CN112435827A - Structure of high-impedance PFC inductor and processing technology thereof - Google Patents
Structure of high-impedance PFC inductor and processing technology thereof Download PDFInfo
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
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- H01F17/00—Fixed inductances of the signal type
- H01F17/04—Fixed inductances of the signal type with magnetic core
- H01F17/06—Fixed inductances of the signal type with magnetic core with core substantially closed in itself, e.g. toroid
- H01F17/062—Toroidal core with turns of coil around it
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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
- H01F27/2895—Windings disposed upon ring cores
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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
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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
- H01F41/06—Coil winding
- H01F41/076—Forming taps or terminals while winding, e.g. by wrapping or soldering the wire onto pins, or by directly forming terminals from the wire
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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
- H01F41/06—Coil winding
- H01F41/08—Winding conductors onto closed formers or cores, e.g. threading conductors through toroidal cores
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Abstract
The application provides a structure of a high-impedance PFC inductor and a processing technology thereof. The magnetic core is of an annular structure, and the winding is symmetrically wound along two sides of the magnetic core; the winding comprises a winding which is continuously and repeatedly wound along one side of the magnetic core and comprises a terminal S and a terminal F; and the windings are axially symmetrically distributed along the center line of the annular section of the magnetic core to form a butterfly winding structure. The butterfly winding structure of the inductor has higher impedance, so that the filter inductor can better inhibit electromagnetic interference signals.
Description
Technical Field
The application relates to the technical field of inductors, in particular to a structure of a high-impedance PFC inductor and a processing technology thereof.
Background
The development of semiconductor devices has been a driving force for the development of module power supplies, which directly promotes the improvement of the efficiency of the module power supplies. In the switching power supply, the output filter inductor plays an important role in storing energy and smoothing the output voltage of the filter. The magnitude of the output filter inductance is related not only to the current peak and effective value of the switching device, but also to the losses associated with the current peak and effective value. In order to control the size of the filter inductance, an inductor is introduced as a core element.
The inductor is similar in structure to a transformer. The inductor is used as a self-inductance electronic component, and has the functions of filtering, inhibiting instantaneous current, alternating current and the like, reducing EMI noise, converting power and the like; therefore, the circuit is widely applied to the field of electronic circuits, such as circuits for oscillation, tuning, coupling, filtering, delaying, deflection and the like.
However, the inventor of the present application has found that the output filter inductor itself in the prior art may have parasitic large parasitic capacitance and distributed capacitance during the manufacturing process, and these parasitic parameters may increase the extra loss of the switching power supply and decrease the efficiency of the switching power supply.
Disclosure of Invention
The application provides a structure of a high-impedance PFC inductor and a processing technology thereof, which are used for solving the problems in the prior art.
In order to solve the technical problem, the embodiment of the application discloses the following technical scheme:
in a first aspect, the present application provides a structure of a high impedance PFC inductor, including: a magnetic core and a winding;
the magnetic core is of an annular structure, and the winding is symmetrically wound along two sides of the magnetic core;
the winding comprises a winding which is continuously and repeatedly wound along one side of the magnetic core and comprises a terminal S and a terminal F; and the windings are axially symmetrically distributed along the center line of the annular section of the magnetic core to form a butterfly winding structure.
In a second aspect, the present application provides a process for processing a high impedance PFC inductor, comprising the following steps:
preparing an inductance material and preprocessing the inductance material, wherein the inductance material comprises a copper wire, a wire harness and a magnetic core;
winding the pretreated inductance material, and carrying out impregnation baking on the wound product;
forming and trimming the baked product by using a forming jig, and peeling and soldering the copper wire of the product;
carrying out parameter test on the product subjected to soldering;
performing wiring harness processing on the product qualified in the parameter test, and performing soldering tin processing on the terminal;
penetrating the terminal subjected to tin soldering into a sleeve, and wrapping the product with a silica gel strip;
and (4) carrying out performance test on the product, and carrying out external inspection and packaging on the product qualified in the performance test.
Optionally, the inductor material is pretreated, including:
cutting a copper wire and a wire harness, and peeling the wire end of the wire harness;
and taking three magnetic cores and adhering to obtain the magnetic core assembly.
Optionally, the impregnation baking is performed on the wound product, and the impregnation baking includes:
soaking the wound product in pre-prepared insulating paint for impregnation;
putting the impregnated product into a dust-free cloth for drip drying;
and baking the product after dripping dry to solidify the insulating paint.
Optionally, the parameter testing of the product after soldering includes:
detecting an inductance value, an impedance value and a direct current resistance value of a product;
and judging whether the inductance value, the impedance value and the direct current resistance value meet preset parameter limit values.
Optionally, the performance testing of the product includes:
carrying out impedance test and interlayer test on the product; the interlaminar tests include position, voltage, area difference, area, corona, and phase difference.
Optionally, the performing external inspection on the product qualified in the performance test includes:
and (3) checking whether the appearance of the product is qualified or not by using the CCD, and checking the appearance of the product, including breakage, dark crack, foreign matter adhesion, copper wire leakage and poor welding.
Compared with the prior art, the beneficial effect of this application is:
the application provides a structure of a high-impedance PFC inductor, which comprises a magnetic core and a winding. The magnetic core is of an annular structure, and the winding is symmetrically wound along two sides of the magnetic core; the winding comprises a winding which is continuously and repeatedly wound along one side of the magnetic core and comprises a terminal S and a terminal F; and the windings are axially symmetrically distributed along the center line of the annular section of the magnetic core to form a butterfly winding structure. The inductor provided by the application has the advantages that the butterfly winding structure has high impedance, and the butterfly winding structure enables the filter inductor to better inhibit electromagnetic interference signals; the influence of parasitic parameters on the switching power supply is reduced from all aspects, the loss is reduced, and the efficiency of the switching power supply is improved.
Drawings
In order to more clearly explain the technical solution of the present application, the drawings needed to be used in the embodiments will be briefly described below, and it is obvious to those skilled in the art that other drawings can be obtained according to the drawings without any creative effort.
Fig. 1 is a structural diagram of a high-impedance PFC inductor according to an embodiment of the present disclosure;
fig. 2 is an overall flowchart of a processing process of the high-impedance PFC inductor according to the embodiment of the present disclosure.
Detailed Description
In order to make those skilled in the art better understand the technical solutions in the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application, and it is obvious that the described embodiments are only a part of the embodiments of the present application, and not all the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present application.
Referring to fig. 1, a structural diagram of a high-impedance PFC inductor according to an embodiment of the present disclosure is shown. Specifically, the inductance includes: a magnetic core and a winding.
Wherein, the magnetic core is of an annular structure.
In the embodiment of the invention, the inductance magnetic core is made of the iron-silicon-aluminum material, so that the inductance magnetic core not only has the characteristics of good current superposition performance and negative temperature coefficient, but also has good constant inductance characteristic and direct current bias resistance. The Curie temperature is above 410 ℃, and the working temperature range is-50 to +200 ℃.
The magnetic core is of an annular structure, and the winding is symmetrically wound along two sides of the magnetic core; the winding comprises a winding which is continuously and repeatedly wound along one side of the magnetic core and comprises a terminal S and a terminal F; and the windings are axially symmetrically distributed along the center line of the annular section of the magnetic core to form a butterfly winding structure.
Specifically, the winding is symmetrically wound along two sides of the magnetic core, the winding is firstly wound back and forth along one side part of the magnetic core at one position of the magnetic core until the winding is close to the magnetic core, and the winding is wound back and forth along the other side part of the magnetic core, so that the winding is axially symmetrically distributed along the center line of the annular section of the magnetic core, and a butterfly winding structure is formed. The butterfly winding structure enables the filter inductor to better restrain electromagnetic interference signals.
Compared with the prior art, the butterfly winding structure of the filter inductor can improve the winding impedance by more than 10 percent compared with a back-and-forth winding mode, and the novel butterfly winding structure enables the filter inductor to better inhibit electromagnetic interference signals; the influence of parasitic parameters on the switching power supply is reduced from all aspects, the loss is reduced, and the efficiency of the switching power supply is improved.
Referring to fig. 2, an overall flowchart of a processing process of the high-impedance PFC inductor according to the embodiment of the present disclosure is shown. The method comprises the following steps:
s1, preparing and preprocessing an inductance material, wherein the inductance material comprises a copper wire, a wire harness and a magnetic core;
s2, winding the pretreated inductance material, and carrying out impregnation baking on the wound copper wire;
s3, forming and trimming the baked product by using a forming jig, and peeling and soldering the wire harness of the product;
s4, performing parameter test on the product subjected to soldering;
s5, carrying out wiring harness processing on the product qualified in the parameter test, and carrying out soldering tin processing on the terminal;
s6, penetrating the soldered terminal into a sleeve, and wrapping the product with a silica gel strip;
and S7, performing performance test on the product, and performing external inspection and packaging on the product qualified in the performance test.
The individual steps are described in detail below:
in step S1, an inductance material including a copper wire harness and a magnetic core is prepared and preprocessed.
Specifically, the inductor material is pretreated, and the pretreatment comprises the following steps:
and cutting the copper wire, and wrapping tin at the wire end of the copper wire to enable the wire end to be smooth. The specification of the copper wire harness adopts a QZY2.0mm copper wire, and the cutting size is set to be 5.7 meters.
And (5) carrying out peeling treatment on the wire harness.
And taking three magnetic cores and adhering to obtain the magnetic core assembly.
In step S2, the inductor material after pretreatment is wound, and the wound product is subjected to impregnation baking.
And carrying out butterfly winding on the copper wire, the wire harness and the magnetic core assembly to obtain a butterfly winding structure. The butterfly winding method may be: winding the 9-turn, 6-turn and 5-turn steel wire by three layers of fixed turns, wherein each layer can not be wound by a few turns or a plurality of turns. And when one layer is wound in the winding process, the counter needs to be cleared in time, and the number of turns of each layer is ensured to be fixed. And the second layer of loop wires are wound by two wires, and no wire can be pressed between every two layers.
Carrying out impregnation baking on the wound product, comprising the following steps:
and soaking the wound product in pre-prepared insulating paint for impregnation. Wherein, the pre-prepared insulating paint position: the varnish type is J-6338; the diluent is S-9816. The proportioning concentration is as follows: 0.93-0.935. Before impregnation, the concentration of the insulating paint needs to be checked, and the concentration is tested once every four hours, so that the accuracy of the insulating paint is guaranteed.
During impregnation, the insulating paint needs to be kept still for 1 minute without vacuumizing, and products are subjected to sampling inspection to ensure the impregnation position.
And (3) dripping the impregnated product in a dust-free cloth for drying, wherein the dripping time can be 30 minutes.
And baking the product after dripping dry to solidify the insulating paint. The temperature is set to be 100 +/-5 ℃, and the baking is carried out for more than 2 hours, so as to ensure that the product is dried.
In step S3, the baked product is trimmed by a molding jig. And then a peeling machine is used for peeling the copper wire of the product.
And then the peeled copper wire is subjected to soldering tin treatment. And (3) dipping the peeled part into the soldering flux during soldering, wherein the depth of the soldering flux is based on the peeling depth, the soldering time is set to be 2s, and the temperature of a tin furnace is set to be 430 +/-15 ℃.
In step S4, a parameter test is performed on the soldered product.
Specifically, the method comprises the following steps:
firstly, the testing conditions are adjusted, and the instrument is corrected at any time in the using process so as to avoid causing larger errors.
And detecting the inductance value, the impedance value and the direct current resistance value of the product by using an inductance testing machine.
And judging whether the inductance value, the impedance value and the direct current resistance value meet preset parameter limit values. Wherein the parameter limit is set as: r (S-F) is 810uH-930uH, 16KHz/1V internal resistance 100' omega (model PT881A of inductance tester, constant temperature 25 ℃). Direct current resistance: (S-F) 28 m.OMEGA.MAX.
In step S5, the wire harness processing is performed on the product that has passed the parameter test, and the soldering processing is performed on the terminal.
Specifically, the specification of the wire harness is as follows: UL1026910 AWG. The positive connection of the red wire harness represents an S end, and the reverse connection of the black wire harness represents an F end.
Before the terminal is subjected to soldering treatment, a jet soldering machine is debugged, the speed of a motor is regulated to about 17 (regulated according to the amount of tin), and the temperature is 430 +/-5 ℃. And (3) dipping the rosin soldering flux on the terminal, and then putting the terminal into a tin furnace for soldering tin, wherein the time is set to be 2-3 seconds.
In step S6, the soldered terminal is inserted into the sleeve, and the product is wrapped with a silicone strip.
Specifically, the terminal after soldering is wrapped by the retaining wall adhesive tape. The specification of the retaining wall adhesive tape is as follows: 20 x 0.14mm, non-woven fabric material. Utilize barricade sticky tape parcel 2.1 circles, need level and smooth, exceed soldering tin position 3mm can. And then, the soldering tin position is completely wrapped by using a heat-shrinkable tube, the heat-shrinkable tube is shrunk by using a hot air gun to heat the tube, and the opening of the heat-shrinkable tube of the black wire harness is closed by using a sharp-nose pliers.
And then wrapping the product with a silica gel strip.
In step S7, the product is subjected to a performance test, and the product that passes the performance test is inspected and packaged.
Wherein, carry out performance test to the product, include: and carrying out impedance test and interlayer test on the product.
The test conditions are adjusted before testing the impedance, and the impedance test instrument is corrected at any time in the using process so as to avoid causing larger errors.
The impedance test comprises three frequency ranges of 200KHz, 1.1MHz, 5MHz and 8.2MHz respectively; the voltage is uniformly 0.5V. The specific test qualification conditions are as follows:
(S-F):1000′ΩMIN 200KHz/0.5V；
3800′ΩMIN 1.1MHz/0.5V；
440′ΩMIN 5MHz/0.5V；
180′ΩMIN 8.2MHz/0.5V。
the interlayer testing included testing the following parameters: position, voltage, area difference, area, corona, and phase difference. The specific test pass conditions were set as: the position is set to be 0-960V, the voltage is 3000V, the area difference is 30%, the area is 30%, the corona is set to be 15%, and the phase difference is 15%.
And (3) performing external inspection on the product qualified in the performance test, including:
and (3) checking whether the appearance of the product is qualified or not by using the CCD, and checking the appearance of the product, including breakage, dark crack, foreign matter adhesion, copper wire leakage and poor welding.
And (5) code spraying and packaging the products qualified by external inspection, sealing and storing to obtain the final products.
In summary, compared with the prior art, the method has the following beneficial effects:
the embodiment of the application provides a structure of a high-impedance PFC inductor, which comprises a magnetic core and a winding. The magnetic core is of an annular structure, and the winding is symmetrically wound along two sides of the magnetic core; the winding comprises a winding which is continuously and repeatedly wound along one side of the magnetic core and comprises a terminal S and a terminal F; and the windings are axially symmetrically distributed along the center line of the annular section of the magnetic core to form a butterfly winding structure. The inductor provided by the application has the advantages that the butterfly winding structure has high impedance, and the butterfly winding structure enables the filter inductor to better inhibit electromagnetic interference signals; the influence of parasitic parameters on the switching power supply is reduced from all aspects, the loss is reduced, and the efficiency of the switching power supply is improved.
Since the above embodiments are all described by referring to and combining with other embodiments, the same portions are provided between different embodiments, and the same and similar portions between the various embodiments in this specification may be referred to each other. And will not be described in detail herein.
It is noted that, in this specification, relational terms such as "first" and "second," and the like, are used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a circuit structure, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such circuit structure, article, or apparatus. The term "comprising" a defined element does not, without further limitation, exclude the presence of other like elements in a circuit structure, article, or device that comprises the element.
Other embodiments of the present application will be apparent to those skilled in the art from consideration of the specification and practice of the disclosure herein. This application is intended to cover any variations, uses, or adaptations of the invention following, in general, the principles of the application and including such departures from the present disclosure as come within known or customary practice within the art to which the invention pertains. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the application being indicated by the following claims. The above-described embodiments of the present application do not limit the scope of the present application.
Claims (7)
1. A structure of a high impedance PFC inductor, comprising: a magnetic core and a winding;
the magnetic core is of an annular structure, and the winding is symmetrically wound along two sides of the magnetic core;
the winding comprises a winding which is continuously and repeatedly wound along one side of the magnetic core and comprises a terminal S and a terminal F; and the windings are axially symmetrically distributed along the center line of the annular section of the magnetic core to form a butterfly winding structure.
2. A processing technology of a high-impedance PFC inductor is characterized by comprising the following steps:
preparing an inductance material and preprocessing the inductance material, wherein the inductance material comprises a copper wire, a wire harness and a magnetic core;
winding the pretreated inductance material, and carrying out impregnation baking on the wound product;
forming and trimming the baked product by using a forming jig, and peeling and soldering the copper wire of the product;
carrying out parameter test on the product subjected to soldering;
performing wiring harness processing on the product qualified in the parameter test, and performing soldering tin processing on the terminal;
penetrating the terminal subjected to tin soldering into a sleeve, and wrapping the product with a silica gel strip;
and (4) carrying out performance test on the product, and carrying out external inspection and packaging on the product qualified in the performance test.
3. The process of claim 2, wherein pre-treating the inductor material comprises:
cutting a copper wire and a wire harness, and peeling the wire end of the wire harness;
and taking three magnetic cores and adhering to obtain the magnetic core assembly.
4. The process of claim 2, wherein the impregnation baking of the wound product comprises:
soaking the wound product in pre-prepared insulating paint for impregnation;
putting the impregnated product into a dust-free cloth for drip drying;
and baking the product after dripping dry to solidify the insulating paint.
5. The process of claim 2, wherein the performing a parametric test on the soldered product comprises:
detecting an inductance value, an impedance value and a direct current resistance value of a product;
and judging whether the inductance value, the impedance value and the direct current resistance value meet preset parameter limit values.
6. The process of claim 2, wherein said performance testing of the product comprises:
carrying out impedance test and interlayer test on the product; the interlaminar tests include position, voltage, area difference, area, corona, and phase difference.
7. The process of claim 2, wherein said inspecting the product for eligibility comprises:
and (3) checking whether the appearance of the product is qualified or not by using the CCD, and checking the appearance of the product, including breakage, dark crack, foreign matter adhesion, copper wire leakage and poor welding.
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114243301A (en) * | 2021-12-07 | 2022-03-25 | 北京铁路信号有限公司 | Magnetic antenna |
| CN114758881A (en) * | 2022-04-18 | 2022-07-15 | 宁波中科毕普拉斯新材料科技有限公司 | Preparation method of chip inductor |
| CN115036117A (en) * | 2022-05-17 | 2022-09-09 | 安徽省昌盛电子有限公司 | Production process of annular inductor |
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| CN115036117A (en) * | 2022-05-17 | 2022-09-09 | 安徽省昌盛电子有限公司 | Production process of annular inductor |
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