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CN116168942A - A kind of preparation method of power inductor - Google Patents

A kind of preparation method of power inductor Download PDF

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Publication number
CN116168942A
CN116168942A CN202211563016.4A CN202211563016A CN116168942A CN 116168942 A CN116168942 A CN 116168942A CN 202211563016 A CN202211563016 A CN 202211563016A CN 116168942 A CN116168942 A CN 116168942A
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groove
magnetic core
planar coil
silver paste
power inductor
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李正龙
林涛
吴长和
王劲
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Jiangsu Lineprinting Materials Co ltd
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Jiangsu Lineprinting Materials Co ltd
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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206Manufacturing of magnetic cores by mechanical means
    • H01F41/0246Manufacturing of magnetic circuits by moulding or by pressing powder
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/34Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06Coil winding
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06Coil winding
    • H01F41/076Forming taps or terminals while winding, e.g. by wrapping or soldering the wire onto pins, or by directly forming terminals from the wire
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/12Insulating of windings
    • H01F41/122Insulating between turns or between winding layers
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02BCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B70/00Technologies for an efficient end-user side electric power management and consumption
    • Y02B70/10Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Coils Or Transformers For Communication (AREA)

Abstract

本发明提供一种功率电感制备方法,涉及电感制备技术领域,包括:制备磁性粉体,并将磁性粉体压制形成带有凹槽的矩形磁芯,凹槽沿矩形磁芯的侧面分别开口;制备银浆,并将银浆印刷至凹槽内,随后烘烤得到烘烤后磁芯;绕制与凹槽的形状相适配的平面线圈,平面线圈具有向外引出的两个引出端子,随后将平面线圈和烘烤后磁芯压合为一体,使得两个引出端子分别由凹槽的侧面开口处引出,形成电感半成品;对电感半成品进行退火处理,随后对引出端子进行电极成型处理,以制备得到功率电感。有益效果是将低温银浆和矩形磁芯一起进行烘烤、退火处理,使电感固有的交流损耗降至最低;在压制成型的矩形磁芯中印刷银浆,使大电流能够安全通过。

Figure 202211563016

The invention provides a method for preparing a power inductance, which relates to the technical field of inductance preparation, comprising: preparing magnetic powder, and pressing the magnetic powder to form a rectangular magnetic core with grooves, and the grooves are respectively opened along the sides of the rectangular magnetic core; Prepare the silver paste, print the silver paste into the groove, and then bake to obtain the baked magnetic core; wind a planar coil that matches the shape of the groove, and the planar coil has two lead-out terminals that are drawn out. Then the planar coil and the baked magnetic core are pressed together, so that the two lead-out terminals are respectively led out from the side opening of the groove to form an inductor semi-finished product; the inductor semi-finished product is annealed, and then the lead-out terminals are subjected to electrode forming treatment, To prepare power inductors. The beneficial effect is that the low-temperature silver paste and the rectangular magnetic core are baked and annealed together, so that the inherent AC loss of the inductor is minimized; the silver paste is printed in the pressed rectangular magnetic core, so that large current can pass through safely.

Figure 202211563016

Description

Preparation method of power inductor
Technical Field
The invention relates to the technical field of inductor preparation, in particular to a power inductor preparation method.
Background
With the rapid promotion of informatization and intelligent development, the electronic products are increasingly widely applied to high-current low-loss devices. At present, the integrated inductor and the ferrite inductor are widely included in the application, but the integrated inductor cannot anneal at high temperature to achieve the purpose of reducing loss because the temperature resistance level of the insulating layer on the surface of the copper coil is below 220 ℃. The sintering temperature of the ferrite inductor needs to reach above 800 ℃, and the loss after sintering is far higher than that of the metal soft magnetic alloy subjected to annealing treatment at about 350-600 ℃, so that how to prepare the high-current low-loss power inductor is a technical problem to be solved.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides a power inductor preparation method, which comprises the following steps:
step S1, preparing magnetic powder, and pressing the magnetic powder to form a rectangular magnetic core with grooves, wherein the grooves are respectively opened along the side surfaces of the rectangular magnetic core;
s2, preparing silver paste, printing the silver paste into the grooves, and then baking to obtain baked magnetic cores;
step S3, winding a planar coil with the shape matched with that of the groove, wherein the planar coil is provided with two outgoing terminals which are led outwards, and then pressing the planar coil and the baked magnetic core into a whole, so that the two outgoing terminals are led out from the side opening of the groove respectively to form an inductance semi-finished product;
and S4, annealing the inductor semi-finished product, and then performing electrode forming treatment on the lead-out terminal to prepare the power inductor.
Preferably, the magnetic powder comprises a soft magnetic metal material and a resin material, and the ratio of the resin material in the magnetic powder is 1% -5%.
Preferably, the soft magnetic metal material comprises at least one of carbonyl iron powder material, ferrosilicon alloy material, ferronickel molybdenum material and nanocrystalline soft magnetic material;
the resin material includes at least one of an epoxy resin and a phenolic resin.
Preferably, the step S3 includes:
step S31, winding a single-layer multi-strand copper wire coated with an inorganic insulating layer to form the planar coil which is matched with the shape of the groove, wherein the planar coil is provided with two lead-out terminals led out outwards;
step S32, placing the planar coil in the groove of the baked magnetic core, and leading out two leading-out terminals from the side openings of the groove respectively;
and step S33, filling powder into the grooves, and pressing the grooves into a whole, so that the powder fills up the gaps among the strands of copper wires of the planar coil and the grooves, and an inductance semi-finished product is formed.
Preferably, the inorganic insulating layer is made of an inorganic particulate material including at least one of silica, alumina and silicon carbide.
Preferably, in the step S2, the silver paste is printed into the recess, and then baked at a baking temperature of 100 ℃ to 200 ℃.
Preferably, in the step S4, an annealing temperature for annealing the inductor semi-finished product is 400 ℃ to 700 ℃.
Preferably, the sintering temperature of the silver paste is below 700 ℃.
The technical scheme has the following advantages or beneficial effects:
1) Roasting and annealing the low-temperature silver paste and the rectangular magnetic core together to minimize inherent alternating current loss of the inductor;
2) Printing silver paste in the rectangular magnetic core formed by pressing, so that large current can safely pass through the rectangular magnetic core;
3) The copper wire coated with the inorganic insulating layer is wound to form the planar coil, and the inorganic insulating layer can resist high temperature, so that the inductor semi-finished product can be annealed at a higher annealing temperature to further reduce loss.
Drawings
FIG. 1 is a schematic flow chart of a power inductor manufacturing method according to a preferred embodiment of the invention;
fig. 2 is a schematic flow chart of step S3 in the preferred embodiment of the invention.
Detailed Description
The invention will now be described in detail with reference to the drawings and specific examples. The present invention is not limited to the embodiment, and other embodiments may fall within the scope of the present invention as long as they conform to the gist of the present invention.
In a preferred embodiment of the present invention, based on the above-mentioned problems existing in the prior art, a method for manufacturing a power inductor is now provided, as shown in fig. 1, which includes:
step S1, preparing magnetic powder, and pressing the magnetic powder to form a rectangular magnetic core with grooves, wherein the grooves are respectively opened along the side surfaces of the rectangular magnetic core;
s2, preparing silver paste, printing the silver paste into the grooves, and then baking to obtain baked magnetic cores;
step S3, winding a planar coil with the shape matched with that of the groove, wherein the planar coil is provided with two lead-out terminals led outwards, and then laminating the planar coil and the baked magnetic core into a whole, so that the two lead-out terminals are led out from the side opening of the groove respectively to form an inductance semi-finished product;
and S4, annealing the inductor semi-finished product, and then performing electrode forming treatment on the lead-out terminal to prepare the power inductor.
Specifically, in this embodiment, the shape of the groove and the opening position of the side face are not limited, the shape of the groove may be a shape of a Chinese character 'ji', and the corresponding openings are symmetrically opened on two side faces of the rectangular magnetic core, and it is understood that the two openings may be both disposed on the same side face of the rectangular magnetic core.
The silver paste is preferably low-temperature silver paste with sintering temperature below 700 ℃, and the silver paste is printed in the grooves of the rectangular magnetic cores, so that the low-temperature silver paste and the rectangular magnetic cores are baked together, and inherent alternating current loss of the prepared power inductor can be effectively reduced.
The grooves are preferably rectangular grooves, flatness is required to be ensured in silver paste printing, and the viscosity of the silver paste is preferably 1100-1800dPa.s. In the viscosity range, the silver paste line is smooth and flat during silver paste printing, no permeation, burrs, gaps and other defects exist, and the adhesive force of the silver paste after baking is strong, so that the planar coil can be stably placed in the groove, and the overall stress uniformity of the planar coil is realized when the planar coil and the baked magnetic core are pressed into a whole. And after the lamination is completed, the inductance semi-finished product can be annealed to prepare the electrode. Preferably, the two lead terminals can be bent to one side of the rectangular magnetic core, which is far away from the planar coil, along the direction of the opening, which is far away from the planar coil, and then the inorganic insulating layer and the copper wire which are coated by the two lead terminals are removed in a laser mode, so that the electrode is formed by electroplating.
Further, the low-temperature silver paste and the rectangular magnetic core are baked together and then annealed together, so that inherent alternating current loss of the prepared power inductor is minimized; in addition, silver paste is printed in the rectangular magnetic core formed by pressing, so that high current can safely pass through the rectangular magnetic core, and the requirements of devices with high current and low power consumption are met.
In a preferred embodiment of the present invention, the magnetic powder includes a soft magnetic metal material and a resin material, and the resin material accounts for 1% -5% of the magnetic powder.
In a preferred embodiment of the present invention, the soft magnetic metal material includes at least one of carbonyl iron powder material, iron-silicon alloy material, iron-nickel-molybdenum material, and nanocrystalline soft magnetic material;
the resin material includes at least one of an epoxy resin and a phenolic resin.
In a preferred embodiment of the present invention, as shown in fig. 2, step S3 includes:
step S31, winding a single-layer multi-strand copper wire coated with an inorganic insulating layer to form a planar coil matched with the shape of the groove, wherein the planar coil is provided with two lead-out terminals led out outwards;
step S32, placing the planar coil in a groove of the baked magnetic core, and leading out two leading-out terminals from side openings of the groove respectively;
and step S33, filling powder into the grooves, and pressing the grooves into a whole, so that the powder fills the gaps among the strands of copper wires of the planar coil and the grooves, and an inductance semi-finished product is formed.
Specifically, in the present embodiment, the inorganic insulating layer is made of an inorganic particulate material including at least one of silica, alumina, and silicon carbide. The inorganic insulating layer is used for coating the copper wire, compared with the existing insulating layer, the temperature resistance level is effectively improved, so that in the step S4, the annealing temperature of annealing treatment of the inductor semi-finished product can reach 400-700 ℃, and compared with the existing annealing treatment below 220 ℃, the purpose of reducing loss can be further achieved. Further, the inorganic insulating layer has insulativity and excellent high-voltage resistance, the copper wire inner core can be effectively protected, the problem that the insulating layer of the existing coated copper wire inner core is easy to damage during pressing to cause short circuit of a product is solved, and based on the problem, relatively high pressing pressure can be allowed during pressing, so that forming density is improved, and magnetic conductivity of the product is improved.
In a preferred embodiment of the present invention, in step S2, silver paste is printed into the grooves, and then baked at a baking temperature of 100-200 ℃.
The foregoing description is only illustrative of the preferred embodiments of the present invention and is not to be construed as limiting the scope of the invention, and it will be appreciated by those skilled in the art that equivalent substitutions and obvious variations may be made using the description and drawings, and are intended to be included within the scope of the present invention.

Claims (8)

1.一种功率电感制备方法,其特征在于,包括:1. A method for preparing a power inductor, comprising: 步骤S1,制备磁性粉体,并将所述磁性粉体压制形成带有凹槽的矩形磁芯,所述凹槽沿所述矩形磁芯的侧面分别开口;Step S1, preparing magnetic powder, and pressing the magnetic powder to form a rectangular magnetic core with grooves, the grooves are respectively opened along the sides of the rectangular magnetic core; 步骤S2,制备银浆,并将所述银浆印刷至所述凹槽内,随后烘烤得到烘烤后磁芯;Step S2, preparing silver paste, printing the silver paste into the groove, and then baking to obtain a baked magnetic core; 步骤S3,绕制与所述凹槽的形状相适配的平面线圈,所述平面线圈具有向外引出的两个引出端子,随后将所述平面线圈和所述烘烤后磁芯压合为一体,使得两个所述引出端子分别由所述凹槽的侧面开口处引出,形成电感半成品;Step S3, winding a planar coil adapted to the shape of the groove, the planar coil has two lead-out terminals, and then press-bonding the planar coil and the baked magnetic core into a Integral, so that the two lead-out terminals are led out from the side opening of the groove respectively, forming a semi-finished inductor; 步骤S4,对所述电感半成品进行退火处理,随后对所述引出端子进行电极成型处理,以制备得到功率电感。Step S4, performing annealing treatment on the semi-finished inductor, and then performing electrode forming treatment on the lead-out terminals, so as to prepare a power inductor. 2.根据权利要求1所述的功率电感制备方法,其特征在于,所述磁性粉体包括软磁金属材料和树脂材料,所述树脂材料在所述磁性粉体中的占比为1%~5%。2. The method for preparing a power inductor according to claim 1, wherein the magnetic powder comprises a soft magnetic metal material and a resin material, and the proportion of the resin material in the magnetic powder is 1% to 1%. 5%. 3.根据权利要求2所述的功率电感制备方法,其特征在于,所述软磁金属材料包括羰基铁粉材料、铁硅合金材料、铁镍合金材料、铁镍钼材料和纳米晶软磁材料中的至少一种;3. The method for preparing a power inductor according to claim 2, wherein the soft magnetic metal material comprises carbonyl iron powder material, iron-silicon alloy material, iron-nickel alloy material, iron-nickel-molybdenum material and nanocrystalline soft magnetic material at least one of; 所述树脂材料包括环氧树脂和酚醛树脂中的至少一种。The resin material includes at least one of epoxy resin and phenolic resin. 4.根据权利要求1所述的功率电感制备方法,其特征在于,所述步骤S3包括:4. The power inductor manufacturing method according to claim 1, wherein said step S3 comprises: 步骤S31,采用包覆有无机绝缘层的单层多股铜线绕制形成与所述凹槽的形状相适配的所述平面线圈,所述平面线圈具有向外引出的两个所述引出端子;Step S31, using a single-layer multi-strand copper wire coated with an inorganic insulating layer to form the planar coil that is adapted to the shape of the groove, and the planar coil has two leads drawn outward terminal; 步骤S32,将所述平面线圈放置于所述烘烤后磁芯的所述凹槽内,两个所述引出端子分别由所述凹槽的侧面开口处引出;Step S32, placing the planar coil in the groove of the baked magnetic core, and the two lead-out terminals are respectively led out from the side openings of the groove; 步骤S33,向所述凹槽内填充粉材后压制为一体,使得所述粉材填平所述平面线圈的各股所述铜线之间以及所述凹槽,形成电感半成品。Step S33 , filling the groove with powder material and then pressing it into one body, so that the powder material fills between the copper wires of the planar coil and the groove to form a semi-finished inductor. 5.根据权利要求4所述的功率电感制备方法,其特征在于,所述无机绝缘层由无机物颗粒材料制备而成,所述无机物颗粒材料包括二氧化硅、氧化铝和碳化硅中的至少一种。5. The method for preparing a power inductor according to claim 4, wherein the inorganic insulating layer is prepared from inorganic granular materials, and the inorganic granular materials include silicon dioxide, aluminum oxide and silicon carbide. at least one. 6.根据权利要求1所述的功率电感制备方法,其特征在于,所述步骤S2中,将所述银浆印刷至所述凹槽内,随后烘烤的烘烤温度为100℃-200℃。6. The method for manufacturing a power inductor according to claim 1, characterized in that, in the step S2, the silver paste is printed into the groove, and the baking temperature of the subsequent baking is 100°C-200°C . 7.根据权利要求1所述的功率电感制备方法,其特征在于,所述步骤S4中,对所述电感半成品进行退火处理的退火温度为400℃-700℃。7 . The method for manufacturing a power inductor according to claim 1 , wherein, in the step S4 , the annealing temperature for annealing the semi-finished inductor is 400° C.-700° C. 7 . 8.根据权利要求1所述的功率电感制备方法,其特征在于,所述银浆的烧结温度在700℃以下。8. The method for manufacturing a power inductor according to claim 1, wherein the sintering temperature of the silver paste is below 700°C.
CN202211563016.4A 2022-12-07 2022-12-07 A kind of preparation method of power inductor Pending CN116168942A (en)

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR20000059248A (en) * 2000-07-26 2000-10-05 엄우식 Laminated complex chip of combining with resistor and inductor and fabricating method therefor
CN107093491A (en) * 2017-04-20 2017-08-25 洛阳理工学院 A kind of middle low temperature burning infiltration silver electrode paste and preparation method thereof
WO2018149422A2 (en) * 2018-05-22 2018-08-23 深圳顺络电子股份有限公司 Integrally formed inductive element and manufacturing method therefor
WO2021043343A2 (en) * 2020-11-17 2021-03-11 深圳顺络电子股份有限公司 Integrally formed inductor and manufacturing method therefor
CN115410802A (en) * 2022-06-08 2022-11-29 东莞市三体微电子技术有限公司 A new type of small-sized power inductor and its manufacturing method

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR20000059248A (en) * 2000-07-26 2000-10-05 엄우식 Laminated complex chip of combining with resistor and inductor and fabricating method therefor
CN107093491A (en) * 2017-04-20 2017-08-25 洛阳理工学院 A kind of middle low temperature burning infiltration silver electrode paste and preparation method thereof
WO2018149422A2 (en) * 2018-05-22 2018-08-23 深圳顺络电子股份有限公司 Integrally formed inductive element and manufacturing method therefor
WO2021043343A2 (en) * 2020-11-17 2021-03-11 深圳顺络电子股份有限公司 Integrally formed inductor and manufacturing method therefor
CN115410802A (en) * 2022-06-08 2022-11-29 东莞市三体微电子技术有限公司 A new type of small-sized power inductor and its manufacturing method

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