Patent Application
20170133150
1. Field of the Invention
The instant disclosure relates to a power inductor and a method of manufacturing the same, and more particularly to a customized SMD (Surface Mount Device) power inductor and a method of manufacturing the same.
2. Description of Related Art
The prior inductor includes a circuit board, a coil attached to the circuit board, and an enclosure. From the enclosure there extend a first conductor and a second conductor each respectively welded to welding pads. The coil is a helical winding body with multiple turns of an erected rectangular cross sectional flat wire. The coil includes an inner side end and an outer side end, and a lead frame is attached to the winding body with its two terminals each respectively welded to the inner side end and the outer side end of the winding body. Afterwards the winding body with both welded conductors is set in a mold, and then the mold filled with preferably, a colloidal magnetic powder. After the magnetic powder is dried and hardened, the lead frame is severed and taken away. The finished product of the inductor is obtained.
One aspect of the instant disclosure relates to a customized SMD power inductor and a method of manufacturing the same.
One of the embodiments of the instant disclosure provides a customized SMD power inductor, comprising a magnetic substrate, a coil structure, a magnetic coating structure, and a terminal electrode structure. The coil structure is disposed on the magnetic substrate. The coil structure includes a conductive extending portion and an insulation extending portion for enclosing the conductive extending portion, the conductive extending portion and the insulation extending portion are extended along a predetermined track, and the conductive extending portion has a first conductive terminal and a second conductive terminal opposite to the first conductive terminal. The magnetic coating structure is disposed on the magnetic substrate to cover the coil structure. The magnetic coating structure includes a middle coating layer disposed on the magnetic substrate and connected to the insulation extending portion and a top coating layer disposed on the coil structure and the middle coating layer, the conductive extending portion is insulated from the magnetic coating structure through the insulation extending portion, the first conductive terminal and the second conductive terminal of the conductive extending portion both are exposed from the middle coating layer, and the middle coating layer has a surrounding perimeter portion. The terminal electrode structure includes a first terminal electrode portion electrically contacting the first conductive terminal and a second terminal electrode portion corresponding to the first terminal electrode portion and electrically contacting the second conductive terminal. The first terminal electrode portion is disposed on a lateral side of the middle coating layer for enclosing a portion of the magnetic substrate and a portion of the top coating layer, and the second terminal electrode portion is disposed on another lateral side of the middle coating layer for enclosing another portion of the magnetic substrate and another portion of the top coating layer. More particularly, the magnetic substrate has a first predetermined relative permeability, the surrounding perimeter portion has a second predetermined relative permeability, the middle coating layer has a third predetermined relative permeability, and the top coating layer has a fourth predetermined relative permeability, the third predetermined relative permeability of the middle coating layer is larger than or equal to the fourth predetermined relative permeability of the top coating layer, the fourth predetermined relative permeability of the top coating layer is larger than or equal to the first predetermined relative permeability of the magnetic substrate, and the first predetermined relative permeability of the magnetic substrate is larger than or equal to the second predetermined relative permeability of the surrounding perimeter portion. Therefore, the electrical property of the customized SMD power inductor is adjusted according to numerical values of the first predetermined relative permeability, the second predetermined relative permeability, the third predetermined relative permeability, and the fourth predetermined relative permeability.
Another one of the embodiments of the instant disclosure provides a customized SMD power inductor, comprising a magnetic substrate, a coil structure, a magnetic coating structure, and a terminal electrode structure. The coil structure is disposed on the magnetic substrate. The coil structure includes a conductive extending portion and an insulation extending portion for enclosing the conductive extending portion, the conductive extending portion and the insulation extending portion are extended along a predetermined track, and the conductive extending portion has a first conductive terminal and a second conductive terminal opposite to the first conductive terminal. The magnetic coating structure is disposed on the magnetic substrate to cover the coil structure. The magnetic coating structure includes a middle coating layer disposed on the magnetic substrate and connected to the insulation extending portion and a top coating layer disposed on the coil structure and the middle coating layer, the conductive extending portion is insulated from the magnetic coating structure through the insulation extending portion, the first conductive terminal and the second conductive terminal of the conductive extending portion both are exposed from the middle coating layer, and the middle coating layer has a surrounding perimeter portion. The terminal electrode structure includes a first terminal electrode portion electrically contacting the first conductive terminal and a second terminal electrode portion corresponding to the first terminal electrode portion and electrically contacting the second conductive terminal. The first terminal electrode portion is disposed on a lateral side of the middle coating layer for enclosing a portion of the magnetic substrate and a portion of the top coating layer, and the second terminal electrode portion is disposed on another lateral side of the middle coating layer for enclosing another portion of the magnetic substrate and another portion of the top coating layer. More particularly, the magnetic substrate is made of a first predetermined soft magnetic material, the insulation extending portion is made of a second predetermined soft magnetic material, the middle coating layer is made of a third predetermined soft magnetic material, the top coating layer is made of a fourth predetermined soft magnetic material, and the first predetermined soft magnetic material, the second predetermined soft magnetic material, the third predetermined soft magnetic material, and the fourth predetermined soft magnetic material are totally different from each other or partially different from each other. Therefore, the electrical property of the customized SMD power inductor is adjusted according to the first predetermined soft magnetic material, the second predetermined soft magnetic material, the third predetermined soft magnetic material, and the fourth predetermined soft magnetic material.
Yet another one of the embodiments of the instant disclosure provides a method of manufacturing a customized SMD power inductor, comprising: providing an initial magnetic substrate unit, wherein the initial magnetic substrate unit is composed of a plurality of magnetic substrates; forming a coil structure unit on the initial magnetic substrate unit, wherein the coil structure unit is composed of a plurality of coil structures respectively disposed on the magnetic substrate, wherein each coil structure includes a conductive extending portion and an insulation extending portion for enclosing the conductive extending portion, and the conductive extending portion and the insulation extending portion are extended along a predetermined track; forming an initial magnetic coating structure unit on the initial magnetic substrate unit to cover the coil structure unit, wherein the initial magnetic coating structure unit is composed of a plurality of magnetic coating structures respectively disposed on the magnetic substrates to respectively cover the coil structures, each magnetic coating structure includes a middle coating layer disposed on the magnetic substrate and connected to the insulation extending portion and a top coating layer disposed on the coil structure and the middle coating layer, the conductive extending portion is insulated from the magnetic coating structure through the insulation extending portion, and the middle coating layer has a surrounding perimeter portion; cutting the initial magnetic substrate unit, the coil structure unit, and the initial magnetic coating structure unit to form a plurality of granulated electronic components, wherein the initial magnetic substrate unit is cut into the magnetic substrates separated from each other, the coil structure unit is cut into the coil structures separated from each other, the initial magnetic coating structure unit is cut into the magnetic coating structures separated from each other, and each granulated electronic component is composed of the magnetic substrate, the coil structure, and the magnetic coating structure; setting the granulated electronic components at a predetermined temperature substantially between 200° C. and 900° C. during a densification treatment; and then respectively forming a plurality of terminal electrode structures on the granulated electronic components, wherein the terminal electrode structure includes a first terminal electrode portion and a second terminal electrode portion respectively disposed on two opposite lateral sides of the granulated electronic component to finish the manufacture of the customized SMD power inductor. More particularly, the conductive extending portion has a first conductive terminal and a second conductive terminal opposite to the first conductive terminal, the first conductive terminal and the second conductive terminal of the conductive extending portion both are exposed from the middle coating layer to respectively electrically contacting the first conductive terminal portion and the second terminal electrode portion, wherein the first terminal electrode portion is disposed on a lateral side of the middle coating layer for enclosing a portion of the magnetic substrate and a portion of the top coating layer, and the second terminal electrode portion is disposed on another lateral side of the middle coating layer for enclosing another portion of the magnetic substrate and another portion of the top coating layer.
Therefore, in one of embodiments, the electrical property of the customized SMD power inductor can be adjusted or determined to pass muster with customer according to numerical values of the first, the second, the third, and the fourth predetermined relative permeability, in order to pass muster with different customers. In another one of embodiments, the electrical property of the customized SMD power inductor can be adjusted or determined according to the first, the second, the third, and the fourth predetermined soft magnetic materials, in order to pass muster with different customers.
To further understand the techniques, means and effects of the instant disclosure applied for achieving the prescribed objectives, the following detailed descriptions and appended drawings are hereby referred to, such that, and through which, the purposes, features and aspects of the instant disclosure can be thoroughly and concretely appreciated. However, the appended drawings are provided solely for reference and illustration, without any intention to limit the instant disclosure.
The accompanying drawings are included to provide a further understanding of the instant disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the instant disclosure and, together with the description, serve to explain the principles of the instant disclosure.
The embodiments of the customized SMD power inductor and the method of manufacturing the same” of the instant disclosure are described. Other advantages and objectives of the instant disclosure can be easily understood by one skilled in the art from the disclosure. The instant disclosure can be applied in different embodiments. Various modifications and variations can be made to various details in the description for different applications without departing from the scope of the instant disclosure. The drawings of the instant disclosure are provided only for simple illustrations, but are not drawn to scale and do not reflect the actual relative dimensions. The following embodiments are provided to describe in detail the concept of the instant disclosure, and are not intended to limit the scope thereof in any way.
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Please note, the magnetic substrate 1 has a first predetermined relative permeability (μ1), the surrounding perimeter portion 312 of the middle coating layer 31 has a second predetermined relative permeability (μ2), the middle filling portion 311 of the middle coating layer 31 has a third predetermined relative permeability (μ3), and the top coating layer 32 has a fourth predetermined relative permeability (μ4). More particularly, the third predetermined relative permeability (μ3) of the middle filling portion 311 of the middle coating layer 31 is larger than or equal to the fourth predetermined relative permeability (μ4) of the top coating layer 32, the fourth predetermined relative permeability (μ4) of the top coating layer 32 is larger than or equal to the first predetermined relative permeability (μ1) of the magnetic substrate 1, and the first predetermined relative permeability (μ1) of the magnetic substrate 1 is larger than or equal to the second predetermined relative permeability (μ2) of the surrounding perimeter portion 312. For example, the range of any one of the first predetermined relative permeability (μl), the second predetermined relative permeability (μ2), the third predetermined relative permeability (μ3), and the fourth predetermined relative permeability (μ4) is substantially between 1 and 53, such as approximately between 1 and 26, or approximately between 26 and 53, so that the first predetermined relative permeability (μ1), the second predetermined relative permeability (μ2), the third predetermined relative permeability (μ3), and the fourth predetermined relative permeability (μ4) conform to the following condition: 53≧μ3≧μ4≧μ1≧μ2≧1, but that is merely an example and is not meant to limit the instant disclosure. For example,
Therefore, the electrical property (such as inductance value, rated current, direct current resistance, and working temperature range) of the customized SMD power inductor Z can be adjusted or determined to pass muster with customer according to numerical values of the first predetermined relative permeability (μl), the second predetermined relative permeability (μ2), the third predetermined relative permeability (μ3), and the fourth predetermined relative permeability (μ4). In other words, the customized SMD power inductor Z of the instant disclosure can provide a customized electrical property by adjusting numerical values of the first predetermined relative permeability (μ1), the second predetermined relative permeability (μ2), the third predetermined relative permeability (μ3), and the fourth predetermined relative permeability (μ4), in order to pass muster with different customers.
More particularly, the magnetic substrate 1 is made of a first predetermined soft magnetic material, the insulation extending portion 22 is made of a second predetermined soft magnetic material, the middle coating layer 31 is made of a third predetermined soft magnetic material, the top coating layer 32 is made of a fourth predetermined soft magnetic material, and the first predetermined soft magnetic material, the second predetermined soft magnetic material, the third predetermined soft magnetic material, and the fourth predetermined soft magnetic material are totally different from each other or partially different from each other. For example, the predetermined soft magnetic material may be an iron based metal (such as CIP (Carbonyl Iron Power), sendust (FeAlSi alloy), FeCrSi alloy, or FeSi alloy etc.), or the predetermined soft magnetic material may be ferrite based oxide, Ni—Zn ferrite, Ni—Cu—Zn ferrite, or Mn—Zn ferrite etc.
Therefore, the electrical property (such as inductance value, rated current, direct current resistance, and working temperature range) of the customized SMD power inductor Z can be adjusted or determined according to the first predetermined soft magnetic material, the second predetermined soft magnetic material, the third predetermined soft magnetic material, and the fourth predetermined soft magnetic material. In other words, the customized SMD power inductor Z of the instant disclosure can provide a customized electrical property by adjusting material characteristics of the first predetermined soft magnetic material, the second predetermined soft magnetic material, the third predetermined soft magnetic material, and the fourth predetermined soft magnetic material, in order to pass muster with different customers.
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In conclusion, in one of embodiments, the electrical property of the customized SMD power inductor Z can be adjusted or determined to pass muster with customer according to numerical values of the first predetermined relative permeability (μ1), the second predetermined relative permeability (μ2), the third predetermined relative permeability (μ3), and the fourth predetermined relative permeability (μ4), in order to pass muster with different customers. In another one of embodiments, the electrical property of the customized SMD power inductor Z can be adjusted or determined according to the first predetermined soft magnetic material, the second predetermined soft magnetic material, the third predetermined soft magnetic material, and the fourth predetermined soft magnetic material, in order to pass muster with different customers.
The aforementioned descriptions merely represent the preferred embodiments of the instant disclosure, without any intention to limit the scope of the instant disclosure which is fully described only within the following claims. Various equivalent changes, alterations or modifications based on the claims of the instant disclosure are all, consequently, viewed as being embraced by the scope of the instant disclosure.
