CN111508694A - Ultralow-impedance hot-press molding inductor and manufacturing method thereof - Google Patents
Ultralow-impedance hot-press molding inductor and manufacturing method thereof Download PDFInfo
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- CN111508694A CN111508694A CN202010424749.4A CN202010424749A CN111508694A CN 111508694 A CN111508694 A CN 111508694A CN 202010424749 A CN202010424749 A CN 202010424749A CN 111508694 A CN111508694 A CN 111508694A
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/2871—Pancake coils
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/04—Fixed inductances of the signal type with magnetic core
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/02—Casings
- H01F27/04—Leading of conductors or axles through casings, e.g. for tap-changing arrangements
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/29—Terminals; Tapping arrangements for signal inductances
- H01F27/292—Surface mounted devices
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/005—Impregnating or encapsulating
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/12—Insulating of windings
- H01F41/127—Encapsulating or impregnating
Abstract
The invention discloses an ultra-low impedance hot press molding inductor and a manufacturing method thereof, wherein the inductor comprises an inductor coated insulator and a group of inductor functional components embedded in the inductor coated insulator; the inductance functional assembly is formed by combining a magnetic core body and a flat coil, the inductance coating insulator coats the peripheral part of the inductance functional assembly in the hot press molding state of the inductance coating insulator and the inductance functional assembly, and two pin parts of the flat coil protrude out of one side end face of the inductance coating insulator. The invention replaces cold press molding with hot press molding, replaces a round coil with a flat coil and the like, thereby greatly improving the insulation performance of the inductance device and improving the use stability of the inductance device. The inductor device can bear higher maximum current, has low alternating current loss in the practical application process, and improves the integral energy-saving effect of the device to the maximum extent.
Description
Technical Field
The invention relates to an integrally formed inductor, in particular to an ultra-low impedance hot-pressed inductor and a corresponding manufacturing method thereof, and belongs to the technical field of inductor processing.
Background
The inductor is one of the most common components in electronic devices and one of the important components in circuits, and is widely used in various circuits to achieve the functions of filtering, storing energy, matching and resonating.
With the recent continuous development of computer communication, artificial intelligence and other technologies, the updating iterations of various hardware devices are increasingly frequent, and the design and manufacture of various hardware devices are also developing towards the trend of integration and miniaturization, so that the hardware devices are fully utilized and the arrangement among the internal components is more compact. Taking manufacturing and processing of the current vehicle-mounted electrical component and part of the cloud server as an example, because requirements of the equipment on external dimensions and internal structures are strict, and the internal space of the hardware equipment needs to be fully utilized during design, the arrangement of the internal components is tighter, and the requirements on the power type inductor used in the equipment are more severe.
At present, most of common inductors in the market are manufactured by adopting a cold pressing process, and coils used in the inductors are almost common coils with circular sections. The inductor manufactured by matching the processing technology with the coil of the type has poor reliability and high Electro Magnetic Interference (EMI), and the inductor has the problems of low bearable maximum current, high alternating current loss, high energy consumption of products and the like in practical use.
Secondly, most of power type inductor devices in the prior art are horizontal and special-shaped structures, and such structures are not only difficult to realize automatic processing operation, but also have too high occupancy rate to space, seriously restrict the overall layout of the circuit and influence the simplified design of the circuit.
Just because the prior art has the defects, several improved production processes of the high-current power inductor are also provided at present, but the practical application stages of the processes still have the problems of high manufacturing difficulty, high production cost, non-ideal practical use effect and the like.
In summary, how to provide a brand-new ultra-low impedance hot-pressed inductor and a corresponding manufacturing method thereof based on various prior arts can ensure that the inductor is suitable for various application scenarios with higher requirements and has higher reliability, and can further improve the production and manufacturing process of devices, so as to realize the automation and mass industrial production of the formed inductor, which becomes a problem to be solved by technical personnel in the field at present.
Disclosure of Invention
In view of the above-mentioned drawbacks of the prior art, an object of the present invention is to provide an integrally formed inductor with ultra-low resistance and a method for manufacturing the same.
An ultra-low impedance hot press molding inductor comprises an inductor coated insulator and a group of inductor functional components embedded in the inductor coated insulator;
the inductance functional assembly is formed by combining a magnetic core body and a flat coil, the magnetic core body comprises a square base, the upper end face of the square base is connected with a coil bulge, the square base and the coil bulge are integrally formed, the coil part of the flat coil is sleeved on the coil bulge, and two pin parts of the flat coil are bent and attached to the outer surface of the square base;
and under the hot press molding state of the inductor coating insulator and the inductor functional component, the inductor coating insulator coats the peripheral part of the inductor functional component, and two pin parts of the flat coil protrude out of one side end face of the inductor coating insulator.
Preferably, the magnetic core body is formed by cold pressing magnetic powder; the bottom surface of the square base of the magnetic core body is provided with a positioning slot hole which is matched with the positioning bulge on the processing mould and used for finishing the integral positioning of the magnetic core body; the coil bulge is formed in the center of the upper end face of the square base of the magnetic core body, the whole coil bulge is cylindrical, the diameter of the coil bulge is matched with the inner diameter of the coil part of the flat coil, and the height of the coil bulge is matched with the whole height of the flat coil.
Preferably, two opposite step surfaces are arranged on the periphery of the square base of the magnetic core body, and the two step surfaces are symmetrically arranged; each step surface is provided with two sections of turns, each turn comprises a middle section part positioned in the middle and side section parts positioned at two sides, the end surfaces of the two side section parts on the same step surface are coplanar, and the middle section part on the same step surface protrudes out of the side section parts; the width of the side section part on the step surface is matched with the width of a flat wire rod wound to form the flat coil, and the height difference between the end surface of the middle section part and the end surface of the side section part on the same step surface is matched with the thickness of the flat wire rod wound to form the flat coil.
Preferably, the turning points of the outer circumferential plane of the magnetic core body are provided with smoothly-transiting chamfer cambered surfaces.
Preferably, the flat coil is formed by winding and processing a flat wire or by flattening and trimming two end pins after winding and forming a round section wire; the wire of the flat coil is self-adhesive wire or non-self-adhesive wire, and the cross section of the wire is flat.
Preferably, the equivalent number of turns of the coil part of the flat coil is greater than 1; the two lead parts of the flat coil extend in the same direction, and the bending forming directions of the two lead parts are consistent.
Preferably, each of the lead portions of the flat coil is bent by three sections, and each of the lead portions is attached to the lower end surface of the square base of the magnetic core body and the side section portions of the step surfaces on the two sides of the square base.
A manufacturing method of an ultralow-impedance hot-press molding inductor is used for processing the ultralow-impedance hot-press molding inductor and comprises the following steps:
s1, processing a functional assembly, namely selecting a magnetic base material, forming a magnetic core body made of a corresponding material through cold press molding, and forming a flat coil by using a self-adhesive or non-self-adhesive flat wire material through winding processing;
s2, performing coil bending processing, namely combining the magnetic core body and the flat coil, so that the coil part of the flat coil is sleeved on the outer peripheral side of the coil protrusion on the magnetic core body, and then bending the pin part of the flat coil in multiple sections, so that the pin part is attached to the outer surface of the upper-shaped base of the magnetic core body, and a complete inductance functional component is obtained;
s3, powder blending processing, namely mixing metal powder, insulating powder, an adhesive, a lubricant and a curing agent to obtain coating powder for pressing;
s4, hot press molding, namely, arranging a processing die consistent with the shape of a product, placing the inductance functional component in the processing die, injecting preheated coating powder for pressing, embedding the inductance functional component in the coating powder for pressing in a reverse buckling manner, exposing two pin parts of a flat coil in the inductance functional component to the upper end surface of the coating powder for pressing, and then integrating the inductance functional component and the coating powder into a whole by hot press molding to obtain an inductance processing intermediate part combining an inductance coating insulator and the inductance functional component;
s5, baking and curing, namely baking and curing the inductance processing piece, and using the cured and formed inductance processing middleware for the subsequent steps;
s6, performing bottom spraying processing, namely performing full-coverage spraying on the end face of one side, exposed with the pin part, of the inductance processing intermediate piece by using an insulating material to form a dense insulating coating on the end face of the inductance processing intermediate piece;
s7, performing pin paint stripping processing, namely processing the pin part on the inductance processing middleware in a paint stripping processing mode, so that the coating on the surface of the pin part on the inductance processing middleware is completely stripped, and the two pin parts are completely exposed and protrude out of the end face of the inductance processing middleware;
s8, performing automatic tin soldering, namely performing automatic tin soldering and tin plating treatment on the two lead parts on the inductance processing intermediate piece to form a compact tin soldering layer on the exposed surfaces of the two lead parts, so as to obtain an inductance processing finished product;
and S9, automatically blanking and processing, wherein a series of subsequent processing is carried out on the finished product of the inductor processing, and finally the blanking and shipment of the finished product of the inductor processing are finished.
Preferably, in S1: the selection range of the magnetic base material comprises one or more of FeSiCr, FeSiAl, FeSi, FeNi, Mn-Zn, Ni-Zn, FeSiBCr and Fe-based alloy.
Preferably, in S3: the material selection range of the metal powder comprises one or more of FeSiCr, FeSiAl, FeSi and Fe-based alloy; the material range of the insulating powder comprises any one or more of epoxy resin, bakelite resin and silicone resin.
Preferably, in S4, the preheating temperature of the coating powder for pressing is 50-80 ℃, and the preheating time is 3-5 sec; in the hot-press molding process, the inductance functional component and the coating powder are heated at the temperature of 80-180 ℃ and the temperature of 1.5t/6.6 x 6.6mm2~2.5t/6.6*6.6mm2The pressure is maintained for 10-60 sec under the pressure condition.
Preferably, in S5: in the baking and curing process, the inductor processing intermediate piece is baked for 4.5-10H at the temperature of 60-180 ℃.
Preferably, in S7: the paint stripping treatment mode is grinding processing or laser cutting processing.
Preferably, in S9: the subsequent processing comprises the following operations which are sequentially executed in sequence, the automatic equipment is adopted to clean the finished inductor processed products, the automatic equipment is adopted to print characters and mark on the finished inductor processed products, the automatic equipment is adopted to test the finished inductor processed products and screen out defective products, and the automatic equipment is adopted to package the finished inductor processed products and finally finish shipment.
The advantages of the invention are mainly embodied in the following aspects:
according to the integrally-formed and ultra-low-impedance hot press forming inductor, the flat coil is adopted inside the inductor to replace a circular-section coil used in the traditional process, so that the insulating property of an inductor is greatly improved, and the use stability of the inductor is improved. The inductor device has higher inductance value, can bear the highest current with high price, has low alternating current loss in the practical application process, and improves the integral energy-saving effect of the inductor device to the maximum extent.
The whole inductor is of a cubic structure, and two pins of the inductor are arranged on the outer surface of the same side of a product, so that the inductor is different from a horizontal type and special-shaped structure in the prior art, the size and the occupied space of the whole inductor are reduced, and the arrangement flexibility of the inductor in various circuit structures and electric appliance parts is ensured. And the more regular shape also provides convenience for the design and production of corresponding die-casting molds, and increases the number of inductor devices which can be molded in the same mold. The structural design of the inductance device in the invention also enables most of steps in the inductance processing process to be completed by using an automatic means, thereby realizing the standardization and the flow of the inductance production and greatly improving the production efficiency of inductance processing enterprises.
Corresponding to the inductor device, in the manufacturing method of the ultra-low impedance hot press molding inductor disclosed by the invention, the cold press molding used in the traditional process is replaced by the hot press molding, so that the finally processed inductor device has a good use effect, the development level of the related technology is fully considered, and the process difficulty of product manufacturing is considered.
According to the method, the insulating material is sprayed on the bottom of the semi-finished product, the paint stripping treatment is carried out on the pin position, and the automatic tin soldering and plating treatment is carried out, so that the shielding property of the final finished product is effectively guaranteed, the electromagnetic interference among electric elements in a use scene is avoided as much as possible, and the method is suitable for high-precision application scenes such as vehicle-mounted parts and cloud server parts.
Finally, the invention also provides reference basis for other related schemes in the same field, so that the extension can be carried out, and the structure and the method are applied to the technical schemes of other inductance devices, thereby having very wide application prospect.
The following detailed description of the embodiments of the present invention is provided in connection with the accompanying drawings for the purpose of facilitating understanding and understanding of the technical solutions of the present invention.
Drawings
FIG. 1 is a schematic structural view of the magnetic core and the flat coil of the present invention in a half-coupled state;
FIG. 2 is a schematic structural view of the magnetic core and the pancake coil of the present invention in a half-coupled state at another viewing angle;
FIG. 3 is a schematic structural view of the magnetic core and the flat coil of the present invention in a combined state;
FIG. 4 is a schematic structural diagram of the magnetic core and the pancake coil in a combined state at another angle of view according to the present invention;
fig. 5 is a schematic view of the external overall structure of the finished product of the inductor according to the present invention.
Wherein: 1. the inductor is covered with an insulator; 2. a magnetic core body; 21. a square base; 22. a coil protrusion; 23. a step surface; 3. a flat coil; 31. a coil section; 32. a pin part.
Detailed Description
The invention provides an integrally formed and ultra-low-impedance hot-press forming inductor and a corresponding manufacturing method thereof, which are as follows.
As shown in fig. 1 to 5, an ultra-low impedance hot press molding inductor includes an inductor-coated insulator 1 and a set of inductor functional components embedded inside the inductor-coated insulator 1.
Inductance function component is formed by the combination of a magnetic core body 2 and a flat coil 3, magnetic core body 2 includes a square base 21, the up end of square base 21 is connected with a coil arch 22, square base 21 with the two integrated into one piece of coil arch 22, the coil portion 31 cover of flat coil 3 is located on the coil arch 22, two pin portions 32 of flat coil 3 buckle to paste and cover in the surface of square base 21.
In the hot press molding state of the inductor coated insulator 1 and the inductor functional component, the inductor coated insulator 1 is coated on the outer periphery of the inductor functional component, and the two pin portions 32 of the flat coil 3 protrude from one side end face of the inductor coated insulator 1.
The magnetic core body 2 is formed by cold pressing magnetic powder. The bottom surface of the square base 21 of the magnetic core body 2 is provided with a positioning slot hole which is matched with the positioning bulge on the processing mould and used for finishing the integral positioning of the magnetic core body 2. The central position of the square base 21 upper end face of the magnetic core body 2 is molded with the coil bulge 22, the coil bulge 22 is integrally cylindrical, the diameter of the coil bulge 22 is matched with the inner diameter of the coil part 31 of the flat coil 3, and the height of the coil bulge 22 is matched with the integral height of the flat coil 3.
The periphery of the square base 21 of the magnetic core body 2 is provided with two opposite step surfaces 23, and the two step surfaces 23 are symmetrically arranged. Each step surface 23 is provided with two sections of turns, and comprises a middle section part positioned in the middle and side section parts positioned on two sides, the two side section parts on the same step surface 23 have coplanar end surfaces, and the middle section part on the same step surface 23 protrudes out of the side section parts. The width of the side section part on the step surface 23 is matched with the width of a flat wire rod wound to form the flat coil 3, and the height difference between the end surface of the middle section part on the step surface 23 and the end surface of the side section part is matched with the thickness of the flat wire rod wound to form the flat coil 3.
In order to facilitate subsequent assembly operation, the turning positions of the outer circumferential plane of the magnetic core body 2 are provided with chamfer cambered surfaces in smooth transition. Similarly, considering the subsequent practical use of the product, the finished inductor product is also provided with a chamfer cambered surface at the plane turning part of the peripheral direction.
The flat coil (3) can be formed by winding and processing flat wires or by flattening and trimming two pins led out from two ends after winding and forming wires with circular sections; the wire of the flat coil 3 is self-adhesive wire or non-self-adhesive wire, and the cross section of the wire is flat. In the present embodiment, the flat coil 3 is formed by winding a flat wire, and it should be emphasized and explained that, in the technical solution of the present invention, the flat wire is actually a preferable choice of components. On the premise of not changing the whole structure of the inductor in the scheme, the flat wire can be replaced by a common wire with a circular section. Although the use effect of the technical scheme of the invention may be affected after the material is replaced, such non-preferred schemes are still at an advanced level compared with the prior art depending on other hardware structures of the technical scheme.
The equivalent number of turns of the coil portion 31 of the flat coil 3 should be guaranteed to be greater than 1 in consideration of the effect of use.
In the hardware structure of the present invention, the two lead portions 32 of the flat coil 3 are extended in the same direction, and the bending directions of the two lead portions are the same. In this embodiment, each of the lead portions 32 of the flat coil 3 is bent by three segments, and each of the lead portions is attached to the lower end surface of the square base 21 of the magnetic core body 2 and the side segment portions of the step surfaces 23 on both sides of the square base 21.
According to the integrally-formed and ultra-low-impedance hot press forming inductor, the flat coil is adopted inside the inductor to replace a circular-section coil used in the traditional process, so that the insulating property of an inductor is greatly improved, and the use stability of the inductor is improved. The inductor device has higher inductance value, can bear the highest current with high price, has low alternating current loss in the practical application process, and improves the integral energy-saving effect of the inductor device to the maximum extent.
The whole inductor is of a cubic structure, and two pins of the inductor are arranged on the outer surface of the same side of a product, so that the inductor is different from a horizontal type and special-shaped structure in the prior art, the size and the occupied space of the whole inductor are reduced, and the arrangement flexibility of the inductor in various circuit structures and electric appliance parts is ensured. And the more regular shape also provides convenience for the design and production of corresponding die-casting molds, and increases the number of inductor devices which can be molded in the same mold. The structural design of the inductance device in the invention also enables most of steps in the inductance processing process to be completed by using an automatic means, thereby realizing the standardization and the flow of the inductance production and greatly improving the production efficiency of inductance processing enterprises.
In addition, the combined arrangement mode of the inductance functional component also provides convenience for practical use, and an operator can select the magnetic core bodies 2 and the flat coils 3 which are made of different materials and have different specifications to be combined according to different use requirements, so that more targeted and targeted inductance finished products are manufactured.
The invention also discloses a manufacturing method of the ultralow-impedance hot-press molding inductor, which is used for processing the ultralow-impedance hot-press molding inductor and comprises the following steps:
and S1, processing the functional assembly, selecting a magnetic base material, forming the magnetic core body 2 made of the corresponding material through cold press molding, and forming the flat coil 3 by using a self-adhesive or non-self-adhesive flat wire material through winding processing.
The selection range of the magnetic base material comprises one or more of FeSiCr, FeSiAl, FeSi, FeNi, Mn-Zn, Ni-Zn, FeSiBCr and Fe-based alloy.
And S2, performing coil bending processing, namely combining the magnetic core body 2 and the flat coil 3, sleeving the coil part 31 of the flat coil 3 on the outer peripheral side of the coil bulge 22 on the magnetic core body 2, and then bending the pin part 32 of the flat coil 3 in multiple sections to enable the pin part to be attached to the outer surface of the upper-side-shaped base 21 of the magnetic core body 2, so as to obtain a complete inductance functional component.
S3, blending the powder, mixing the metal powder, the insulating powder, the binder, the lubricant, and the curing agent to obtain the coated powder for pressing.
The range of the material of the metal powder includes one or more of fesicricr, fesai, FeSi, and Fe-based alloy, and in this embodiment, since the insulating powder is doped in the coating powder for pressing and has an insulating effect, the material of the metal powder can be the same as that of the magnetic substrate described above.
The insulating powder accounts for about 1-10% of the coating powder for pressing, and the material range of the insulating powder comprises any one or more of epoxy resin, bakelite resin and silicone resin.
S4, hot press molding, namely, arranging a processing die consistent with the shape of the product, placing the inductance functional component in the processing die, injecting preheated coating powder for pressing, embedding the inductance functional component in the coating powder for pressing in a reverse buckling manner, exposing the two pin parts 32 of the flat coil 3 in the inductance functional component out of the upper end surface of the coating powder for pressing, and then integrating the inductance functional component and the coating powder by hot press molding to obtain an inductance processing intermediate part combining the inductance coated insulator 1 and the inductance functional component.
The preheating temperature of the coating powder for pressing is 50-80 ℃, and the preheating time is 3-5 sec.
In the hot-press molding process, the inductance functional component and the coating powder are heated at the temperature of 80-180 ℃ and the temperature of 1.5t/6.6 x 6.6mm2~2.5t/6.6*6.6mm2The pressure is maintained for 10-60 sec under the pressure condition.
And S5, baking and curing, namely baking and curing the inductance processing piece, and using the cured and formed inductance processing middleware for the subsequent steps.
In the baking and curing process, the inductor processing intermediate piece is baked for 4.5-10H at the temperature of 60-180 ℃.
And S6, performing bottom spraying processing, namely performing full-coverage spraying on the end face of one side, exposed out of the pin part 32, of the inductance processing intermediate piece by using an insulating material, so that a dense insulating coating is formed on the end face of the inductance processing intermediate piece.
S7, processing the lead parts 32 on the inductance processing intermediate piece in a paint stripping mode, so that the coating on the surfaces of the lead parts 32 on the inductance processing intermediate piece is completely stripped, and the two lead parts 32 are completely exposed and protrude out of the end face of the inductance processing intermediate piece;
the paint stripping treatment mode can be a mechanical processing mode such as grinding processing or laser cutting processing or some specific chemical agent treatment modes. The optimal way of stripping in this embodiment is a laser cutting process that is well established and widely used in the prior art, considering the technical realization and the industrial basis of the technology means relied upon.
And S8, performing automatic tin soldering, namely performing automatic tin soldering and tinning treatment on the two pin parts 32 on the inductance processing intermediate piece to form a dense tin soldering layer on the exposed surfaces of the two pin parts 32, so as to obtain an inductance processing finished product.
And S9, automatically blanking and processing, wherein a series of subsequent processing is carried out on the finished product of the inductor processing, and finally the blanking and shipment of the finished product of the inductor processing are finished.
The subsequent processing comprises the following operations which are sequentially executed in sequence, the automatic equipment is adopted to clean the finished inductor processing products, the automatic equipment is adopted to print characters and mark on the finished inductor processing products, the automatic equipment is adopted to test the inductor processing products and screen out defective products, and the automatic equipment is adopted to package the finished inductor processing products and finally finish the shipment.
In the automatic operation flow, the processing enterprise can add other automatic operation steps to the part according to actual use requirements, so that the automation degree of the method is further improved, and the execution efficiency of the method is improved.
Corresponding to the inductor device, in the manufacturing method of the ultra-low impedance hot press molding inductor disclosed by the invention, the cold press molding used in the traditional process is replaced by the hot press molding, so that the finally processed inductor device has a good use effect, the development level of the related technology is fully considered, and the process difficulty of product manufacturing is considered.
According to the method, the insulating material is sprayed on the bottom of the semi-finished product, the paint stripping treatment is carried out on the pin position, and the automatic tin soldering and plating treatment is carried out, so that the shielding property of the final finished product is effectively guaranteed, the electromagnetic interference among electric elements in a use scene is avoided as much as possible, and the method is suitable for high-precision application scenes such as vehicle-mounted parts and cloud server parts.
In addition, the invention also provides reference basis for other related schemes in the same field, so that the extension can be carried out, and the structure and the method are applied to the technical schemes of other inductance devices, thereby having very wide application prospect.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein, and any reference signs in the claims are not intended to be construed as limiting the claim concerned.
Finally, it should be understood that although the present description refers to embodiments, not every embodiment contains only a single technical solution, and such description is for clarity only, and those skilled in the art should integrate the description, and the technical solutions in the embodiments can be appropriately combined to form other embodiments understood by those skilled in the art.
Claims (14)
1. An ultralow impedance hot briquetting inductance which characterized in that: the inductor comprises an inductor-coated insulator (1) and a group of inductor functional components embedded in the inductor-coated insulator (1); the inductance functional component is formed by combining a magnetic core body (2) and a flat coil (3), wherein the magnetic core body (2) comprises a square base (21), the upper end face of the square base (21) is connected with a coil bulge (22), the square base (21) and the coil bulge (22) are integrally formed, a coil part (31) of the flat coil (3) is sleeved on the coil bulge (22), and two pin parts (32) of the flat coil (3) are bent and attached to the outer surface of the square base (21); under the hot press molding state of the inductor coating insulator (1) and the inductor functional component, the inductor coating insulator (1) coats the periphery of the inductor functional component, and two pin parts (32) of the flat coil (3) protrude out of one side end face of the inductor coating insulator (1).
2. The ultra-low impedance hot press molding inductor according to claim 1, wherein: the magnetic core body (2) is formed by cold pressing magnetic powder; the bottom surface of the square base (21) of the magnetic core body (2) is provided with a positioning slot hole which is matched with the positioning bulge on the processing mould and used for finishing the integral positioning of the magnetic core body (2); the central point of the square base (21) up end of the magnetic core body (2) puts the shaping and has coil arch (22), coil arch (22) is whole cylindrically, the diameter of coil arch (22) with the internal diameter phase-match of flat coil (3) coil portion (31), the height of coil arch (22) with the whole height phase-match of flat coil (3).
3. The ultra-low impedance hot press molding inductor according to claim 2, wherein: the periphery of the square base (21) of the magnetic core body (2) is provided with two opposite step surfaces (23), and the two step surfaces (23) are symmetrically arranged; each step surface (23) is provided with two sections of turns, and comprises a middle section part positioned in the middle and side section parts positioned at two sides, the end surfaces of the two side section parts on the same step surface (23) are coplanar, and the middle section part on the same step surface (23) protrudes out of the side section parts; the width of the side section part on the step surface (23) is matched with the width of a flat wire rod wound to form the flat coil (3), and the height difference between the end surface of the middle section part on the same step surface (23) and the end surface of the side section part is matched with the thickness of the flat wire rod wound to form the flat coil (3).
4. The ultra-low impedance hot press molding inductor according to claim 3, wherein: the turning positions of the peripheral plane on the magnetic core body (2) are provided with chamfer cambered surfaces in smooth transition.
5. The ultra-low impedance hot press molding inductor according to claim 3, wherein: the flat coil (3) is formed by winding and processing flat wires or by flattening and trimming two end pins after winding and forming round section wires; the wire of the flat coil (3) is self-adhesive wire or non-self-adhesive wire, and the cross section of the wire is flat.
6. The ultra-low impedance hot press molding inductor according to claim 5, wherein: the equivalent number of turns of a coil part (31) of the flat coil (3) is more than 1; the two pin parts (32) of the flat coil (3) extend in the same direction, and the bending forming directions of the two pin parts are consistent.
7. The ultra-low impedance hot press molding inductor according to claim 6, wherein: each lead part (32) of the flat coil (3) is bent by three sections, and each lead part is attached to the lower end face of the square base (21) of the magnetic core body (2) and the side section parts of the step faces (23) on the two sides of the square base (21).
8. A manufacturing method of an ultra-low impedance hot press molding inductor, which is used for processing the ultra-low impedance hot press molding inductor as claimed in any one of claims 1 to 7, and is characterized by comprising the following steps:
s1, processing a functional assembly, selecting a magnetic base material, forming a magnetic core body (2) made of a corresponding material through cold press molding, and forming a flat coil (3) by using a self-adhesive or non-self-adhesive flat wire through winding processing;
s2, performing coil bending processing, namely combining the magnetic core body (2) and the flat coil (3), sleeving a coil part (31) of the flat coil (3) on the outer peripheral side of a coil bulge (22) on the magnetic core body (2), and then bending a pin part (32) of the flat coil (3) in multiple sections to enable the pin part to be attached to the outer surface of a square base (21) above the magnetic core body (2) to obtain a complete inductance functional component;
s3, powder blending processing, namely mixing metal powder, insulating powder, an adhesive, a lubricant and a curing agent to obtain coating powder for pressing;
s4, hot press molding, namely arranging a processing die consistent with the shape of a product, placing the inductance functional component in the processing die, injecting preheated coating powder for pressing, embedding the inductance functional component in the coating powder for pressing in a reverse buckling manner, exposing two pin parts (32) of a flat coil (3) in the inductance functional component out of the upper end surface of the coating powder for pressing, and then integrating the inductance functional component and the coating powder into a whole by adopting hot press molding to obtain an inductance processing intermediate piece combining an inductance coating insulator (1) and the inductance functional component;
s5, baking and curing, namely baking and curing the inductance processing piece, and using the cured and formed inductance processing middleware for the subsequent steps;
s6, performing bottom spraying processing, namely performing full-coverage spraying on the end face of one side, exposed out of the lead part (32), of the inductance processing intermediate piece by using an insulating material to form a dense insulating coating on the end face of the inductance processing intermediate piece;
s7, lead stripping processing, namely processing the lead parts (32) on the inductance processing intermediate piece in a manner of stripping treatment so that the coating on the surfaces of the lead parts (32) on the inductance processing intermediate piece is completely stripped, and the two lead parts (32) are completely exposed and protrude out of the end surface of the inductance processing intermediate piece;
s8, automatic tin soldering, namely, carrying out automatic tin soldering and tin plating treatment on the two pin parts (32) on the inductance processing intermediate piece to form a compact tin soldering layer on the exposed surfaces of the two pin parts (32) to obtain an inductance processing finished product;
and S9, automatically blanking and processing, wherein a series of subsequent processing is carried out on the finished product of the inductor processing, and finally the blanking and shipment of the finished product of the inductor processing are finished.
9. The method for manufacturing an ultra-low impedance hot press molded inductor according to claim 8, wherein in S1: the selection range of the magnetic base material comprises one or more of FeSiCr, FeSiAl, FeSi, FeNi, Mn-Zn, Ni-Zn, FeSiBCr and Fe-based alloy.
10. The method for manufacturing an ultra-low impedance hot press molded inductor according to claim 8, wherein in S3: the material selection range of the metal powder comprises one or more of FeSiCr, FeSiAl, FeSi and Fe-based alloy; the material range of the insulating powder comprises any one or more of epoxy resin, bakelite resin and silicone resin.
11. The method of claim 8, wherein in S4, the preheating temperature of the coated powder for pressing is 50-80 ℃, the preheating time is 3-5 sec; in the hot-press molding process, the inductance functional component and the coating powder are heated at the temperature of 80-180 ℃ and the temperature of 1.5t/6.6 x 6.6mm2~2.5t/6.6*6.6mm2The pressure is maintained for 10-60 sec under the pressure condition.
12. The method for manufacturing an ultra-low impedance hot press molded inductor according to claim 8, wherein in S5: in the baking and curing process, the inductor processing intermediate piece is baked for 4.5-10H at the temperature of 60-180 ℃.
13. The method for manufacturing an ultra-low impedance hot press molded inductor according to claim 8, wherein in S7: the paint stripping treatment mode is grinding processing or laser cutting processing.
14. The method for manufacturing an ultra-low impedance hot press molded inductor according to claim 8, wherein in S9: the subsequent processing comprises the following operations which are sequentially executed in sequence, the automatic equipment is adopted to clean the finished inductor processed products, the automatic equipment is adopted to print characters and mark on the finished inductor processed products, the automatic equipment is adopted to test the finished inductor processed products and screen out defective products, and the automatic equipment is adopted to package the finished inductor processed products and finally finish shipment.
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113380524A (en) * | 2021-05-21 | 2021-09-10 | 无锡蓝沛新材料科技股份有限公司 | Preparation method of integrally-formed inductor solidified by magnetic field |
| CN113593843A (en) * | 2021-07-13 | 2021-11-02 | 三积瑞科技（苏州）有限公司 | Ultra-low-resistance hot-pressing non-coupling double inductor and manufacturing method thereof |
| CN113593843B (en) * | 2021-07-13 | 2024-05-03 | 三积瑞科技（苏州）有限公司 | Ultra-low-resistance hot-pressing non-coupling double inductor and manufacturing method thereof |
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2020
- 2020-05-19 CN CN202010424749.4A patent/CN111508694A/en active Pending
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113380524A (en) * | 2021-05-21 | 2021-09-10 | 无锡蓝沛新材料科技股份有限公司 | Preparation method of integrally-formed inductor solidified by magnetic field |
| CN113593843A (en) * | 2021-07-13 | 2021-11-02 | 三积瑞科技（苏州）有限公司 | Ultra-low-resistance hot-pressing non-coupling double inductor and manufacturing method thereof |
| CN113593843B (en) * | 2021-07-13 | 2024-05-03 | 三积瑞科技（苏州）有限公司 | Ultra-low-resistance hot-pressing non-coupling double inductor and manufacturing method thereof |
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