CN112509797A - Manufacturing process of patch type integrally formed inductor - Google Patents
Manufacturing process of patch type integrally formed inductor Download PDFInfo
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- CN112509797A CN112509797A CN202011337549.1A CN202011337549A CN112509797A CN 112509797 A CN112509797 A CN 112509797A CN 202011337549 A CN202011337549 A CN 202011337549A CN 112509797 A CN112509797 A CN 112509797A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 16
- 238000004804 winding Methods 0.000 claims abstract description 34
- 239000000843 powder Substances 0.000 claims abstract description 13
- 238000003825 pressing Methods 0.000 claims abstract description 13
- 239000011248 coating agent Substances 0.000 claims abstract description 12
- 238000000576 coating method Methods 0.000 claims abstract description 12
- 238000000465 moulding Methods 0.000 claims abstract description 11
- 238000005520 cutting process Methods 0.000 claims abstract description 6
- 238000007650 screen-printing Methods 0.000 claims description 11
- 239000000696 magnetic material Substances 0.000 claims description 10
- 238000003466 welding Methods 0.000 claims description 10
- 238000005096 rolling process Methods 0.000 claims description 7
- 238000005507 spraying Methods 0.000 claims description 6
- 239000002002 slurry Substances 0.000 claims description 5
- 239000000853 adhesive Substances 0.000 claims description 4
- 230000001070 adhesive effect Effects 0.000 claims description 4
- 239000000919 ceramic Substances 0.000 claims description 4
- 239000003989 dielectric material Substances 0.000 claims description 4
- 238000007731 hot pressing Methods 0.000 claims description 4
- 229910000859 α-Fe Inorganic materials 0.000 claims description 4
- 238000009713 electroplating Methods 0.000 claims description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 abstract description 5
- 238000010438 heat treatment Methods 0.000 abstract 1
- 238000000034 method Methods 0.000 description 4
- 206010066054 Dysmorphism Diseases 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000007747 plating Methods 0.000 description 1
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Classifications
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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
- H01F27/00—Details of transformers or inductances, in general
- H01F27/02—Casings
-
- 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
- H01F41/0206—Manufacturing of magnetic cores by mechanical means
- H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
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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
- H01F41/061—Winding flat conductive wires or sheets
-
- 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
- H01F41/071—Winding coils of special form
-
- 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
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Coils Or Transformers For Communication (AREA)
- Manufacturing Cores, Coils, And Magnets (AREA)
Abstract
The invention discloses a manufacturing process of a patch type integrally formed inductor, which comprises the following steps: s1, cold pressing of the shell: the shell is formed by cold pressing, and the shell groove is D-shaped; s2, winding of the coil: winding a flat wire on the surface of the cylindrical jig in an alpha winding mode, namely winding the middle part of the flat wire on the surface of the cylindrical jig, continuously winding the two ends of the flat wire on the cylindrical jig to form a coil, and cutting and fixing the tail wire of the coil through the jig; s3, coil assembly: combining the coil with the housing; s4, powder coating and hot press molding: and feeding the combined product into a hot press for powder coating and heating for forming. According to the invention, the D-shaped groove shell is adopted, the flat wire is matched to wind the coil in the alpha winding mode, the D-shaped groove shell is manufactured firstly, and then the wound coil is placed in the shell, so that the damage of a copper wire during hot press molding can be effectively avoided, the saturation value of a product is further improved, the heavy current passing of the product is improved, the yield of the product is improved, and the thickness of the product is thinner.
Description
Technical Field
The invention relates to the technical field of electronic equipment, in particular to a manufacturing process of a surface mount type integrally formed inductor.
Background
An Inductor (Inductor) is a component that can convert electrical energy into magnetic energy and store the magnetic energy, and is also called a choke, a reactor, or a dynamic reactor. The inductor is similar to a transformer in structure but has only one winding, the inductor has certain inductance which only hinders the change of current, and if the inductor is in a state of no current passing through, the inductor tries to hinder the current from flowing through the inductor when a circuit is switched on; if the inductor is in a state of passing current, the inductor tries to maintain the current unchanged when a circuit is disconnected, the product process of the traditional inductor is to wind a coil firstly and then carry out powder coating and pressing, the product reject ratio is high, the density and the hardness in the magnetic core cannot meet the product requirements, other material numbers are required to be used for replacement, and the cost is increased and cannot be avoided.
Disclosure of Invention
In order to overcome the defects in the prior art, the embodiment of the invention provides a manufacturing process of a chip integrally formed inductor, which is used for solving the problems in the background art.
The invention discloses: a manufacturing process of a patch type integrally formed inductor comprises the following steps:
step 1: cold pressing of the shell: the shell is formed by cold pressing, and the shell groove is D-shaped;
step 2: based on the step 1, winding the flat wire on the surface of the cylindrical jig in an alpha winding mode, namely winding the middle part of the flat wire on the surface of the cylindrical jig, continuously winding the two ends of the flat wire to form a coil, and cutting and fixing the tail wire of the coil;
and step 3: based on the steps 1-2, assembling the coil and the shell: placing the coil in a D-shaped shell;
and 4, step 4: based on the steps 1-3, powder coating hot press molding: and placing the combined product into a hot-press forming die, and adding one or two of a magnetic material and a non-magnetic material to perform dry hot-press forming.
Preferably, after powder coating hot pressing, rolling spraying is carried out through a rolling spraying machine, and then laser welding is carried out: two pins of the coil are parallel, and the pin end of the coil is welded with an electrode plate through laser.
Preferably, after laser welding, screen printing is performed: ferrite or ceramic dielectric material is mixed with adhesive to form slurry suitable for silk screen printing, and the slurry is printed on the surface of the electrode plate to form a dielectric film.
Preferably, the screen printing is followed by electroplating: plating layers are plated on the pin parts at the two ends of the coil.
Preferably, the inner groove of the shell is in an oval shape or other special-shaped structures.
Preferably, an arc slope is arranged in the groove in the shell, and the wire ends at two ends of the coil are laid on the arc slope.
The invention has the following beneficial effects: according to the invention, the D-shaped groove shell is adopted, the flat wire is matched to wind the coil in the alpha winding mode, the D-shaped shell is manufactured firstly, and then the wound coil is placed in the shell, so that the damage of a copper wire during hot press molding can be effectively avoided, the saturation value of a product is further improved, the heavy current passing of the product is improved, the yield of the product is improved, and the thickness of the product is thinner.
In order to make the aforementioned and other objects, features and advantages of the invention comprehensible, preferred embodiments accompanied with figures are described in detail below.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a schematic view of a D-groove housing of the present invention;
FIG. 2 is a schematic view of a coil of the present invention;
FIG. 3 is a schematic view of the coil and housing assembly of the present invention;
FIG. 4 is a schematic view of a molded product of the present invention;
FIG. 5 is a schematic view of the process of the present invention.
Reference numerals of the above figures: the D-shaped shell 1, the coil 2 and the electrode plate 5.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of 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 invention.
Example 1
Referring to fig. 1 to 5, a manufacturing process of a chip type integrally formed inductor includes the following steps:
step 1: cold pressing of the shell: the shell is formed by cold pressing, and the shell groove is D-shaped;
step 2: based on the step 1, winding a coil: winding a flat wire on the surface of the cylindrical jig in an alpha winding mode, namely winding the middle of the flat wire on the surface of the cylindrical jig, continuously winding the two ends of the flat wire to form a coil, and cutting and fixing the tail wire of the coil;
and step 3: based on the steps 1-2, assembling the coil and the shell: placing the coil in a D-shaped shell 1;
and 4, step 4: based on the steps 1-3, powder coating hot press molding: and placing the combined product into a hot-press forming die, and adding one or two of a magnetic material and a non-magnetic material to perform dry hot-press forming.
According to the invention, the D-shaped groove shell is adopted, the flat wire is matched to wind the coil in the alpha winding mode, the D-shaped shell is manufactured firstly, and then the wound coil is placed in the shell, so that the damage of a copper wire during hot press molding can be effectively avoided, the saturation value of a product is further improved, the heavy current passing of the product is improved, the yield of the product is improved, and the thickness of the product is thinner.
Example 2
Referring to fig. 1 to 5, a manufacturing process of a chip type integrally formed inductor includes the following steps:
step 1: cold pressing of the shell: the shell is formed by cold pressing, and the shell groove is D-shaped;
step 2: based on the step 1, winding a coil: winding a flat wire on the surface of the cylindrical jig in an alpha winding mode, namely winding the middle of the flat wire on the surface of the cylindrical jig, continuously winding the two ends of the flat wire to form a coil, and cutting and fixing the tail wire of the coil;
and step 3: based on the steps 1-2, assembling the coil and the shell: placing the coil in a D-shaped shell 1;
and 4, step 4: based on the steps 1-3, powder coating hot press molding: and placing the combined product into a hot-press forming die, and adding one or two of a magnetic material and a non-magnetic material to perform dry hot-press forming.
According to the invention, the D-shaped groove shell is adopted, the flat wire is matched to wind the coil in the alpha winding mode, the D-shaped shell is manufactured firstly, and then the wound coil is placed in the shell, so that the damage of a copper wire during hot press molding can be effectively avoided, the saturation value of a product is further improved, the heavy current passing of the product is improved, the yield of the product is improved, and the thickness of the product is thinner.
Further, this embodiment adopts to cover to spout through rolling the machine of spouting after the powder hot pressing, carries out laser welding afterwards, and two pins of coil 2 are parallel, and the pin end of coil 2 passes through laser welding electrode slice 5.
Further, after laser welding, screen printing is carried out: ferrite or ceramic dielectric materials are added with adhesive and the like to prepare slurry suitable for screen printing, and the dielectric film is printed on the surface of the electrode slice 5.
Example 3
Referring to fig. 1 to 5, a manufacturing process of a chip type integrally formed inductor includes the following steps:
step 1: cold pressing of the shell: the shell is formed by cold pressing, and the shell groove is D-shaped;
step 2: based on the step 1, winding a coil: winding a flat wire on the surface of the cylindrical jig in an alpha winding mode, namely winding the middle of the flat wire on the surface of the cylindrical jig, continuously winding the two ends of the flat wire to form a coil, and cutting and fixing the tail wire of the coil;
and step 3: based on the steps 1-2, assembling the coil and the shell: placing the coil in a D-shaped shell 1;
and 4, step 4: based on the steps 1-3, powder coating hot press molding: and placing the combined product into a hot-press forming die, and adding one or two of a magnetic material and a non-magnetic material to perform dry hot-press forming.
According to the invention, the D-shaped groove shell is adopted, the flat wire is matched to wind the coil in the alpha winding mode, the D-shaped shell is manufactured firstly, and then the wound coil is placed in the shell, so that the damage of a copper wire during hot press molding can be effectively avoided, the saturation value of a product is further improved, the heavy current passing of the product is improved, the yield of the product is improved, and the thickness of the product is thinner.
Further, after powder coating hot pressing, rolling spraying is carried out through a rolling spraying machine, then laser welding is carried out, two pins of the coil 2 are parallel, and pin ends of the coil 2 pass through the laser welding electrode plate 5.
Further, in the present embodiment, after laser welding, screen printing is performed, and a slurry suitable for screen printing is prepared by adding an adhesive or the like to a ferrite or ceramic dielectric material, and is printed on the surface of the electrode sheet 5 to form a dielectric film.
Further, this embodiment electroplates after screen printing, plates at coil 2's both ends pin position, and the inside recess of shell is oval or other dysmorphism, can play the guard action to coil 2's both ends.
Furthermore, an arc slope is arranged in the groove in the shell, and the wire ends at the two ends of the coil are laid on the arc slope and used for supporting the wire ends at the two ends of the coil and preventing the wire ends at the two ends of the coil from being deformed and damaged in the powder coating hot press forming process.
The principle and the implementation mode of the invention are explained by applying specific embodiments in the invention, and the description of the embodiments is only used for helping to understand the method and the core idea of the invention; meanwhile, for a person skilled in the art, according to the idea of the present invention, there may be variations in the specific embodiments and the application scope, and in summary, the content of the present specification should not be construed as a limitation to the present invention.
Claims (6)
1. A manufacturing process of a patch type integrally formed inductor is characterized by comprising the following steps of: a manufacturing process of a patch type integrally formed inductor comprises the following steps:
step 1: cold pressing of the shell: the shell is formed by cold pressing, and the shell groove is D-shaped;
step 2: based on the step 1, winding the flat wire on the surface of the cylindrical jig in an alpha winding mode, namely winding the middle part of the flat wire on the surface of the cylindrical jig, continuously winding the two ends of the flat wire to form a coil, and cutting and fixing the tail wire of the coil;
and step 3: based on the steps 1-2, assembling the coil and the shell: placing the coil in a D-shaped shell 1;
and 4, step 4: based on the steps 1-3, powder coating hot press molding: and placing the combined product into a hot-press forming die, and adding one or two of a magnetic material and a non-magnetic material to perform dry hot-press forming.
2. The manufacturing process of the chip type integrally formed inductor according to claim 1, wherein: after powder coating and hot pressing, rolling spraying is carried out through a rolling spraying machine, then laser welding is carried out, two pins of the coil are parallel, and pin ends of the coil are welded with an electrode plate through laser.
3. The manufacturing process of the chip type integrally formed inductor according to claim 2, wherein: after laser welding, screen printing is carried out, ferrite or ceramic dielectric materials are made into slurry suitable for screen printing by adding adhesive and the like, and dielectric films are printed on the surfaces of the electrode plates.
4. The manufacturing process of the patch type integrated inductor according to claim 3, wherein: electroplating is carried out after screen printing, and electroplating layers are plated on the pin parts at the two ends of the coil.
5. The manufacturing process of the patch type integrated inductor according to claim 4, wherein: the inner groove of the shell is in an oval shape or other special-shaped structures.
6. The manufacturing process of the chip type integrally formed inductor according to claim 5, wherein: an arc slope is arranged in the groove in the shell, and the wire ends at two ends of the coil are laid on the arc slope.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202011337549.1A CN112509797A (en) | 2020-11-25 | 2020-11-25 | Manufacturing process of patch type integrally formed inductor |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202011337549.1A CN112509797A (en) | 2020-11-25 | 2020-11-25 | Manufacturing process of patch type integrally formed inductor |
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| CN112509797A true CN112509797A (en) | 2021-03-16 |
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| CN202011337549.1A Pending CN112509797A (en) | 2020-11-25 | 2020-11-25 | Manufacturing process of patch type integrally formed inductor |
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114050036A (en) * | 2021-11-24 | 2022-02-15 | 横店集团东磁股份有限公司 | Integrally-formed cup-core inductor and preparation method thereof |
| CN114464439A (en) * | 2022-02-20 | 2022-05-10 | 广东创芯电子有限公司 | Shielding type power chip inductor and forming method thereof |
| US11823828B2 (en) | 2021-08-26 | 2023-11-21 | Chilisin Electronics Corp. | Inductive device and method of manufacturing the same |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN110718386A (en) * | 2019-10-21 | 2020-01-21 | 通友智能装备(江苏)有限公司 | Manufacturing process of integrally formed inductor |
| CN111986904A (en) * | 2020-08-14 | 2020-11-24 | 江苏华磁电子科技有限公司 | Manufacturing process of integrally formed inductor |
| CN111986903A (en) * | 2020-08-14 | 2020-11-24 | 江苏华磁电子科技有限公司 | Manufacturing process of integrally-formed four-electrode inductor |
-
2020
- 2020-11-25 CN CN202011337549.1A patent/CN112509797A/en active Pending
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN110718386A (en) * | 2019-10-21 | 2020-01-21 | 通友智能装备(江苏)有限公司 | Manufacturing process of integrally formed inductor |
| CN111986904A (en) * | 2020-08-14 | 2020-11-24 | 江苏华磁电子科技有限公司 | Manufacturing process of integrally formed inductor |
| CN111986903A (en) * | 2020-08-14 | 2020-11-24 | 江苏华磁电子科技有限公司 | Manufacturing process of integrally-formed four-electrode inductor |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US11823828B2 (en) | 2021-08-26 | 2023-11-21 | Chilisin Electronics Corp. | Inductive device and method of manufacturing the same |
| CN114050036A (en) * | 2021-11-24 | 2022-02-15 | 横店集团东磁股份有限公司 | Integrally-formed cup-core inductor and preparation method thereof |
| CN114464439A (en) * | 2022-02-20 | 2022-05-10 | 广东创芯电子有限公司 | Shielding type power chip inductor and forming method thereof |
| CN114464439B (en) * | 2022-02-20 | 2024-05-17 | 广东创芯电子有限公司 | Shielded power patch inductor and forming method thereof |
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