Abstract: A power inductor device and a manufacturing method thereof are provided. The power inductor device includes a first magnetic core body, a second magnetic core body, a third magnetic core body and a metal conductor. The first magnetic core body is formed by a first magnetic powder, the second magnetic core body is formed by a second magnetic powder and the third magnetic core body is formed by a third magnetic powder. The metal conductor is disposed between the columnar body and the groove. The first magnetic core body, the metal conductor, the second magnetic core body and the third magnetic core body are closely combined to obtain an integrated power inductor structure. The first magnetic powder, the second magnetic powder and the third magnetic powder include an iron-based magnetic powder having the large particle size, the medium particle size and the small particle size.

Abstract: A power inductor device and a manufacturing method thereof are provided. The power inductor device includes a first magnetic core body, a second magnetic core body and a metal conductor. The first magnetic core body is formed by a first magnetic powder and the second magnetic core body is formed by a second magnetic powder. The metal conductor is disposed in the accommodating space between the first magnetic core body and the second magnetic core body. The first magnetic core body, the metal conductor and the second magnetic body are closely combined by a heating and pressing molding process to obtain an integrated power inductor structure. The first magnetic powder and the second magnetic powder include an iron-based magnetic powder having the large particle size, the medium particle size and the small particle size.

Abstract: A power inductor device and a manufacturing method thereof are provided. The power inductor device includes a magnetic core body and a metal conductor. The magnetic core body is formed by a magnetic powder. The metal conductor is disposed in the magnetic core body and two ends of the metal conductor are exposed outside the magnetic core body. The magnetic powder is closely combined with the metal conductor and the magnetic powder is partially embedded into a skin layer of the metal conductor to obtain an integrated power inductor structure with crystallized structures. The magnetic core and the metal conductor are assembled and formed by a heating and pressing molding process, and the crystallized structures are generated by a section heating process, a calcining process, a tempering process and a cooling process.