CN102737802A - Coil and magnetic powder integrated inductor and manufacturing method thereof - Google Patents
Coil and magnetic powder integrated inductor and manufacturing method thereof Download PDFInfo
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- CN102737802A CN102737802A CN2012102286343A CN201210228634A CN102737802A CN 102737802 A CN102737802 A CN 102737802A CN 2012102286343 A CN2012102286343 A CN 2012102286343A CN 201210228634 A CN201210228634 A CN 201210228634A CN 102737802 A CN102737802 A CN 102737802A
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Abstract
The invention provides a coil and magnetic powder integrated inductor. The coil and magnetic powder integrated inductor comprises a cubic magnetic material block (5) which is internally provided with an embedded coil (4), wherein an end electrode (6) is arranged on each of two opposite sides, each of the end electrodes is connected with one end of the coil, the magnetic material block consists of more than two kinds of magnetic powder in different average particle sizes and insulation resin, and the general formula of the compositions of the magnetic powder is Fe100-x-y-z SixCryBz. A manufacturing method comprises the following steps: (I) uniformly mixing the magnetic powder in different particle sizes; (II) mixing the magnetic powder and the insulation resin into a compound magnetic material group; (III) manufacturing the hollow coil; (IV) heating a forming mold and a lower punch, filling the compound magnetic material group and the hollow coil, molding in compression, preserving heat till the resin is solidified, and then demolding; (V) polishing the two end faces; and (VI) performing vacuum sputtering to prepare the electrode. The compression molding operation can be carried out with relatively low pressure, and the magnetic particle and the coil are barely damaged in the compressing process.
Description
Technical field
The present invention relates to coil magnetic integrate shaped type inductance of a kind of use for electronic products and preparation method thereof.
Background technology
In recent years, the MPU processing speed of using along with notebook computer, server develops to high speed, has advanced the big electric currentization of supply of current.This wherein is used for the power inductance of DC/DC transducer, because the needs of the big electric current of miniaturization, one-body molded inductance shown in Figure 1 is also moving towards commercialization.Chinese patent CN1304145A describes the manufacturing approach of such inductance in detail.The used magnetic material of this type inductance is normally by insulating material be combined intos such as metal magnetic powder and resins; Metal magnetic powder and the mixing powder particle that forms of mixed with resin are obtained inductor with the cold pressing method compacting of press-powder moulding of mould, and this method is generally used.
Existing this type inductor because magnetic core is to be pressed into the high metal magnetic of saturation induction density, so not only volume is little, and is compared with the FERRITE CORE inductor, and the overlapping excellent of electric current has satisfied the requirement of big electric currentization.But its shortcoming is to compare the high magnetic permeability of very difficult acquisition with the FERRITE CORE inductor.In order to improve magnetic permeability; Just must improve the volume occupation rate of metal magnetic; Therefore the density of formed body just has to improve, since the friction between the powder particle, every square centimeter of briquetting pressure that just must apply of unit from several tons to tens of tons; Under this briquetting pressure effect, the metal magnetic of formed body is understood stressed and is deformed; When pressure was excessive, particle can be cracked; Receive the external magnetic field and do the time spent, the loss increase causes device heating, and the power inductance that is applied in the DC/DC transducer will weaken circuit efficiency; Simultaneously, the hollow coil in the inductance component has also born bigger briquetting pressure, and when wire rod contacted with powder, the insulation cortex of wire rod just destroyed easily, so just occurs short circuit problem probably.
Summary of the invention
The present invention is intended to propose a kind of coil magnetic integrate shaped type inductance, can make with less briquetting pressure, and magnet density is high, and the loss of magnetic device is less; Another purpose of the present invention is the manufacture method that proposes this coil magnetic integrate shaped type inductance.
This coil magnetic integrate shaped type inductance comprises a cube shaped piece of magnetic material, and a flush type coil is arranged in the piece of magnetic material, on two opposite faces of piece of magnetic material a termination electrode is arranged respectively, and each termination electrode links to each other with an end of coil respectively.Magnetic and insulating resin that piece of magnetic material in this coil magnetic integrate shaped type inductance is made up of two or more different average grain diameters are formed, and general formula Fe is used in the molecular composition of this magnetic
100-x-y-zSi
xCr
yB
zExpression, 3 ≦ x ≦ 8,2 ≦ y ≦ 6,1.5 ≦ z ≦ 4 wherein, described insulating resin evenly is wrapped in the magnetic powder particle surface.
The manufacture method of this coil magnetic integrate shaped type inductance adopts the warm compaction molding method, and step is:
(1) in predetermined ratio two or more varigrained magnetics is evenly mixed mutually;
(2) magnetic of first step gained and insulating resin evenly are blended into the claylike composite magnetic material group that between 80 ℃ ~ 120 ℃, is plasticity cement body in predetermined ratio;
(3) make hollow coil;
(4) be heated to 80 ℃ ~ 120 ℃ to mould and low punch, the hollow coil that the composite magnetic material is rolled into a ball and the 3rd step reorganized and outfit of reorganizing and outfit for second step is filled into warmed-up mould the inside, makes hollow coil be embedded in the composite magnetic; Pressurization compression moulding, pressure limit: every square centimeter of 1kgf～1 * 10
3Kgf; Heating mould to 140 ~ 160 ℃ when keeping briquetting pressure are incubated the demoulding behind the resin solidification, obtain a coil and are embedded in the block in the body of magnetic material;
(5) will go up the polishing of two of hollow coil lead end end faces will be arranged on the block that obtains of step;
(6) use vacuum sputtering, on two good end faces of polishing, process electrode.
This coil magnetic integrate shaped type inductance is owing to adopt composition to use general formula Fe
100-x-y-zSi
xCr
yB
zLow-loss non-crystaline amorphous metal magnetic of expression, and magnetic consist of two or more different average grain diameters, the magnet density that hot pressing obtains is very high, so the loss of magnetic device is less relatively.Again owing to added insulating resin in the magnetic; In advance to magnetic group and mold heated, magnetic group is plasticity cement body under this temperature, be convenient to compression moulding when compacting; Can accomplish the compression moulding operation with less pressure, pressing process is all very little to the damage of magnetic grain and coil.
Description of drawings
Fig. 1 is the structural representation of existing one-body molded inductance;
Fig. 2 is the structure chart of coil magnetic integrate shaped type inductance of the present invention;
Fig. 3 is the schematic diagram of the compression moulding of coil magnetic integrate shaped type inductance;
The course of processing sketch map of Fig. 4 product of the present invention.
Embodiment
The structure of existing one-body molded inductance is as shown in Figure 1, comprises magnetic material 2, imbeds two lead ends 3 of the coil 1 in the magnetic material.
As shown in Figure 2; This coil magnetic integrate shaped type inductance of the present invention comprises a cube shaped piece of magnetic material 5; A flush type coil 4 is arranged in the piece of magnetic material, on two opposite faces of piece of magnetic material a termination electrode 6 is arranged respectively, each termination electrode links to each other with an end of coil respectively.Magnetic and insulating resin that piece of magnetic material 5 is made up of two or more different average grain diameters are formed, and the composition of described magnetic is used general formula Fe
100-x-y-zSi
xCr
yB
zExpression, 3 ≦ x ≦ 8,2 ≦ y ≦ 6,1.5 ≦ z ≦ 4 wherein, described insulating resin evenly is wrapped in the magnetic powder particle surface.With between 80 ℃-120 ℃, be plasticity cement body before the mutually composite magnetic of the insulating resin briquettingization, be convenient to compression moulding.
Insulating resin in this coil magnetic integrate shaped type inductance can be epoxy resin, phenolic resins or silicone resin; As long as the softening temperature of insulating resin between 80 ℃ ~ 120 ℃, curing temperature between 140 ℃ ~ 160 ℃ and heatproof can use greater than 320 ℃, addition can be 4 ~ 6% of magnetic weight by weight.
The average grain diameter of the magnetic in this coil magnetic integrate shaped type inductance can be two kinds; Its average grain diameter is respectively 20 ~ 25 μ m and 3.5 ~ 6 μ m, and mixing ratio is weight ratio 75: 25 (that is: the weight of the magnetic of average grain diameter 20 ~ 25 μ m: the weight of the magnetic of average grain diameter 3.5 ~ 6 μ m=75:25).
Embodiment 1
Fe with average particulate diameter 23 μ m and 4.6 μ m
89Si
6.5Cr
2.5B
2Iron is amorphous metal magnetic powder, respectively with weight ratio 100 to 0,75 to 25 and 50 to 50 three kinds of ratio mixed.In every kind of magnetic powder, add the E5284 single-component high temperature curing high-temperature-resistant epoxy resin (boat logical boat Science and Technology Ltd. in Beijing produces) of magnetic grain weight amount 4.8% again, mix.Magnaglo is become claylike material group with mixed with resin.Group is heated to 100 ℃ in advance with the argillaceous material, is filled in the ring mould.Pressure compression moulding with every square centimeter of 1kgf.Sample size is external diameter 17mm, internal diameter 7.0mm, and height 5.0mm keeps the maximum pressure state, makes mold heated arrive 140-160 ℃, and insulation 8-15 divides swollen, makes resin solidification.Under the condition of 300Khz-40mT, measure the performance of magnetic material with the B-H analyzer, test result is as shown in table 1.
The varigrained magnetic of table 1 mixes the influence to properties of product
Can know that by result in the table magnetic of two kinds of different average grain diameters mixes, and can improve filling rate, when the magnetic weight ratio of average particulate diameter 23 μ m and 4.6 μ m is 75 to 25, at 1kgf/cm
2Lower pressure compacting down, its relative density is 97.5%, near solid density.And its magnetic permeability is maximum, loss is minimum.
Result by this embodiment 1 can know, when the magnetic in this coil magnetic integrate shaped type inductance adopted two kinds of different average grain diameters, the excellent mixing ratio of selecting was weight ratio 75: 25.
The making step of this coil magnetic integrate shaped type inductance is as shown in Figure 4:
(1) mixes varigrained magnetic: two or more varigrained magnetics are evenly mixed mutually in predetermined ratio;
(2) the mix insulation resin, be prepared into argillaceous material group: the magnetic of first step gained and insulating resin evenly are blended into the claylike composite magnetic material group that between 80 ℃～120 ℃, is plasticity cement body in predetermined ratio;
(3) make coil: the copper cash of hollow coil is flat preferably, and the outer insulating resin of coil requires high temperature resistant, preferably selects 220 grades for use;
(4) cured resin under warm compaction molding, the packing state: be heated to 80 ℃～120 ℃ to mould and low punch 9; Shown in Fig. 3 (a); The composite magnetic material group the 8 and the 3rd of reorganizing and outfit for second step goes on foot the hollow coil of reorganizing and outfit 4 and is filled into warmed-up mould 7 the insides, makes hollow coil be embedded in the composite magnetic; Shown in Fig. 3 (b), the upper punch 10 that closes, pressurization compression moulding, pressure limit: every square centimeter of 1kgf～1 * 10
3Kgf; Heating mould to 140～160 ℃ when keeping briquetting pressure be incubateds 9-10 minute, behind resin solidification, and cooling, the demoulding obtains a coil and is embedded in the interior block of body of magnetic material;
(5) end face polishing: will go up to go on foot has the polishing of two of hollow coil lead end end faces on the block that obtains;
(6) vacuum sputtering forms termination electrode: use vacuum sputtering, on two good end faces of polishing, process electrode, the electrode material of vacuum sputtering can be platinum, gold or their alloy body.
Process the inductor of overall dimension 6.7*7.4*3.0mm with method of the present invention, inductance value 1.0 μ H, used magnetic composition is Fe
88.5Si
6.5Cr
2.5B
2.5The non-crystaline amorphous metal magnetic, average particulate diameter 23 μ m and 5 μ m, weight ratio is 75: 25; The epoxy resin addition is a magnetic weight 4.8%, and the enamelled wire of used coil is a flat, width 1.8mm; Thickness 0.25mm, the paint film specification is 220-II (the good wire rod Co., Ltd of rising in Jiangxi produces).Be heated to 100 ℃ to mould and low punch, magnetic material group is heated to 100 ℃, coil and magnetic material group are inserted in the mould, pressurization, pressure 120 ± 1kgf is warmed up to 150 ± 2 ℃, pressure heat-preserving 9-10 minute, takes out manufactured goods.With Φ 500 diamond fine sand polished end faces, final vacuum sputter platinum product forms extraction electrode.
Inductor with the measure-alike inductance value made from the method for common press-powder moulding of identical appearance uses on the DC/DC transducer, its circuit efficiency compared, and test frequency 300KHz, the result is as shown in table 2.
Table 2 press-powder shaped article and embodiment of the invention product circuit efficiency are relatively
Can know that from table 2 data compare with common press-powder shaped article, the product that the present invention obtains has higher relatively circuit efficiency.This one of them important reasons is that with relatively low exert pressure moulding, inner coil sustains damage very little, and it is also little that while magnetic is examined ruined possibility, and the loss of inductor is less relatively thus.
Claims (4)
1. coil magnetic integrate shaped type inductance; Comprise a cube shaped piece of magnetic material (5); A flush type coil (4) is arranged in the piece of magnetic material, on two opposite faces of piece of magnetic material a termination electrode (6) is arranged respectively, each termination electrode links to each other with an end of coil respectively; It is characterized in that magnetic and insulating resin that described piece of magnetic material is made up of two or more different average grain diameters form, the composition of described magnetic is used general formula Fe
100-x-y-zSi
xCr
yB
zExpression, 3 ≦ x ≦ 8,2 ≦ y ≦ 6,1.5 ≦ z ≦ 4 wherein, described insulating resin evenly is wrapped in the magnetic powder particle surface.
2. coil magnetic integrate shaped type inductance as claimed in claim 1 is characterized in that described insulating resin is an epoxy resin, and addition is 4 ~ 6% of magnetic weight by weight.
3. coil magnetic integrate shaped type inductance as claimed in claim 1, the average grain diameter that it is characterized in that described magnetic is two kinds, and its average grain diameter is respectively 20 ~ 25 μ m and 3.5 ~ 6 μ m, and mixing ratio is weight ratio 75:25.
4. the manufacture method of claim 1,2 or 3 described coil magnetic integrate shaped type inductance is characterized by molding mode and uses the warm compaction molding method, and step is:
(1) in claim 1,2 or 3 described ratios two or more varigrained magnetics is evenly mixed mutually;
(2) magnetic of first step gained and insulating resin evenly are blended into the claylike composite magnetic material group that between 80 ℃ ~ 120 ℃, is plasticity cement body in claim 1,2 or 3 described ratios;
(3) make hollow coil;
(4) be heated to 80 ℃ ~ 120 ℃ to mould and low punch, the hollow coil that the composite magnetic material is rolled into a ball and the 3rd step reorganized and outfit of reorganizing and outfit for second step is filled into warmed-up mould the inside, makes hollow coil be embedded in the composite magnetic; Pressurization compression moulding, pressure limit: every square centimeter of 1kgf～1 * 10
3Kgf; Heating mould to 140 ~ 160 ℃ when keeping briquetting pressure are incubated the demoulding behind the resin solidification, obtain a coil and are embedded in the block in the body of magnetic material;
(5) will go up the polishing of two of hollow coil lead end end faces will be arranged on the block that obtains of step;
(6) use vacuum sputtering, on two good end faces of polishing, process electrode.
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| CN2012102286343A CN102737802A (en) | 2012-07-02 | 2012-07-02 | Coil and magnetic powder integrated inductor and manufacturing method thereof |
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| CN103700478A (en) * | 2013-12-14 | 2014-04-02 | 和瑞电子(中山)有限公司 | Manufacturing method of miniaturized inductor |
| CN103714961A (en) * | 2012-10-03 | 2014-04-09 | Tdk株式会社 | Inductor and manufacturing method thereof |
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| CN104347228A (en) * | 2013-07-29 | 2015-02-11 | 三星电机株式会社 | Chip electronic component and manufacturing method thereof |
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