WO2023134436A1

WO2023134436A1 - Integrally formed inductor and manufacturing method therefor

Info

Publication number: WO2023134436A1
Application number: PCT/CN2022/142288
Authority: WO
Inventors: 刘海波; 周小兵; 刘攀
Original assignee: 昆山玛冀电子有限公司
Priority date: 2022-01-11
Filing date: 2022-12-27
Publication date: 2023-07-20
Also published as: TW202329168A; CN114520112A

Abstract

The present disclosure relates to an integrally formed inductor and a manufacturing method therefor. A U-shaped magnetic core, an I-shaped magnetic core, and a flat magnetic core are pressed according to a preset rule. A coil is wound on the I-shaped magnetic core to form an I-shaped magnetic core on which the coil is wound. The I-shaped magnetic core on which the coil is wound is placed in the U-shaped magnetic core, and the two pins of the coil are bent onto the U-shaped magnetic core to form a combined device. The combined device is placed in a specified mold for pressing to form an integrally formed inductor. The density of the pressing can be improved and material characteristics of soft magnetic metal powder are fully exerted; a coil design space is increased; the structure of the coil is simple, production efficiency can be improved, and the production cost can be reduced.

Description

Integrated molded inductor and manufacturing method thereof

technical field

The present disclosure relates to the technical field of integrally formed inductors, in particular to an integrally formed inductor and a manufacturing method thereof.

Background technique

Inductance is a property of a closed loop. When the current passes through the coil, a magnetic field effect is formed in the coil, and the induced magnetic field will generate an induced current to resist the current passing through the coil. Inductance is a circuit parameter that describes the induced electromotive force effect in this coil or in another coil due to the change of current in the coil. The current one-piece inductor is to weld the coil and the lead frame, and then put it into a mold and press it with soft magnetic metal powder. After the pressing is completed, the lead frame is cut and bent to form the electrodes of the inductor. The production process is not only complicated and inefficient, but also the lead frame embedded in the soft magnetic metal powder will greatly reduce the design space of the coil, and the compaction density is low, and the characteristics of the soft magnetic metal powder cannot be fully utilized. The cost of the lead frame is high, and the electrode forming needs to be cut and bent, resulting in waste of materials.

Contents of the invention

Based on this, it is necessary to address the above technical problems to provide an integrated inductor and its production that can increase the compaction density, give full play to the characteristics of the soft magnetic metal powder material, increase the coil design space, improve production efficiency and reduce production costs. method.

In a first aspect, the present disclosure provides a method for manufacturing an integrally formed inductor. The methods include:

Squeeze U-shaped magnetic cores, I-shaped magnetic cores and flat magnetic cores respectively according to preset rules;

Winding a coil on the I-shaped magnetic core to form an I-shaped magnetic core wound with a coil;

Putting the I-shaped magnetic core wound with a coil into the U-shaped magnetic core and bending the two pins of the coil onto the U-shaped magnetic core to form a combined device;

The combined device is put into a designated mold for pressing to form an integrated inductor.

In one of the embodiments, before putting the combined device into a designated mold for pressing to form an integral molded inductor, the method further includes:

placing the flat magnetic core on the I-type magnetic core wound with a coil;

Put the I-shaped magnetic core wound with a coil into the U-shaped magnetic core and bend the two pins of the coil onto the U-shaped magnetic core to form a combined device comprising:

Put the I-shaped magnetic core wound with a coil into the U-shaped magnetic core and bend the two pins of the coil onto the U-shaped magnetic core, place the flat magnetic core on the A combined device is formed on an I-shaped magnetic core wound with a coil.

In one embodiment, the method also includes:

The I-shaped magnetic core wound with the coil is put into the U-shaped magnetic core and the two pins of the coil are bent onto the flat magnetic core to form a combined device.

In one embodiment, the method also includes:

placing the flat magnetic core on the I-type magnetic core wound with a coil;

Put the I-shaped magnetic core wound with a coil into the U-shaped magnetic core and bend the two pins of the coil onto the flat magnetic core to form a combined device comprising:

Put the I-shaped magnetic core wound with coils into the U-shaped magnetic core, place the flat magnetic core on the I-shaped magnetic core wound with coils, and place the two leads of the coils The feet are bent over the planar magnetic core to form a combined assembly.

In one of the embodiments, said respectively pressing the U-shaped magnetic core, the I-shaped magnetic core and the planar magnetic core according to preset rules includes:

According to preset rules, U-shaped magnetic cores, I-shaped magnetic cores and flat magnetic cores are respectively pressed with soft magnetic metal powder.

According to preset rules, U-shaped magnetic cores, I-shaped magnetic cores and planar magnetic cores are respectively pressed by means of cold pressing.

In one of the embodiments, putting the combined device into a designated mold for pressing to form an integral molded inductor includes:

The combined device is put into a designated mold for high-temperature pressing to form an integral molded inductor, and the high-temperature pressing includes high-temperature pressing at 160°C.

In one of the embodiments, the I-shaped magnetic core wound with a coil is put into the U-shaped magnetic core and the two pins of the coil are bent onto the U-shaped magnetic core , forming a combined device comprising:

putting the coil-wound I-shaped magnetic core into the U-shaped magnetic core and bending the two pins of the coil onto the U-shaped magnetic core to form a combined device, wherein the The two pins of the coil are parallel on the U-shaped core.

In one of the embodiments, the I-shaped magnetic core wound with a coil is put into the U-shaped magnetic core and the two pins of the coil are bent onto the flat magnetic core to form a combination Devices include:

Put the I-shaped magnetic core wound with a coil into the U-shaped magnetic core and bend the two pins of the coil on the flat magnetic core to form a combined device, wherein the two pins of the coil pins are parallel on the planar core.

In a second aspect, the present disclosure also provides an integrally formed inductor. Prepared based on the method in any one of the above-mentioned embodiments.

In the embodiment provided by the present disclosure, a U-shaped magnetic core, an I-shaped magnetic core and a flat magnetic core are pre-pressed according to preset rules, and a coil is wound on the I-shaped magnetic core to form an I-shaped magnetic core wound with coils. The I-shaped magnetic core wound with the coil is put into the U-shaped magnetic core and the two pins of the coil are bent onto the U-shaped magnetic core to form a combined device. The combined device is put into a designated mold for pressing to form an integrated inductor. By pre-pressing U-shaped magnetic cores, I-shaped magnetic cores and flat magnetic cores according to preset rules, the density of pressing can be increased, and the material properties of soft magnetic metal powder can be fully utilized; the combined device is put into a designated mold for pressing, Forming an integrally molded inductor can increase the design space of the coil; the structure of the coil is simple, which can improve production efficiency and reduce production cost.

Description of drawings

In order to more clearly illustrate the technical solutions in the embodiments of this specification or the prior art, the following will briefly introduce the drawings that need to be used in the description of the embodiments or the prior art. Obviously, the drawings in the following description are only These are some implementations described in this specification. Those skilled in the art can also obtain other drawings based on these drawings without any creative effort.

Fig. 1 is a schematic flow chart of a method for manufacturing an integrally formed inductor in one embodiment;

Fig. 2 is a schematic flow chart of a method for manufacturing an integrally formed inductor in one embodiment;

Fig. 3 is a schematic flow chart of a method for manufacturing an integrally formed inductor in an embodiment;

4 is a schematic flow diagram of a method for manufacturing an integrally formed inductor in an embodiment;

Figure 5a is a top view of a U-shaped magnetic core of an integrally formed inductor in one embodiment;

Fig. 5b is a three-dimensional perspective view of a U-shaped magnetic core of an integrally formed inductor in one embodiment;

Figure 6a is a top view of an I-shaped magnetic core of an integrally formed inductor in one embodiment;

Fig. 6b is a three-dimensional perspective view of an I-shaped magnetic core of an integrally formed inductor in one embodiment;

Figure 7a is a top view of the planar magnetic core of the integrally formed inductor in one embodiment;

Fig. 7b is a three-dimensional perspective view of a planar magnetic core of an integrally formed inductor in one embodiment;

Fig. 8 is a diagram of an assembly device of an integrally formed inductor in one embodiment.

Detailed ways

In order to make the purpose, technical solutions and advantages of the present disclosure clearer, the present disclosure will be further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described here are only used to explain the present disclosure, not to limit the present disclosure.

It should be noted that when an element is referred to as being “fixed” to another element, it can be directly on the other element or there can also be an intervening element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or intervening elements may also be present. As used herein, the terms "vertical", "horizontal", "left", "right", "upper", "lower", "front", "rear", "circumferential" and similar expressions are based on the The orientation or positional relationship shown in the figure is only for the convenience of describing the present invention and simplifying the description, and does not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be construed as a reference to this invention. Invention Limitations.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the technical field of the invention. The terms used herein in the description of the present invention are for the purpose of describing specific embodiments only, and are not intended to limit the present invention. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

With the development of the electronics industry, the requirements for inductors are getting higher and higher. How to realize an inductor that is small in size, high in power and suitable for installation is an urgent need of the electronics industry. Traditional plug-in inductors, wire-wound chip inductors, etc. can no longer meet the urgent needs of the electronics industry, so a new type of inductor-integrated inductor has emerged. One-piece molded inductors, also called "alloy inductors" or "molded inductors". Compared with traditional inductors, integrated inductors have the following advantages: 1) Magnetic shielding structure, closed magnetic circuit, strong anti-electromagnetic interference, ultra-low beeping, and high-density installation. 2) Low-loss alloy powder die-casting, low impedance, no lead terminals, and small parasitic capacitance. 3) Integral molding structure, solid and firm, precise thickness of the product, durable anti-rust. 4) Small size, high current, can still maintain excellent temperature rise current and saturation current characteristics in high frequency and high temperature environments. 5) Exquisite selection of materials, fine workmanship, wide coverage of working frequency, the frequency range can reach above 5MHz.

In one embodiment, as shown in FIG. 1 , a method for manufacturing an integrally formed inductor is provided, and the method includes the following steps:

S102, press the U-shaped magnetic core, the I-shaped magnetic core and the planar magnetic core respectively according to the preset rules.

Wherein, the preset rules may include rules for limiting the shapes and sizes of U-shaped magnetic cores, I-shaped magnetic cores and planar magnetic cores set according to experience or actual needs. The magnetic core may include an iron powder core, which is mainly obtained by adding an insulating agent and a binder to pure iron powder, and is obtained by extrusion molding. The iron powder core is usually used for a power type magnetic ring inductor. The magnetic core may also include a nickel-zinc-iron core, which is mainly a soft magnetic oxygen core. The magnetic core may also include a manganese zinc core. The magnetic core may also include iron alloys.

Specifically, U-shaped magnetic cores, I-shaped magnetic cores and planar magnetic cores can be respectively pressed according to preset rules. Exemplarily, the I-shaped magnetic core may be circular, and the radius of the circle of the I-shaped magnetic core may be smaller than the radius of the inner circle of the U-shaped magnetic core.

S104, winding a coil on the I-shaped magnetic core to form an I-shaped magnetic core wound with a coil.

Wherein, the coil may include a circular wire winding.

Specifically, coils may be wound on I-shaped cores, and in some embodiments, wire windings may be wound on I-shaped cores.

S106. Put the I-shaped magnetic core wound with the coil into the U-shaped magnetic core and bend the two pins of the coil onto the U-shaped magnetic core to form a combined device.

Wherein, two pins of the coil are bent to the U-shaped magnetic core to form electrodes.

Specifically, the combined device can be formed by putting the I-shaped magnetic core wound with the coil into the U-shaped magnetic core, and then bending the two pins of the coil onto the U-shaped magnetic core. In some embodiments, the radius of the circle of the I-shaped magnetic core wound with a coil is equal to the radius of the inner circle in the U-shaped magnetic core, so that the I-shaped magnetic core wound with a coil can be seamless Put it into the inner circle of the U-shaped magnetic core, bend the two pins of the coil onto the U-shaped magnetic core to use as electrodes, put the coil wound in the U-shaped magnetic core The I-shaped magnet and the U-shaped core together form a combined device.

S108, putting the combination device into a designated mold for pressing to form an integrated inductor.

Wherein, the specified mold may include a mold for pressing an integrally formed inductor that matches the shape of the combined device.

Specifically, the integrated inductor can be formed by putting the combined device into a designated mold for pressing.

In the manufacturing method of the above integral molding inductor, the U-shaped magnetic core, the I-shaped magnetic core and the flat magnetic core are pre-pressed according to preset rules, and the coil is wound on the I-shaped magnetic core to form an I-shaped magnetic core wound with a coil. core. The I-shaped magnetic core wound with the coil is put into the U-shaped magnetic core and the two pins of the coil are bent onto the U-shaped magnetic core to form a combined device. The combined device is put into a designated mold for pressing to form an integrated inductor. By pre-pressing U-shaped magnetic cores, I-shaped magnetic cores and flat magnetic cores according to preset rules, the density of pressing can be increased, and the material properties of soft magnetic metal powder can be fully utilized; the combined device is put into a designated mold for pressing, Forming an integrally molded inductor can increase the design space of the coil; the structure of the coil is simple, which can improve production efficiency and reduce production cost.

In one embodiment, as shown in FIG. 2 , step S108 puts the combined device into a designated mold for pressing, and before forming an integrally molded inductor, the method further includes the following steps:

S202. Place a flat magnetic core on the I-shaped magnetic core wound with a coil.

Specifically, a planar magnetic core may be placed on the I-shaped magnetic core wound with coils. In some embodiments, placement of the planar magnetic core may include completely covering the coil-wound I-shaped magnetic core.

Step S106 puts the I-shaped magnetic core wound with a coil into the U-shaped magnetic core and bends the two pins of the coil onto the U-shaped magnetic core to form a combined device comprising:

S204, putting the I-shaped magnetic core wound with a coil into the U-shaped magnetic core and bending the two pins of the coil onto the U-shaped magnetic core, and placing the flat magnetic core on A combined device is formed on the I-shaped magnetic core wound with coils.

Wherein, the radius of the circle of the I-shaped magnetic core wound with the coil is equal to the radius of the inner circle of the U-shaped magnetic core. Bending the two legs of the coil onto the U-shaped magnetic core may include bending the two legs of the collar onto the U-shaped magnetic core to serve as electrodes.

Specifically, the I-shaped magnetic core wound with a coil can be put into the U-shaped magnetic core, and then the two pins of the coil are bent onto the U-shaped magnetic core as electrodes, and the flat magnetic core is placed on the winding On the I-shaped magnetic core with coils, a combined device is formed. In some embodiments, the I-shaped magnetic core wound with a coil can be put into the U-shaped magnetic core, wherein the circle radius of the I-shaped magnetic core wound with a coil and the inner circle of the U-shaped magnetic core The radii are equal in size. Put the I-shaped magnetic core wound with a coil into the inner circle of the U-shaped magnetic core seamlessly, then bend the two pins of the coil to the U-shaped magnetic core as electrodes, and place the flat magnetic core A combined device is formed on the I-shaped magnetic core wound with coils, wherein the combined device includes an I-shaped magnetic core wound with coils, a U-shaped magnetic core and a planar magnetic core.

In this embodiment, by bending the two pins of the coil on the U-shaped magnetic core as electrodes and placing the flat magnetic core on the I-shaped magnetic core wound with the coil, a combined device is formed, which can increase the The design space of the coil is large, and the structure of the coil is simple, which can improve the production efficiency.

In one embodiment, the method also includes:

Specifically, by putting the I-shaped magnetic core wound with a coil into the U-shaped magnetic core, and bending the two pins of the coil onto the flat magnetic core as electrodes, the I-shaped magnetic cores wound with coils, U-shaped magnetic cores and flat magnetic cores with coil pins form a combined device. In some embodiments, the I-shaped magnetic core wound with coils is put into the U-shaped magnetic core, wherein the circle radius of the I-shaped magnetic core wound with coils and the U-shaped magnetic core The inner circle radii are equal in size. The two pins of the coil are bent onto the flat magnetic core to form a composite device, and the composite device may include an I-shaped magnetic core and a U-shaped magnetic core wound with a coil.

In this embodiment, the combined device is formed by putting the I-shaped magnetic core wound with a coil into the U-shaped magnetic core and bending the two pins of the coil onto the flat magnetic core. , can increase the design space of the coil and improve the production efficiency.

In one embodiment, as shown in Figure 3, the method further includes:

S302. Place a flat magnetic core on the I-shaped magnetic core wound with a coil.

Specifically, a planar magnetic core may be placed on the I-shaped magnetic core wound with coils.

S304. Put the I-shaped magnetic core wound with coils into the U-shaped magnetic core, place the flat magnetic core on the I-shaped magnetic core wound with coils, and place the two A pin is bent onto the planar magnetic core to form a combined device.

Specifically, the I-shaped magnetic core wound with coils can be put into the U-shaped magnetic core, and then the flat magnetic core is placed on the I-shaped magnetic core wound with coils, and the two coils The pins are bent onto the flat magnetic core as electrodes, and the I-shaped magnetic core wound with coils, the U-shaped magnetic core and the flat magnetic core with coil pins form a combined device. In some embodiments, the I-shaped magnetic core wound with a coil can be put into the U-shaped magnetic core, wherein the circle radius of the I-shaped magnetic core wound with a coil and the inner circle of the U-shaped magnetic core The radii are equal in size. Place the I-shaped magnetic core wound with a coil into the inner circle of the U-shaped magnetic core seamlessly, then bend the two pins of the coil onto the flat magnetic core as electrodes, and place the flat magnetic core on the A combined device is formed on the I-shaped magnetic core wound with a coil, wherein the combined device includes an I-shaped magnetic core wound with a coil, a U-shaped magnetic core and a flat magnetic core.

In this embodiment, by bending the two pins of the coil onto the flat magnetic core, and placing the flat magnetic core on the I-shaped magnetic core wound with the coil, the design space of the coil can be increased, and The structure of the coil is simple, and the production efficiency can be improved.

In one embodiment, said pressing U-shaped magnetic cores, I-shaped magnetic cores and planar magnetic cores respectively according to preset rules includes:

Wherein, the soft magnetic metal powder may include alloy powder for metal magnetic powder cores. The magnetic core may include an iron powder core, which is mainly obtained by adding an insulating agent and a binder to pure iron powder, and is obtained by extrusion molding. The iron powder core is usually used for a power type magnetic ring inductor. The magnetic core may also include a nickel-zinc-iron core, which is mainly a soft magnetic oxygen core. The magnetic core may also include a manganese zinc core. The magnetic core may also include iron alloys.

Specifically, U-shaped magnetic cores, I-shaped magnetic cores and planar magnetic cores can be respectively pressed with soft magnetic metal powder according to preset rules. Exemplarily, U-shaped magnetic cores, I-shaped magnetic cores and planar magnetic cores can be respectively pressed with metal magnetic powder cores and alloy powders according to preset rules.

In this embodiment, by pressing the U-shaped magnetic core, the I-shaped magnetic core and the flat magnetic core respectively with the soft magnetic metal powder, the pressing density can be increased, and the material properties of the soft magnetic metal powder can be fully utilized.

Wherein, cold pressing may include pressing at room temperature. The magnetic core may include an iron powder core, which is mainly obtained by adding an insulating agent and a binder to pure iron powder, and is obtained by extrusion molding. The iron powder core is usually used for a power type magnetic ring inductor. The magnetic core may also include a nickel-zinc-iron core, which is mainly a soft magnetic oxygen core. The magnetic core may also include a manganese zinc core. The magnetic core may also include iron alloys.

Specifically, U-shaped magnetic cores, I-shaped magnetic cores and planar magnetic cores can be respectively pressed by cold pressing according to preset rules.

In this embodiment, the U-shaped magnetic core, the I-shaped magnetic core and the flat magnetic core are respectively pressed by cold pressing, so that the pressing density can be increased and the material properties of the soft magnetic metal powder can be fully utilized.

In one embodiment, putting the combined device into a designated mold for pressing to form an integrally molded inductor includes:

Wherein, high-temperature pressing may include pressing at a temperature above 100°C.

Specifically, the combined device can be put into a designated mold for high-temperature pressing to form an integral molded inductor. In some embodiments, the combined device can be put into a designated mold for high-temperature pressing at 160° C. to form an integrated molded inductor.

In this embodiment, the integrated inductor is formed by putting the combined device into a designated mold for high-temperature pressing, wherein the high-temperature pressing can include high-temperature pressing at 160°C, which can make the integrally-molded inductor more firm and The design space of the coil can be increased, the production efficiency can be increased, and the production cost can be reduced.

In one embodiment, step S106 puts the I-shaped magnetic core wound with a coil into the U-shaped magnetic core and bends two pins of the coil onto the U-shaped magnetic core, Forming a combined device includes:

Specifically, the I-shaped magnetic core wound with a coil can be put into the U-shaped magnetic core and the two pins of the coil are bent onto the U-shaped magnetic core, and the The two pins of the coil are parallel on said U-shaped magnetic core, forming a combined device. In some embodiments, the I-shaped magnetic core wound with a coil can be put into a U-shaped magnetic core, wherein the circle radius of the I-shaped magnetic core wound with a coil and the inner circle of the U-shaped magnetic core The radii are equal in size. Put the I-shaped magnetic core wound with a coil into the inner circle of the U-shaped magnetic core seamlessly, and then bend the two pins of the coil onto the U-shaped magnetic core as electrodes, and the coil The two pins are parallel on the U-shaped core.

In this embodiment, by putting the I-shaped magnetic core wound with a coil into the U-shaped magnetic core and bending the two pins of the coil onto the U-shaped magnetic core, a combined The device, wherein the two pins of the coil are parallel on the U-shaped magnetic core, so that the structure of the coil is simple and the production efficiency can be improved.

In one embodiment, step S304 puts the I-shaped magnetic core wound with the coil into the U-shaped magnetic core and bends the two pins of the coil onto the flat magnetic core to form a combined device include:

Specifically, the I-shaped magnetic core wound with a coil can be put into the U-shaped magnetic core and the two pins of the coil are bent onto the flat magnetic core, and the two pins of the coil Pins are parallel on the planar magnetic core to form a combined device. In some embodiments, the I-shaped magnetic core wound with a coil can be put into a U-shaped magnetic core, wherein the circle radius of the I-shaped magnetic core wound with a coil and the inner circle of the U-shaped magnetic core The radii are equal in size. Put the I-shaped magnetic core wound with a coil into the inner circle of the U-shaped magnetic core seamlessly, and then bend the two pins of the coil onto the flat magnetic core as electrodes, and the coil’s Two pins are parallel on the planar core.

In this embodiment, the combined device is formed by putting the I-shaped magnetic core wound with a coil into the U-shaped magnetic core and bending the two pins of the coil onto the flat magnetic core, wherein , the two pins of the coil are parallel on the flat magnetic core, so that the structure of the coil is simple and the production efficiency can be improved.

In one embodiment, as shown in FIG. 4 , a method for manufacturing an integrally formed inductor is provided, and the method includes the following steps:

S402, press the U-shaped magnetic core, the I-shaped magnetic core and the planar magnetic core respectively according to the preset rules.

S404, winding a coil on the I-shaped magnetic core to form an I-shaped magnetic core wound with a coil.

S406. Place the flat magnetic core on the I-shaped magnetic core wound with the coil.

S408, putting the I-shaped magnetic core wound with a coil into the U-shaped magnetic core and bending the two pins of the coil onto the U-shaped magnetic core, and placing the flat magnetic core on A combined device is formed on the I-shaped magnetic core wound with coils.

S410, putting the I-shaped magnetic core wound with coils into the U-shaped magnetic core, placing the flat magnetic core on the I-shaped magnetic core wound with coils, and placing the two coils of the coil A pin is bent onto the planar magnetic core to form a combined device.

S412, putting the combined device into a designated mold for pressing to form an integrated molded inductor.

In one embodiment, an integrally formed inductor is provided, as shown in FIG. 5 a , a top view of a U-shaped magnetic core of the integrally formed inductor, wherein the z-axis is a coordinate axis perpendicular to the plane of the U-shaped magnetic core. Figure 5b shows a three-dimensional perspective view of a U-shaped magnetic core with an integrally formed inductor. FIG. 6 a shows a top view of an I-shaped magnetic core with an integrally formed inductor, wherein the z-axis is a coordinate axis perpendicular to the plane of the I-shaped magnetic core. Fig. 6b shows a three-dimensional perspective view of an I-shaped magnetic core with an integrally formed inductor. Fig. 7a shows a top view of the planar magnetic core of the integrally formed inductor, and Fig. 7b shows a three-dimensional perspective view of the planar magnetic core of the integrally formed inductor, wherein the z-axis is a coordinate axis perpendicular to the plane of the planar magnetic core. FIG. 8 shows a combined device diagram of an integrally formed inductor, wherein the z-axis is a coordinate axis perpendicular to the plane of the combined device.

It should be understood that although the various steps in the flow chart of the accompanying drawings are displayed sequentially according to the arrows, these steps are not necessarily executed sequentially in the order indicated by the arrows. Unless otherwise specified herein, there is no strict order restriction on the execution of these steps, and these steps can be executed in other orders. Moreover, at least some of the steps in the drawings may include multiple steps or stages, these steps or stages are not necessarily executed at the same time, but may be executed at different times, and the execution order of these steps or stages is also It is not necessarily performed sequentially, but may be performed alternately or alternately with other steps or at least a part of steps or stages in other steps.

In one embodiment, an integrally formed inductor is provided, which is manufactured based on any one of the above-mentioned methods.

The technical features of the above embodiments can be combined arbitrarily. To make the description concise, all possible combinations of the technical features in the above embodiments are not described. However, as long as there is no contradiction in the combination of these technical features, they should be It is considered to be within the range described in this specification.

The above-mentioned embodiments only express several implementation modes of the present disclosure, and the description thereof is relatively specific and detailed, but should not be construed as limiting the patent scope of the present disclosure. It should be noted that those skilled in the art can make several modifications and improvements without departing from the concept of the present disclosure, and these all belong to the protection scope of the present disclosure. Therefore, the protection scope of the present disclosure should be determined by the appended claims.

Claims

A method for manufacturing an integrally formed inductor, characterized in that the method comprises:

Squeeze U-shaped magnetic cores, I-shaped magnetic cores and flat magnetic cores respectively according to preset rules;

Winding a coil on the I-shaped magnetic core to form an I-shaped magnetic core wound with a coil;

Putting the I-shaped magnetic core wound with a coil into the U-shaped magnetic core and bending the two pins of the coil onto the U-shaped magnetic core to form a combined device;

The combined device is put into a designated mold for pressing to form an integrated inductor.
The method according to claim 1, characterized in that, before putting the combination device into a designated mold for pressing to form an integrally molded inductor, the method further includes:

placing the flat magnetic core on the I-type magnetic core wound with a coil;

Put the I-shaped magnetic core wound with a coil into the U-shaped magnetic core and bend the two pins of the coil onto the U-shaped magnetic core to form a combined device comprising:

Put the I-shaped magnetic core wound with a coil into the U-shaped magnetic core and bend the two pins of the coil onto the U-shaped magnetic core, place the flat magnetic core on the A combined device is formed on an I-shaped magnetic core wound with a coil.
The method according to claim 1, further comprising:

The I-shaped magnetic core wound with the coil is put into the U-shaped magnetic core and the two pins of the coil are bent onto the flat magnetic core to form a combined device.
The method according to claim 3, characterized in that the method further comprises:

placing the flat magnetic core on the I-type magnetic core wound with a coil;

Put the I-shaped magnetic core wound with a coil into the U-shaped magnetic core and bend the two pins of the coil onto the flat magnetic core to form a combined device comprising:

Put the I-shaped magnetic core wound with coils into the U-shaped magnetic core, place the flat magnetic core on the I-shaped magnetic core wound with coils, and place the two leads of the coils The feet are bent over the planar magnetic core to form a combined assembly.
The method according to any one of claims 1 to 4, wherein said pressing U-shaped magnetic cores, I-shaped magnetic cores and flat magnetic cores respectively according to preset rules comprises:

According to preset rules, U-shaped magnetic cores, I-shaped magnetic cores and flat magnetic cores are respectively pressed with soft magnetic metal powder.
The method according to claim 1, wherein said pressing the U-shaped magnetic core, the I-shaped magnetic core and the planar magnetic core respectively according to preset rules comprises:

According to preset rules, U-shaped magnetic cores, I-shaped magnetic cores and planar magnetic cores are respectively pressed by means of cold pressing.
The method according to claim 1, characterized in that, putting the combined device into a designated mold for pressing to form an integrally molded inductor comprises:

The combined device is put into a designated mold for high-temperature pressing to form an integral molded inductor, and the high-temperature pressing includes high-temperature pressing at 160°C.
The method according to claim 1, wherein the I-shaped magnetic core wound with a coil is put into the U-shaped magnetic core and the two pins of the coil are bent to the On the above-mentioned U-shaped magnetic core, the forming combination device includes:

putting the coil-wound I-shaped magnetic core into the U-shaped magnetic core and bending the two pins of the coil onto the U-shaped magnetic core to form a combined device, wherein the The two pins of the coil are parallel on the U-shaped core.
The method according to claim 3, characterized in that the I-shaped magnetic core wound with a coil is placed into the U-shaped magnetic core and the two pins of the coil are bent to a flat plate on the magnetic core, forming a combined device comprising:

Put the I-shaped magnetic core wound with a coil into the U-shaped magnetic core and bend the two pins of the coil on the flat magnetic core to form a combined device, wherein the two pins of the coil pins are parallel on the planar core.
An integrally formed inductor, characterized in that it is manufactured based on the method described in any one of claims 1-9.