muM for designed electrode line width and 90 muM for line thickness, and 180 muM for the first substrate 110, the second substrate 120 and the third substrate 130, wherein the manufacturing method comprises the following steps:

1) preparing materials: the preparation method comprises the steps of uniformly mixing amorphous soft magnetic alloy powder, a plasticizer, an adhesive, a curing agent, a dispersing agent and an organic solvent according to a certain proportion to form slurry with certain viscosity, wherein in the amorphous soft magnetic alloy powder, coarse powder is nanocrystalline, the particle size D50 is 24 micrometers, fine powder is nanocrystalline, the particle size D50 is 5 micrometers, the mass ratio of the coarse powder to the fine powder is 9:1, the amorphous soft magnetic alloy powder is subjected to insulation coating treatment, the curing temperature of a prepared tablet is 180 ℃, and the tablet is high-temperature curing adhesive prepared by mixing epoxy resin and polycyanamine according to a certain proportion.

2) Manufacturing a raw magnetic tape: uniformly coating the mixed slurry on a PET film with the thickness of 50 mu m by using a casting machine, and drying to form a green magnetic tape with the thickness of 180 mu m, wherein the stripping force is 10-25 g/inch, the drying parameter is 60-90 ℃, and the speed is 3-5 m/min.

3) Slicing: cutting the green magnetic tape into a first substrate 110, a third substrate 130 and a second substrate semi-finished product, wherein the length and the width of the first substrate semi-finished product are 6 inches;

4) punching: the second substrate 120 is fabricated by punching a through hole in a predetermined position (usually a center position) of the second substrate semi-finished product according to design requirements, and forming a first notch 121 and a second notch 122 in two opposite side walls of the through hole. Then, engraving a registration mark required by cutting in the subsequent step by using laser;

5) first stacking: stacking a second substrate 120 on the first substrate 110, the through holes of the second substrate 120 forming open cavities with the first substrate 110;

6) implanting a coil: the first coil 200 and the second coil 300 are placed in the opening cavity, one side end face of the first coil 200 is attached to one side end face of the second coil 300, the winding end portion of the first coil 200 is placed in the first notch 121, the winding end portion of the second coil 300 is placed in the second notch 122, the first coil 200 and the second coil 300 are both made of enameled flat copper wires wound by a winding machine, the wire width of the enameled flat copper wires is 35 micrometers, the wire thickness is 90 micrometers, the enameled film thickness wrapping the copper wires is 6 micrometers, and the lead leading-out modes of the two coils are outer leading-out.

7) Filling slurry: pouring the slurry prepared in the step 1) into gaps among the first coil 200, the second coil 300 and the open cavity in a scraper printing mode to fill and level the pits, and drying at the temperature of 90 ℃ for 50 min;

8) and (3) second stacking: stacking the third substrate 130 on the second substrate 120 and performing a first pressing to form a bar block, wherein the pressing pressure is 18 tons and the pressure maintaining time is 40 s;

9) and (3) second pressing: putting the blocks into an isostatic pressing machine for secondary pressing, wherein the pressing pressure is 30MPa, the time is 30min, and the temperature is 75 ℃;

10) cutting: cutting the barblock subjected to the secondary pressing by using a dicing saw according to the mark carved by the laser in the step 4) to obtain a single product;

11) baking and curing: baking the cut single product at 185 ℃, and keeping the temperature for 3.5 hours to solidify the colloid;

12) processing an outer electrode: and coating the low-temperature cured silver paste on the outer sides of the first notch 121 and the second notch 122 to be used as an outer electrode led out by the inner electrode, and then baking at the baking temperature of 180 ℃ for 60 min.

13) Electroplating of an external electrode: electroplating a nickel layer and a tin layer on the terminal silver, wherein the thickness of the nickel layer is 1-5 mu m, and the thickness of the tin layer is 5-12 mu m;

14) and (5) testing the electrical property.

The following are electrical performance test data for the three exemplary inductor products described above, where sample 1 is the first exemplary product, sample 2 is the second exemplary product, and sample 3 is the third exemplary product:

item	Sample 1	Sample 2	Sample 3
				Product size L/mm	1.21	2.08	1.21
Product size W/mm	1.02	1.21	1.03
				Product size H/mm	0.57	0.73	0.52
Inductance L/nH	100.28	1001.12	1000.25
				RDC/mΩ	28	75	178
Rated current	1.2	2.9	1.1

According to the data, the product manufactured by the method has good performance consistency and meets the design requirements.

It should be understood that the above-described embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the embodiments of the present invention. Numerous obvious variations, adaptations and substitutions will occur to those skilled in the art without departing from the scope of the utility model. And are neither required nor exhaustive of all embodiments. Any modification, equivalent replacement, and improvement made within the spirit and principle of the present invention should be included in the protection scope of the claims of the present invention.

Claims (8)

1. The utility model provides an inductor, its characterized in that includes base plate (100), first coil (200) and second coil (300), base plate (100) are equipped with and hold the chamber, first coil (200) reach second coil (300) are all arranged in hold the intracavity, a side end face of first coil (200) with a side end face laminating of second coil (300), the opposite side terminal surface of first coil (200) with the inner wall laminating that holds the chamber, the opposite side terminal surface of second coil (300) with the inner wall laminating that holds the chamber, first coil (200) and second coil (300) are made by enameled flat copper wire.

2. The inductor according to claim 1, further comprising a first external electrode (400) and a second external electrode (500), wherein the substrate (100) is provided with a first cutout (121) and a second cutout (122), wherein a winding end of the first coil (200) is connected to the first external electrode (400) through the first cutout (121), and a winding end of the second coil (300) is connected to the second external electrode (500) through the second cutout (122).

3. The inductor according to claim 2, characterized in that the substrate (100) comprises a first substrate (110), a second substrate (120) and a third substrate (130), the first substrate (110), the second substrate (120) and the third substrate (130) being stacked in sequence, the second substrate (120) being provided with a through hole forming the receiving cavity with the first substrate (110) and the third substrate (130).

4. An inductor according to claim 3, characterized in that the first cut-out (121) and the second cut-out (122) both open on the second substrate (120).

5. An inductor according to claim 3 or 4, characterized in that the first substrate (110), the second substrate (120) and the third substrate (130) are of equal thickness.

6. An inductor according to any of claims 1-4, characterized in that the substrate (100) is made of amorphous soft magnetic alloy powder.

7. An inductor according to claim 6, characterized in that the gap between the substrate (100) and the first (200) and second (300) coils is filled with a slurry made of amorphous soft magnetic alloy powder.

8. An inductor according to claim 7, wherein the amorphous soft magnetic alloy powder has two or more kinds of particle sizes.

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