CN112151242A - Electromagnetic element and manufacturing method thereof - Google Patents

Abstract

The application discloses an electromagnetic component and a manufacturing method thereof, the electromagnetic component comprises: the transmission line comprises a substrate, a magnetic core, a transmission line layer and a plurality of conductive parts; the substrate comprises a central part and a peripheral part, wherein the central part is provided with a plurality of inner through holes penetrating through the substrate, the peripheral part is provided with a plurality of outer through holes penetrating through the substrate, and an annular accommodating groove is formed between the central part and the peripheral part to accommodate the magnetic core; the transmission line layers are arranged on two opposite sides of the substrate and comprise a plurality of conducting wire patterns which are arranged at intervals along the circumferential direction of the annular accommodating groove, and each conducting wire pattern is bridged between one corresponding inner conducting hole and one corresponding outer conducting hole; the plurality of conductive pieces are arranged in the inner conducting hole and the outer conducting hole and used for sequentially connecting the conductive wire patterns on the two transmission line layers so as to form a coil loop for transmitting current around the magnetic core; wherein, an air gap is arranged on the magnetic core. The air gap is arranged on the magnetic core, so that the stability of the magnetic core on the influence of current can be improved.

Description

Electromagnetic element and method of making the same

technical field

The present application relates to the technical field of electromagnetic component manufacturing, and in particular, to an electromagnetic component and a manufacturing method thereof.

Background technique

In the existing buried magnetic electromagnetic device, a magnetic core is usually embedded in a substrate, then conductive metal layers are arranged on both sides of the substrate, and the conductive metal layers on both sides are electrically connected by punching holes, thereby forming a surrounding magnetic field. The turns of the core set.

However, the existing buried magnetic electromagnetic device is easily affected by the current in the turns during operation, resulting in the phenomenon of magnetic saturation.

SUMMARY OF THE INVENTION

The present application provides an electromagnetic component and a manufacturing method thereof, so as to solve the problem of magnetic saturation caused by the fact that the buried magnetic electromagnetic device in the prior art is easily affected by the current in the turns during operation. .

In order to solve the above technical problems, a technical solution adopted in the present application is to provide an electromagnetic element, wherein the electromagnetic element includes:

Substrate, including:

a center portion, on which a plurality of internal via holes are opened through the substrate; and

a peripheral part, on which is opened a plurality of external via holes penetrating the substrate; an annular accommodating groove is formed between the central part and the peripheral part;

a magnetic core, accommodated in the annular accommodating groove;

A transmission line layer, a transmission line layer is disposed on opposite sides of the substrate, wherein each of the transmission line layers includes a plurality of conductor patterns arranged at intervals along the circumferential direction of the annular receiving groove, each of which is each of the wire patterns is bridged between a corresponding one of the inner vias and a corresponding one of the outer vias; and

a plurality of conductive parts, arranged in the inner via hole and the outer via hole, for connecting the wire patterns on the two transmission line layers in sequence, thereby forming a current capable of transmitting current around the magnetic core the coil loop;

Wherein, the magnetic core is provided with an opening to cut off its annular body to form an air gap of the magnetic core.

Wherein, the opening is arranged along the direction extending from the center of the magnetic core to the outer contour of the magnetic core.

Wherein, in the direction extending from the center of the magnetic core to the outer contour of the magnetic core, the widths of the openings are equal everywhere.

Wherein, the width of the opening is 0.2-0.5mm.

Wherein, it is characterized in that the magnetic core is a circular ring body or a square ring body.

Wherein, the electromagnetic element is a transformer, a filter or an inductor.

Wherein, the substrate is formed of resin material, and the magnetic core is formed of ferrite core material.

In order to solve the above-mentioned technical problems, another technical solution adopted in the present application is to provide a method for manufacturing an electromagnetic component, which includes:

Cutting the annular magnetic core to form the air gap of the magnetic core;

disposing the magnetic core after forming the air gap into a base plate having an annular accommodating groove, wherein the annular accommodating groove divides the base plate into a central part and a peripheral part;

A conductive sheet is respectively pressed on both sides of the substrate;

A plurality of internal via holes penetrating the substrate and the conductive sheet are formed at the center portion, and a plurality of external via holes penetrating the substrate and the conductive sheet are formed corresponding to the peripheral portion. ;

A plurality of wire patterns are fabricated on each of the conductive sheets to form a transmission line layer, and a conductive member is respectively disposed in each of the inner via holes and each of the outer via holes; the plurality of wire patterns are along the The annular accommodating grooves are arranged at intervals in the circumferential direction, and each of the wire patterns is bridged between a corresponding one of the inner through holes and one of the outer through holes, and the wire patterns pass through the The conductive members are connected in sequence to form a coil loop capable of transmitting current around the magnetic core.

In order to solve the above-mentioned technical problems, another technical solution adopted in the present application is to provide a method for manufacturing an electromagnetic component, which includes:

providing a base plate, and opening an annular accommodating groove on the base plate to divide the base plate into a central part and a peripheral part;

Burying a magnetic core matching the shape of the annular accommodating groove into the annular accommodating groove;

A conductive sheet is respectively pressed on both sides of the substrate;

A plurality of internal via holes penetrating the substrate and the conductive sheet are formed at the center portion, and a plurality of external via holes penetrating the substrate and the conductive sheet are formed corresponding to the peripheral portion. ;

A plurality of wire patterns are fabricated on each of the conductive sheets to form a transmission line layer, and a conductive member is respectively disposed in each of the inner via holes and each of the outer via holes; the plurality of wire patterns are along the The annular accommodating grooves are arranged at intervals in the circumferential direction, and each of the wire patterns is bridged between a corresponding one of the inner through holes and one of the outer through holes, and the wire patterns pass through the the conductive members are connected in sequence to form a coil loop capable of transmitting current around the magnetic core;

The magnetic core in the substrate is cut at a preset position on one side of the substrate to form an air gap of the magnetic core.

Wherein, cutting the magnetic core in the substrate at a preset position on one side of the substrate to form an air gap of the magnetic core includes:

The magnetic core is cut from one side of the substrate by means of laser cutting, and the cutting position of the laser cutting avoids the wire pattern.

In the present application, the magnetic core of the buried magnetic electromagnetic element is provided with an air gap of the magnetic core, so as to avoid the problem of magnetic saturation during the operation of the electromagnetic element, thereby increasing the stability of the influence of the magnetic core itself on the current.

Description of drawings

In order to illustrate the technical solutions in the embodiments of the present application more clearly, the following briefly introduces the drawings that are used in the description of the embodiments. Obviously, the drawings in the following description are only some embodiments of the present application. For those of ordinary skill in the art, under the premise of no creative work, other drawings can also be obtained from these drawings, wherein:

FIG. 1 is a schematic structural diagram of an embodiment of an electromagnetic element provided by the present application;

FIG. 2 is a schematic structural diagram of the mating of a substrate and a magnetic core in the electromagnetic component shown in FIG. 1;

Fig. 3 is the structural representation of the cross-sectional view of the electromagnetic element shown in Fig. 1 at A-A' section;

4 is a schematic flowchart of an embodiment of a method for manufacturing an electromagnetic component provided by the present application;

FIG. 5 is a schematic flowchart of another embodiment of a method for manufacturing an electromagnetic component provided by the present application.

Detailed ways

The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, but not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by those of ordinary skill in the art without creative work fall within the scope of protection of this application.

It should be noted that if there are directional indications (such as up, down, left, right, front, back, etc.) involved in the embodiments of the present application, the directional indications are only used to explain a certain posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication also changes accordingly.

In addition, if there are descriptions related to "first", "second", etc. in the embodiments of the present application, the descriptions of "first", "second", etc. are only for the purpose of description, and should not be construed as indicating or implying Its relative importance or implicitly indicates the number of technical features indicated. Thus, a feature delimited with "first", "second" may expressly or implicitly include at least one of that feature. In addition, the technical solutions between the various embodiments can be combined with each other, but must be based on the realization by those of ordinary skill in the art. When the combination of technical solutions is contradictory or cannot be realized, it should be considered that the combination of such technical solutions does not exist. , is not within the scope of protection claimed in this application.

Please refer to FIG. 1-FIG. 3. FIG. 1 is a schematic structural diagram of an embodiment of an electromagnetic component provided by the present application, FIG. 2 is a structural schematic diagram of the mating of a substrate and a magnetic core in the electromagnetic component shown in FIG. 1; 1 is a schematic structural diagram of the cross-sectional view of the electromagnetic element at the AA' section.

The electromagnetic element 110 may generally include: a substrate 10 , a magnetic core 16 embedded in the substrate 10 , a plurality of conductive connectors 17 , and transmission line layers (divided into a first transmission line layer 20 and a second transmission line layer) disposed on opposite sides of the substrate 10 . 30).

Among them, the substrate may be made of resin material. It is made by impregnating resin adhesive with reinforcing material and drying, cutting, laminating and other processes.

The substrate 10 may include a central portion 12 and a peripheral portion 14 disposed around the central portion 12 . An annular receiving groove 18 is formed between the central portion 12 and the peripheral portion 14 of the substrate 10 for receiving the magnetic core 16 .

In this embodiment, the central portion 12 and the peripheral portion 14 can be integrally constructed, that is, the substrate 10 is divided into the central portion 12 and the peripheral portion 14 by opening an annular accommodating groove 18 at the center of the substrate 10 . Of course, in other embodiments, the central portion 12 and the peripheral portion 14 may be separate structures, for example, a circular accommodating groove is formed at the center of the substrate 10 and then the central portion 12 is fixed to the circular accommodating groove by, for example, bonding. The annular accommodating groove 18 is formed between the central portion 12 and the peripheral portion 14 , and both end surfaces of the central portion 12 and the peripheral portion 14 are flush with each other.

In this embodiment, the cross-sectional shape of the annular accommodating groove 18 is substantially the same as that of the magnetic core 16 , so that the magnetic core 16 can be accommodated in the annular accommodating groove 18 .

Continuing to refer to FIGS. 1-3 , the central portion 12 is provided with a plurality of internal vias 13 penetrating the central portion 12 . Wherein, a plurality of internal vias 13 are disposed adjacent to the outer sidewall of the central portion 12 and are arranged along the circumferential direction of the central portion 12 . Correspondingly, the peripheral portion 14 is provided with a plurality of external vias 15 penetrating the peripheral portion 14 , and the plurality of external vias 15 are disposed adjacent to the inner sidewall of the peripheral portion 14 , that is, the internal vias 13 are located in the central portion. The top surface of 12 is arranged around the top inner peripheral wall of the magnetic core 16 , and the outer through holes 15 are arranged around the top outer peripheral wall of the magnetic core 16 on the top surface of the peripheral portion 14 .

Further, a plurality of conductive members 17 may be disposed in the inner via hole 13 and the outer via hole 15 , and the conductive members 17 electrically connect the first transmission line layer 20 and the second transmission line layer 30 on both sides of the substrate 10 .

In one embodiment, the conductive member 17 may be a metal pillar, and the diameter of the metal pillar corresponding to each inner via hole 13 or each outer via hole 15 is smaller than or equal to the inner via hole 13 or The diameter of the external via hole 15 . The material of the metal pillar includes but is not limited to copper, aluminum, iron, nickel, gold, silver, platinum group, chromium, magnesium, tungsten, molybdenum, lead, tin, indium, zinc or alloys thereof.

In this embodiment, referring to FIG. 2 , a metal layer can be formed on the inner walls of the inner via hole 13 and the outer via hole 15 by, for example, electroplating, coating, etc., so that the transmission lines located on the opposite sides of the substrate 10 are separated from each other. The layers 20 and 30 are electrically connected. The material of the metal layer is the same as the material of the metal column in the previous embodiment, which is not repeated here.

The magnetic core 16 is provided with an opening 161 , and the opening 161 cuts off one end of the closed annular magnetic core 16 , thereby forming an air gap of the magnetic core 16 . The function of the opening 161 is to avoid the problem of magnetic saturation during the operation of the electromagnetic element, thereby increasing the stability of the magnetic core itself on the influence of the current.

As mentioned above, the shape of the magnetic core 16 may be a circular ring, a square ring, an ellipse, or the like. Wherein, the opening 161 may be provided along the direction extending from the center of the magnetic core 16 to the outer contour of the magnetic core 16 . Specifically, taking the magnetic core 16 as an annular shape as an example, the opening 161 may be disposed on a connecting line from the center of the magnetic core 16 to the outer end of the magnetic core 16 , wherein the widths of the openings 161 are equal. And the width of the opening can be set to 0.2-0.5mm, and in a specific embodiment, the width of the opening 161 is set to be 0.2, 0.3, 0.4 or 0.5mm.

In this embodiment, the electromagnetic element 110 may be a transformer, a filter or an inductor. It can also be an integrated transformer composed of a combination of a transformer and a filter.

Further, the present application also provides a method for manufacturing an electromagnetic component. Please refer to FIG. 4 , which is a schematic flowchart of an embodiment of the method for manufacturing an electromagnetic component provided by the present application. The manufacturing method specifically includes the following steps.

S110 : providing the substrate 10 , and opening an annular receiving groove 18 on the substrate 10 to divide the substrate 10 into a central portion 12 and a peripheral portion 14 .

In this embodiment, the substrate 10 may be a plate without a conductive metal layer, and any surface of the substrate 10 may be provided with an annular accommodating groove 18 . In yet another embodiment, a base block can also be provided, wherein the base block includes a substrate 10, a connection layer and a transmission line layer stacked in sequence; and a ring-shaped accommodating groove 18 is opened on the side of the substrate 10 on which the transmission line layer is not provided to The substrate 10 is divided into a central portion 12 and a peripheral portion 14 .

Wherein, the base plate 10 may be made of a resin material with a flame-resistant grade up to FR4, and may be milled to form an annular receiving groove 18 on the base plate 10 by milling grooves.

S120 : Embed the magnetic core 16 matching the shape of the annular accommodating groove 18 into the annular accommodating groove 18 .

The magnetic core 16 may include magnetic metal oxides such as manganese-zinc ferrite or nickel-zinc ferrite. The magnetic core 16 can be disposed in the annular receiving groove 18 by means of interference fit, so that the magnetic core 16 can be fixed in the annular receiving groove 18 of the base plate 10 . In another embodiment, the size of the magnetic core 16 is slightly smaller than the size of the annular accommodating groove 18 , and the height of the magnetic core 16 should be less than or equal to the height of the annular accommodating groove, so as to reduce the size of the magnetic core 16 during small pressing. pressure, reducing the probability of the magnetic core 16 breaking.

Wherein, part or all of the surface of the magnetic core 16 can be wrapped with elastic material, and then the magnetic core 16 (wherein, the number of the magnetic cores 16 can be one or N, at least one part of the magnetic core 16 of the N magnetic cores or All surfaces are wrapped with elastic material) are respectively disposed in the corresponding annular receiving grooves 18, and then an insulating layer is disposed on the surface of the opening side of the corresponding annular receiving grooves 18 on the substrate 10 to form a cavity ( closed cavity or non-closed cavity).

Further, the surface of the magnetic core 16 may be provided with a layer of coating, and the magnetic core 16 is fixed in the annular receiving groove 18 by this coating.

S130: Pressing a conductive sheet on both sides of the substrate 10 respectively.

The two conductive sheets are respectively arranged on both sides of the substrate 10 , and the two conductive sheets are respectively arranged on both sides of the substrate 10 to be fixedly connected to the substrate 10 by means of thermal compression. A connection layer may be provided between each conductive sheet and the substrate 10 , and the conductive sheet and the substrate 10 can be fixed by thermocompression through the connection layer.

S140 : opening an inner via hole 13 penetrating the substrate 10 and the two conductive sheets at the corresponding central portion 12 , and opening an outer via hole 15 penetrating the substrate 10 and the two conductive sheets at the corresponding peripheral portion 14 .

After the two conductive sheets on both sides of the substrate 10 are disposed, the inner via 13 needs to be opened at the position of the central portion 12 of the substrate 10 , and the outer via 15 needs to be opened at the position of the outer portion 14 . The inner via hole 13 and the outer via hole 15 both penetrate through the substrate 10 and the two conductive sheets.

S150 : forming a plurality of conducting wire patterns 22 on each conductive sheet to form a transmission line layer respectively, and disposing a conductive member 17 in each inner via hole 13 and each outer via hole 15 respectively. Wherein, the plurality of conducting wire patterns 22 are arranged at intervals along the circumferential direction of the annular accommodating groove 18 , and each conducting wire pattern 22 bridges between a corresponding inner via hole 13 and an outer via hole 15 . All the conductive members 17 in the inner vias 13 and the conductive members 17 in the outer vias 15 are sequentially connected to the corresponding wire patterns 22 on the two transmission line layers 30 , thereby forming a coil capable of transmitting current around the magnetic core 16 loop.

Among them, the conductive sheet can be etched to obtain a wire pattern 22 with a predetermined shape and quantity; the conductive member is formed on the inner wall of the inner via hole 13 and the outer via hole 15 by electroplating, thereby forming a conductive The through holes thereby electrically connect the conductor patterns 22 on both sides of the substrate 10 to form turns arranged around the magnetic core.

S160: Cutting the magnetic core in the substrate at a preset position on one side of the substrate to form an air gap of the magnetic core.

In this step, after step S150 is completed, that is, after the conductive sheet is etched to form the required wire pattern 22, the magnetic core 16 is cut by laser cutting, so that the magnetic core 16 can be formed as described above. The opening 161 further forms the air gap of the magnetic core 16 . When cutting the magnetic core 16 , its cutting position does not intersect with the wire patterns 22 , that is, the cutting position of the laser cutting can be set between two adjacent wire patterns 22 .

Further, the present application also provides another method for manufacturing an electromagnetic component, please refer to FIG. 5 , which is a schematic flowchart of another embodiment of the method for manufacturing an electromagnetic component provided by the present application.

S210: Cut the annular magnetic core to form an air gap of the magnetic core.

In this step, a magnetic core 16 having a preset size may be selected, and then one side of the magnetic core 16 may be cut to form an air gap of the magnetic core 16 .

S220: Disposing the magnetic core after forming the air gap into a substrate having an annular receiving groove, wherein the annular receiving groove divides the substrate into a central part and a peripheral part.

After completing the step S210, after processing the air gap of the magnetic core 16, the magnetic core 16 with the air gap can be set into a preset substrate, wherein the substrate is provided with an annular groove matching the shape of the magnetic core 16, The magnetic core 16 is accommodated in the annular groove.

S230: Press a conductive sheet on both sides of the substrate respectively;

S240 : opening a plurality of internal vias penetrating the substrate and the conductive sheet at the corresponding central portion, and opening a plurality of external vias penetrating the substrate and the conductive sheet at the corresponding peripheral portion;

S250 : forming a plurality of conductor patterns on each conductive sheet to form a transmission line layer, and disposing a conductive member in each inner via hole and each outer via hole respectively; the plurality of conductor patterns along the circumference of the annular receiving groove They are arranged at intervals, and each wire pattern is bridged between a corresponding inner via hole and an outer via hole, and the wire patterns are sequentially connected by conductive members to form a coil loop capable of transmitting current around the magnetic core .

The difference between the method in this embodiment and the electromagnetic element provided in the previous embodiment is:

In the foregoing embodiment, the annular magnetic core 16 is arranged in the annular groove of the substrate 10, and then between the wire patterns 22 as described above are formed on both sides of the substrate, and then the magnetic field in the annular groove is adjusted. The core 16 is cut, wherein the magnetic core 16 needs to be cut by means of laser cutting, ie, the insulating material disposed on both sides of the magnetic core 16 . In this solution, the requirement for cutting precision is high, and it is necessary to ensure that after the cutting of the magnetic core 16 is completed, the substrate 10 will not be cut through.

The technical solution in this embodiment is to first cut the magnetic core 16 by machining to form an air gap, and then set the magnetic core 16 with the air gap into the annular groove of the substrate 10, and then proceed to Subsequent manufacturing flow to form the electromagnetic element as previously described.

To sum up, an electromagnetic component and its manufacturing method are provided. The magnetic core of the buried magnetic electromagnetic component is provided with an air gap of the magnetic core, so as to avoid the problem of magnetic saturation during the operation of the electromagnetic component, thereby increasing the magnetic field. The stability of the core itself against the influence of the current.

The above description is only an embodiment of the present application, and is not intended to limit the scope of the patent of the present application. Any equivalent structure or equivalent process transformation made by using the contents of the description and drawings of the present application, or directly or indirectly applied to other related technologies Fields are similarly included within the scope of patent protection of this application.

Claims (10)

1. An electromagnetic component, comprising:

a substrate, comprising:

a central portion having a plurality of inner via holes formed therethrough; and

a peripheral portion having a plurality of external via holes formed therethrough; an annular receiving groove is formed between the central portion and the peripheral portion;

the magnetic core is accommodated in the annular accommodating groove;

the transmission line layers are respectively arranged on two opposite sides of the substrate, each transmission line layer comprises a plurality of conductor patterns which are arranged at intervals along the circumferential direction of the annular accommodating groove, and each conductor pattern is bridged between one corresponding inner conducting hole and one corresponding outer conducting hole; and

a plurality of conductive members disposed in the inner via hole and the outer via hole for sequentially connecting the conductive wire patterns on the two transmission line layers to form a coil loop capable of transmitting current around the magnetic core;

the magnetic core is provided with an opening for cutting off the annular body of the magnetic core so as to form an air gap of the magnetic core.

2. The electromagnetic component of claim 1, wherein the opening is disposed along a direction in which a center of the core extends toward an outer contour of the core.

3. The electromagnetic component of claim 2, wherein the opening width is equal everywhere in a direction extending along a center of the core toward an outer contour of the core.

4. The electromagnetic component of claim 3, wherein the opening is 0.2-0.5mm wide.

5. The electromagnetic component of claim 1, wherein the magnetic core is a torus or a square torus.

6. A traction device according to claim 1, wherein the electromagnetic element is a transformer, a filter or an inductor.

7. The towing attachment in accordance with claim 1, wherein the base plate is formed of a resin material and the core is formed of a ferrite core material.

8. A method of manufacturing an electromagnetic component, comprising:

cutting the annular magnetic core to form an air gap of the magnetic core;

arranging the magnetic core with the air gap formed into a substrate with an annular accommodating groove, wherein the substrate is divided into a central part and a peripheral part by the annular accommodating groove;

pressing a conducting strip on each of two sides of the substrate;

a plurality of inner through holes penetrating through the substrate and the conducting plate are formed at the position corresponding to the central part, and a plurality of outer through holes penetrating through the substrate and the conducting plate are formed at the position corresponding to the peripheral part;

manufacturing a plurality of conducting wire patterns on each conducting sheet to form a transmission line layer, and respectively arranging a conducting piece in each internal conducting hole and each external conducting hole; the plurality of conductor patterns are arranged at intervals along the circumferential direction of the annular accommodating groove, each conductor pattern is bridged between one corresponding inner conducting hole and one corresponding outer conducting hole, and the conductor patterns are sequentially connected through the conductive pieces to form a coil loop capable of transmitting current around the magnetic core.

9. A method of manufacturing an electromagnetic component, comprising:

providing a substrate, and forming an annular containing groove on the substrate to divide the substrate into a central part and a peripheral part;

embedding the magnetic core matched with the shape of the annular accommodating groove into the annular accommodating groove;

pressing a conducting strip on each of two sides of the substrate;

a plurality of inner through holes penetrating through the substrate and the conducting plate are formed at the position corresponding to the central part, and a plurality of outer through holes penetrating through the substrate and the conducting plate are formed at the position corresponding to the peripheral part;

manufacturing a plurality of conducting wire patterns on each conducting sheet to form a transmission line layer, and respectively arranging a conducting piece in each internal conducting hole and each external conducting hole; the plurality of conductor patterns are arranged at intervals along the circumferential direction of the annular accommodating groove, each conductor pattern is bridged between one corresponding inner conducting hole and one corresponding outer conducting hole, and the conductor patterns are sequentially connected through the conductive pieces to form a coil loop capable of transmitting current around the magnetic core;

and cutting the magnetic core in the substrate at a preset position on one side of the substrate to form an air gap of the magnetic core.

10. The method of claim 9, wherein cutting the core in the substrate at a predetermined position on one side of the substrate to form the air gap of the core comprises:

and cutting the magnetic core from one side of the substrate in a laser cutting mode, wherein the cutting position of the laser cutting is kept away from the wire pattern.

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