CN110164673A - 一种金属软磁复合材料电感及其制作方法 - Google Patents

一种金属软磁复合材料电感及其制作方法 Download PDF

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CN110164673A
CN110164673A CN201910380702.XA CN201910380702A CN110164673A CN 110164673 A CN110164673 A CN 110164673A CN 201910380702 A CN201910380702 A CN 201910380702A CN 110164673 A CN110164673 A CN 110164673A
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CN110164673B (zh
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余鑫树
夏胜程
李有云
车鑫
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Shenzhen Shunluo Automotive Electronics Co ltd
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Shenzhen Sunlord Electronics Co Ltd
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Abstract

本发明公开了一种金属软磁复合材料电感及其制作方法，包括将Fe、Si和Cr进行熔炼后以水雾化或气雾化的方式制成合金粉末，按粒径筛分后将不同粒径等级的粉末混合并进行包覆绝缘处理，而后造粒得到金属软磁复合材料造粒粉，利用该造粒粉压制料饼并进行传递模塑成型，以液相包覆模穴中的空心线圈，固化脱模得到半成品，再对半成品继续加热固化，制作端电极即得到成品电感。本发明所制得的电感其内部线圈皮膜几乎无受损，且具有致密度高、强度高、电性可靠性高等优点。

Description

一种金属软磁复合材料电感及其制作方法
技术领域
本发明涉及一种金属软磁复合材料电感及其制作方法。
背景技术
在科技迅猛发展的当今时代，电子产品更新换代也十分迅速，人们对电子产品的性能和可靠性的要求越发严格，因此电子产品所使用的电子元器件也须得随之更新换代。例如电感元件，电感的使用电压、电流、频率等要求越来越高，传统的粉末材料模压电感存在很多不足，无法根本地解决模压电感的痛点。
传统的粉末材料模压电感是通过将粉末填在型腔中，再通过很大压力将粉末挤压成产品，该过程受力不均匀，产品存在暗裂、短路、开路等风险。
以上背景技术内容的公开仅用于辅助理解本发明的发明构思及技术方案，其并不必然属于本专利申请的现有技术，在没有明确的证据表明上述内容在本专利申请的申请日前已经公开的情况下，上述背景技术不应当用于评价本申请的新颖性和创造性。
发明内容
本发明的主要目的在于克服现有粉末材料特性的不足，提出一种金属软磁复合材料电感及其制造方法，可采用较小的压力通过液相成型的原理，将材料均匀填充在型腔内(避免了电感产品内部的暗裂问题)，包覆空心线圈组件，但对空心线圈零损伤，避免了电感产品的短路、开裂风险。
本发明为达上述目的提出以下技术方案：
一种金属软磁复合材料电感的制作方法，包括如下步骤：
1)将Fe、Si和Cr按照如下配比混合熔炼：85～95wt％的Fe、4～10wt％的Si、1～5wt％的Cr，得到合金溶液；
2)通过水雾化或气雾化的方式将所述合金熔液制成合金粉末；
3)将所述合金粉末按粒径筛分为15～45um的第一粉末、大于45um的第二粉末以及小于15um的第三粉末；
4)将第一粉末、第二粉末和第三粉末按照如下配比进行混合：60～80wt％的第一粉末、5～20wt％的第二粉末、15～35wt％的第三粉末，并对混合粉末进行包覆绝缘处理；
5)将绝缘处理后的粉末依次进行破碎、整粒、过筛得到造粒粉，并将造粒粉压制成料饼；
6)将预制好的空心线圈组件放置于模穴中，将料饼放置于料仓，通过传递模塑成型的方式使料饼液化进入模穴，包覆线圈组件；
7)固化脱模，去除流道，得到半成品；
8)将所述半成品进行固化并制作端电极，得到成品电感。
本发明上述技术方案所提出的制作方法，其有益效果在于：所制成的造粒粉在传递模塑成型时可以液化，内部无气息，无暗裂，空间利空率高，密度更高，产品特性优；正因为该造粒粉可以液化，可以采用传递模塑成型，从而可以以较低的成型压力得到致密性、强度较好的产品，且电感产品内线圈受力很小，线圈无变形无损伤，产品无短路、开裂现象，产品可靠性更高。
附图说明
图1是本发明具体实施例的电感与现有的粉末一体成型电感的密度对比图；
图2是本发明具体实施例的电感与现有的粉末一体成型电感的强度对比图；
图3是本发明具体实施例的电感与现有的粉末一体成型电感饱和特性对比图；
图4是本发明具体实施例的电感与现有的粉末一体成型电感高温(165℃)老化试验感值对比图；
图5是本发明具体实施例的电感与现有的粉末一体成型电感高温(165℃)老化试验损耗对比图；
图6是本发明具体实施例的电感与现有的粉末一体成型电感内空心线圈皮膜受损对比图。
具体实施方式
下面结合附图和具体的实施方式对本发明作进一步说明。
本发明的具体实施方式提供了一种金属软磁复合材料电感的制作方法，包括如下步骤：
1)将Fe、Si和Cr按照如下配比混合熔炼：85～95wt％的Fe、4～10wt％的Si、1～5wt％的Cr，得到合金溶液；
2)通过水雾化或气雾化的方式将所述合金熔液制成合金粉末；还可进一步对合金粉末进行热处理以去除应力；
3)将所述合金粉末按粒径筛分为15～45um的第一粉末、大于45um的第二粉末以及小于15um的第三粉末；
4)将第一粉末、第二粉末和第三粉末按照如下配比进行混合：60～80wt％的第一粉末、5～20wt％的第二粉末、15～35wt％的第三粉末，并对混合粉末进行包覆绝缘处理。所述包覆绝缘处理的其中一种方式是将混合粉末加入树脂混合液进行混炼，其中，树脂混合液的用量占所述混合粉末的1～5.5wt％。所述树脂混合液采用固态树脂与有机溶剂混合而成，该固态树脂内含固化剂和脱模剂；其中，固态树脂占树脂混合液的1～10wt％。混炼过程使树脂混合液均匀分布到每颗粉末上，待有机溶剂挥发完全后，即得到绝缘好的粉末。更优选地，所采用的固态树脂可在60～200℃液化且液化后粘度达到10000～50000mPa.s，故需在-5℃以下冷藏保存；
5)将绝缘处理后的粉末依次进行破碎、整粒、过筛得到造粒粉，并将造粒粉压制成料饼；本发明对料饼的形状不作限制，最好是与料仓的形状相似。在传递模塑前先将造粒粉压制成为料饼再放入料仓，这样做的目的是，可在有限体积的料仓中放入更大量的造粒粉，也是提高产品密度的一个方面；
6)将预制好的空心线圈组件放置于模穴中，将料饼放置于料仓，通过传递模塑成型的方式使料饼液化进入模穴，包覆线圈组件；采用的模具是MGP模具，进行传递模塑时，设置模具的温度为150～200℃，保温时间100～500s，成型压强只需5～20MPa；
7)固化脱模，去除流道，得到半成品；
8)将所述半成品进行固化并制作端电极，得到成品电感。
下面通过一个具体的实施例对本发明的制作方法进行说明，并利用制作得到的电感与现有的粉末一体成型电感进行各方面特性对比，以印证本发明的有益效果。
①将Fe、Si和Cr按照前述提供的配比进行混炼，得到合金溶液后，采用水雾化的方式得到FeSi6.5Cr3(at％)合金粉末；
②将上述合金粉末按粒径筛分为15～45um的第一粉末、大于45um的第二粉末以及小于15um的第三粉末；
③将上述第一、第二、第三粉末按照6:3:1的质量份数比进行混合，得到混合粉末；
④将内含固化剂和脱模剂的环氧树脂与酒精按照1:10的质量份数比进行混合，得到所述树脂混合液；再加入上述混合粉末5.5wt％的树脂混合液进行混炼，使树脂混合液均匀分布在每颗粉末上，待酒精挥发完全后，进行破碎-整粒，最后过100目筛网，得到造粒粉；
⑤将上述造粒粉压制成柱状料饼；
⑥将预制好的空心线圈组件放入MGP模具的模穴中，将上述料饼放置在模具填料口即料仓中，并设置模具温度为180℃，保温300s，压强12MPa，进行传递模塑成型；
⑦固化脱模，去除流道，得到半成品；
⑧将所述半成品180℃下烘烤4h进行固化，然后制作端电极，得到样品电感。
将上述具体实施例得到的样品电感在室温、1MHz条件下进行各方面的特性测试，并与现有的粉末一体成型技术制得的电感特性比较，其中：本发明上述具体实施例制得的电感与现有技术制得的电感在密度、强度、饱和特性、高温老化试验感值、高温老化试验损耗这五个方面的对比分别如图1至图5所示。图6中(a)为现有的粉末一体成型电感内线圈皮膜受损图，(b)为本发明上述具体实施例制得的电感的内部线圈皮膜受损图。可见，采用本发明的金属软磁复合材料(即所述造粒粉)、按照本发明的制作方法制成的电感与现有的粉末一体成型电感相比，其密度、强度、饱和电流均有大幅度的提升，并且经过长时间的老化试验，产品电性基本无变化，可以看出产品的可靠性十分高。并且，从图6的对比可以看出，(a)中所示线圈受损较明显，(b)中线圈受损几乎看不到，即，本发明的制作方法对线圈皮膜的保护有本质的改善，解决了一体成型电感的痛点。
以上内容是结合具体的优选实施方式对本发明所作的进一步详细说明，不能认定本发明的具体实施只局限于这些说明。对于本发明所属技术领域的技术人员来说，在不脱离本发明构思的前提下，还可以做出若干等同替代或明显变型，而且性能或用途相同，都应当视为属于本发明的保护范围。

Claims (10)

1.一种金属软磁复合材料电感的制作方法，其特征在于，包括如下步骤：
1)将Fe、Si和Cr按照如下配比混合熔炼：85～95wt％的Fe、4～10wt％的Si、1～5wt％的Cr，得到合金溶液；
2)通过水雾化或气雾化的方式将所述合金熔液制成合金粉末；
3)将所述合金粉末按粒径筛分为15～45um的第一粉末、大于45um的第二粉末以及小于15um的第三粉末；
4)将第一粉末、第二粉末和第三粉末按照如下配比进行混合：60～80wt％的第一粉末、5～20wt％的第二粉末、15～35wt％的第三粉末，并对混合粉末进行包覆绝缘处理；
5)将绝缘处理后的粉末依次进行破碎、整粒、过筛得到造粒粉，并将造粒粉压制成料饼；
6)将预制好的空心线圈组件放置于模穴中，将料饼放置于料仓，通过传递模塑成型的方式使料饼液化进入模穴，包覆线圈组件；
7)固化脱模，去除流道，得到半成品；
8)将所述半成品进行固化并制作端电极，得到成品电感。
2.如权利要求1所述的制作方法，其特征在于，步骤2)得到的合金粉末为FeSi6.5Cr3。
3.如权利要求1所述的制作方法，其特征在于，步骤2)还包括对合金粉末进行热处理以去除应力。
4.如权利要求1所述的制作方法，其特征在于，步骤4)中，将所述混合粉末加入树脂混合液进行包覆绝缘处理；其中，树脂混合液的用量占所述混合粉末的1～5.5wt％。
5.如权利要求4所述的制作方法，其特征在于，所述树脂混合液采用固态树脂与有机溶剂混合而成；其中，所述固态树脂内含固化剂和脱模剂，所述固态树脂占树脂混合液的1～10wt％。
6.如权利要求5所述的制作方法，其特征在于，所述固态树脂在60～200℃液化且液化后粘度达到10000～50000mPa.s，保存方式为-5℃以下冷藏保存。
7.如权利要求5所述的制作方法，其特征在于，步骤4)中，将所述混合粉末加入树脂混合液进行包覆绝缘处理包括：将所述混合粉末与所述树脂混合液进行混炼，使树脂混合液均匀分布到每颗粉末上，待有机溶剂挥发完全后，完成包覆绝缘处理。
8.如权利要求1所述的制作方法，其特征在于，步骤5)过筛时采用100目筛。
9.如权利要求1所述的制作方法，其特征在于，步骤6)传递模塑成型时的成型压强为5～20MPa，模具温度为150～200℃，保温100～500s。
10.一种金属软磁复合材料电感，其特征在于：采用权利要求1至9任一项所述的制作方法制作而成。
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