US 12,148,564 B2
Manufacturing method of an integrally formed inductor
Xinshu Yu, Guangdong (CN); Youyun Li, Guangdong (CN); Shengcheng Xia, Guangdong (CN); Zehong Yao, Guangdong (CN); Yupeng Hong, Guangdong (CN); Yingying Wang, Guangdong (CN); Qiang Su, Guangdong (CN); Wanhe Yi, Guangdong (CN); and Xin Che, Guangdong (CN)
Assigned to Shenzhen Sunlord Electronics Co., Ltd., Guangdong (CN)
Filed by Shenzhen Sunlord Electronics Co., Ltd., Guangdong (CN)
Filed on May 18, 2021, as Appl. No. 17/322,920.
Application 17/322,920 is a continuation of application No. PCT/CN2020/129432, filed on Nov. 17, 2020.
Prior Publication US 2022/0157519 A1, May 19, 2022
Int. Cl. H01F 7/06 (2006.01); H01F 1/24 (2006.01); H01F 17/04 (2006.01); H01F 27/255 (2006.01); H01F 27/29 (2006.01); H01F 41/02 (2006.01)
CPC H01F 41/0246 (2013.01) [H01F 1/24 (2013.01); H01F 17/045 (2013.01); H01F 27/255 (2013.01); H01F 27/292 (2013.01); H01F 2017/048 (2013.01)] 8 Claims
OG exemplary drawing
 
1. A manufacturing method of an integrally formed inductor, comprising the following steps of:
sintering a soft magnetic material to prepare a magnetic core plate, wherein the magnetic core plate is provided with a plurality of grooves, and a magnetic core middle column is formed in each groove;
respectively putting prefabricated hollow coils into the plurality of grooves, wherein the magnetic core middle column penetrates into the coils, and two terminals of the coils are left outside the grooves;
putting the magnetic core plate provided with the coils into a forming die, adding a soft magnetic material in a fluid state, and integrally forming the soft magnetic material in the fluid state on the magnetic core plate through pressing; wherein enabling a temperature of the forming die to reach 120-200° C., adding the soft magnetic material liquefiable at 120-200° C., integrally forming the soft magnetic material in the fluid state on the magnetic core plate by using the pressure of less than 20 MPa, and baking at 100-300° C. for no less than 1 hour to completely solidify organic resin in the soft magnetic material in the fluid state;
exposing two terminals of the coils contained in the pressed magnetic core plate by removing a part of the soft magnetic material, and cutting the magnetic core plate into a plurality of corresponding semi-finished inductors corresponding to each coil;
coating the semi-finished inductor with an insulating material to form an insulating coating layer, and exposing only two terminals of the coils;
forming electrodes of the integrally formed inductor by metallizing areas where two terminals of the coils are exposed on a surface of the insulating coating layer.