# US 12,119,169 B1 · Hot press molding method for inductor

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- Number: US 12,119,169 B1
- Document ID: US12119169B1
- Status: Granted
- Kind: B1
- Application number: 18/748,188
- Filed: 2024-06-20
- Granted: 2024-10-15
- Earliest claimed: 2023-12-14
- Assignees: Shenzhen Topsun Technology Co., Ltd.
- Applicants: Shenzhen Topsun Technology Co., Ltd.
- Inventors: Lin Tian; Weifeng Wu
- Web page: https://patentgrep.com/patent/US12119169B1

## CPC

- H01F 41/0246: {Manufacturing of magnetic circuits by moulding or by pressing powder (magnetic cores made by moulding or by pressing powder H01F27/255; soft magnetic particles H01F1/20, H01F1/36)}
- B22F 3/14: simultaneously
- B22F 3/24: After-treatment of workpieces or articles {(B22F3/1146 takes precedence)}
- B22F 7/062: {involving the connection or repairing of preformed parts}
- B22F 7/08: with one or more parts not made from powder {(B22F7/062 takes precedence)}
- H01F 17/04: with magnetic core
- H01F 27/292: {Surface mounted devices}
- H01F 41/04: for manufacturing coils {(coils for transformer or inductances H01F27/28)}
- H01F 41/10: Connecting leads to windings (making electric connections in general H01R43/00)
- B22F 2003/242: {Coating}
- B22F 2003/248: {Thermal after-treatment}
- B22F 2998/10: Processes characterised by the sequence of their steps
- C22C 2202/02: Magnetic
- C25D 5/12: at least one layer being of nickel or chromium
- H01F 2017/048: {with encapsulating core, e.g. made of resin and magnetic powder}
- Y02P 10/25: Process efficiency
- H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- C22C: ALLOYS (treatment of alloys C21D, C22F)
- C25D: PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

Disclosed is a hot press molding method for an inductor, including: S1: manufacturing an inductance coil, a first magnetic powder block and a second magnetic powder block; the inductance coil being in a U shape, and one side of the first magnetic powder block being provided with an embedding groove; S2: placing the inductance coil into the embedding groove; pins of the inductance coil being located outside the embedding groove; S3: placing the second magnetic powder block into the inductance coil; the second magnetic powder block being simultaneously attached to inner walls of the inductance coil and the embedding groove; S4: hot-pressing the inductance coil, the first magnetic powder block and the second magnetic powder block by a hot pressing mold.

## Claims

### Claim 1

A hot press molding method for an inductor, comprising:
S1: manufacturing two inductance coils, a first magnetic powder block and two second magnetic powder blocks;
wherein, the two inductance coils are both in a U shape, and a first side of the first magnetic powder block is provided with two embedding grooves; depth directions of the two embedding grooves are parallel to each other;
in the step S1, each of the two second magnetic powder blocks comprises a first block and a second block, the first block is provided with a first inclined surface, and the second block is provided with a second inclined surface;
S2: placing the two inductance coils into the two embedding grooves respectively;
wherein, pins of the two inductance coils are arranged outside the two embedding grooves;
S3: placing the two second magnetic powder blocks into the two inductance coils respectively;
wherein, the two second magnetic powder blocks are attached to inner walls of the two inductance coils and the two embedding grooves respectively;
S4: hot-pressing the two inductance coils, the first magnetic powder block and the two second magnetic powder blocks by a hot pressing mold;
wherein, the first side of the first magnetic powder block is set as a first hot pressing surface, and a second side of the first magnetic powder block away from the two embedding grooves is set as a second hot pressing surface;
in the step S4, the two second magnetic powder blocks are placed in the two embedding grooves respectively; when the two inductance coils, the first magnetic powder block and the two second magnetic powder blocks are hot-pressed, the first inclined surface abuts against the second inclined surface, and the first block and the second block move away from each other;
S5: performing rolling spraying on the two inductance coils, the first magnetic powder block and the two second magnetic powder blocks;
S6: stripping paint from the pins of the two inductance coils; and
S7: electroplating the pins of the two inductance coils.

### Claim 2 (depends on 1)

The hot press molding method for an inductor according to claim 1, wherein, the first magnetic powder block and the two second magnetic powder blocks are both molded by cold-pressing soft magnetic alloy powder with a cold press molding pressure of 2-6 t/cm2, the soft magnetic alloy powder is doped with organic resin, and a mass percent of the organic resin is 3+/−1%.

### Claim 3 (depends on 1)

The hot press molding method for an inductor according to claim 1, wherein, in the step S5, before performing the rolling spraying on the two inductance coils, the first magnetic powder block, and the two second magnetic powder blocks, baking the two inductance coils, the first magnetic powder block, and the two second magnetic powder blocks.

### Claim 4 (depends on 3)

The hot press molding method for an inductor according to claim 3, wherein, a temperature of the baking is 150-180° C., and time for the baking is 3-6 h.

### Claim 5 (depends on 1)

The hot press molding method for an inductor according to claim 1, wherein, in the step S4, a pressure of the hot-pressing the two inductance coils, the first magnetic powder block and the two second magnetic powder blocks is 4-10 t/cm2, a temperature of the hot-pressing the two inductance coils, the first magnetic powder block and the two second magnetic powder blocks is 150-250° C., and time for the hot-pressing the two inductance coils, the first magnetic powder block and the two second magnetic powder blocks is 60-180 s.

### Claim 6 (depends on 5)

The hot press molding method for an inductor according to claim 5, wherein, in the step S4, before placing the two inductance coils, the first magnetic powder block, and the two second magnetic powder blocks into the hot pressing mold, preheating the hot pressing mold with a temperature of 300±50° C.

### Claim 7 (depends on 1)

The hot press molding method for an inductor according to claim 1, wherein, in the step S5, before performing the rolling spraying the pins of the two inductance coils, chamfering corners of the first magnetic powder block with a chamfering radius of 0.1-0.3 mm.

### Claim 8 (depends on 1)

The hot press molding method for an inductor according to claim 1, wherein, in the step S7, after the pins of the two inductance coils are electroplated, an electroplated layer is formed, the electroplated layer comprises a copper plated layer, a nickel plated layer, and a tin plated layer, a thickness of the copper plated layer is 4-10 μm, a thickness of the nickel plated layer is 3-10 μm, and a thickness of the tin plated layer is 5-12 μm.