CN112786302A - Inductor and compression molding method thereof - Google Patents
Inductor and compression molding method thereof Download PDFInfo
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- CN112786302A CN112786302A CN202011629809.2A CN202011629809A CN112786302A CN 112786302 A CN112786302 A CN 112786302A CN 202011629809 A CN202011629809 A CN 202011629809A CN 112786302 A CN112786302 A CN 112786302A
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- 238000000034 method Methods 0.000 title claims abstract description 45
- 238000000748 compression moulding Methods 0.000 title claims abstract description 20
- 239000006247 magnetic powder Substances 0.000 claims abstract description 51
- 238000009413 insulation Methods 0.000 claims abstract description 23
- 238000000465 moulding Methods 0.000 claims abstract description 10
- 239000011248 coating agent Substances 0.000 claims description 24
- 238000000576 coating method Methods 0.000 claims description 24
- 239000002245 particle Substances 0.000 claims description 15
- 238000003825 pressing Methods 0.000 claims description 15
- 239000011230 binding agent Substances 0.000 claims description 13
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 12
- 229920000647 polyepoxide Polymers 0.000 claims description 9
- 229910000838 Al alloy Inorganic materials 0.000 claims description 7
- -1 iron-silicon-aluminum Chemical compound 0.000 claims description 7
- 239000002923 metal particle Substances 0.000 claims description 7
- 238000005507 spraying Methods 0.000 claims description 7
- 229910000599 Cr alloy Inorganic materials 0.000 claims description 6
- XEVZIAVUCQDJFL-UHFFFAOYSA-N [Cr].[Fe].[Si] Chemical compound [Cr].[Fe].[Si] XEVZIAVUCQDJFL-UHFFFAOYSA-N 0.000 claims description 6
- 229920003180 amino resin Polymers 0.000 claims description 6
- 239000000788 chromium alloy Substances 0.000 claims description 6
- 239000003822 epoxy resin Substances 0.000 claims description 6
- 230000000149 penetrating effect Effects 0.000 claims description 6
- 229920002050 silicone resin Polymers 0.000 claims description 6
- 229910000676 Si alloy Inorganic materials 0.000 claims description 4
- 239000012774 insulation material Substances 0.000 claims description 4
- XWHPIFXRKKHEKR-UHFFFAOYSA-N iron silicon Chemical compound [Si].[Fe] XWHPIFXRKKHEKR-UHFFFAOYSA-N 0.000 claims description 4
- 239000000843 powder Substances 0.000 claims description 4
- 239000011810 insulating material Substances 0.000 claims description 3
- 229910045601 alloy Inorganic materials 0.000 claims description 2
- 239000000956 alloy Substances 0.000 claims description 2
- 238000011049 filling Methods 0.000 claims description 2
- 230000007246 mechanism Effects 0.000 claims description 2
- 238000004804 winding Methods 0.000 abstract description 8
- 238000011161 development Methods 0.000 abstract description 5
- 238000002360 preparation method Methods 0.000 abstract description 4
- 239000000853 adhesive Substances 0.000 description 6
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- 229910052751 metal Inorganic materials 0.000 description 6
- 239000002184 metal Substances 0.000 description 6
- 238000004519 manufacturing process Methods 0.000 description 5
- 239000007787 solid Substances 0.000 description 5
- 239000004593 Epoxy Substances 0.000 description 3
- 239000003973 paint Substances 0.000 description 3
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 2
- 229920001225 polyester resin Polymers 0.000 description 2
- 239000004645 polyester resin Substances 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229910052710 silicon Inorganic materials 0.000 description 2
- 239000010703 silicon Substances 0.000 description 2
- 239000002966 varnish Substances 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 239000004642 Polyimide Substances 0.000 description 1
- 238000007792 addition Methods 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000002457 bidirectional effect Effects 0.000 description 1
- 230000000903 blocking effect Effects 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction 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
- 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
-
- 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
-
- 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
-
- 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
-
- 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
- H01F2017/048—Fixed inductances of the signal type with magnetic core with encapsulating core, e.g. made of resin and magnetic powder
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Coils Or Transformers For Communication (AREA)
- Manufacturing Cores, Coils, And Magnets (AREA)
Abstract
The invention provides an inductor and a method for press forming the same, wherein the method comprises the following steps: placing the inductance coil in a mold, then adding magnetic powder to fill the inside and the outside of the inductance coil, and performing compression molding in the mold to obtain a molded part; and curing the formed part, and performing insulation treatment to obtain the inductor. According to the method, the inductor is prepared in a one-step compression molding mode, and the magnetic core of the inductance coil and the outer side molding part are integrally molded to form a whole, so that the problem of unstable structure of the inductance coil is solved, the high strength of the inductor is ensured, and the performance of the inductor is excellent; the method simplifies the preparation process of the inductor, the magnetic core and the outer side forming part do not need to be pressed in a sub-step mode, the space utilization rate of the inductor coil during winding is high, and the miniaturization development of the inductor is facilitated.
Description
Technical Field
The invention belongs to the technical field of electronic equipment, and relates to an inductor and a press forming method thereof.
Background
An inductor, also called an inductor coil, is capable of converting electrical energy into magnetic energy and storing the magnetic energy, is one of the basic elements constituting an electronic circuit, and is widely used in the electronic circuit. The structure of the inductor is similar to that of a transformer, but only one winding with certain inductance only blocks the change of current, so that the inductor plays roles of current blocking, voltage reduction, cross-linking coupling, loading and the like in an alternating current circuit.
With the size of electronic components becoming smaller and smaller, the size of inductors is also becoming smaller and smaller, and the space utilization of inductors is also required to be improved. Early inductors were mainly wire-wound inductors, in which enameled wires were wound around the outside of a magnetic conductor to form a cylindrical, i-shaped, or toroidal inductor, etc. However, because the coil and the magnetizer of the wire-wound inductor are not of an integrated structure, the inductance value is low, the consistency of product parameters is difficult to ensure, and the processing production efficiency is low. At present, the integrally formed inductor is used more, but the integrally formed inductor generally has defects in structure and forming method. For example, the lead frame is usually soldered to the terminals of the conductive elements, but the lead frame usually occupies a large space, and the space utilization is reduced, so that the lead frame is not suitable for the trend of miniaturization of electronic components.
CN 202183292U discloses an improved integrally formed inductor, which comprises a coil, a magnetic solid body and two electrode pins, wherein the coil is embedded in the magnetic solid body, one end of the electrode pin is a first end portion, the other end of the electrode pin is a second end portion, the first end portions of the two electrode pins are respectively embedded in the magnetic solid body, and the two electrode pins are respectively welded with two ends of the coil. The inductor forming step comprises the steps of manufacturing an electrode pin, assembling a coil, passing through a baking furnace, pressing and forming a magnetic solid body, cutting the electrode pin and bending the electrode pin, the improvement mainly lies in the welding between the electrode pin and an electrode slice, no emphasis is put on the pressing and forming, and a central magnetic core of the inductor and the magnetic solid body outside the coil are also two separated parts and need to be pressed and formed twice.
CN 101377975a discloses an integrated inductor and its manufacturing method, the inductor includes a pressed metal magnetic powder block and an inductance coil, the inductance coil includes a coil body and two terminals, the coil body is made of metal enameled wire, the coil body is embedded in the metal magnetic powder block, the terminals are located outside two sides of the metal magnetic powder block, the coil body is a bidirectional spiral structure, and the manufacturing method includes winding the inductance coil first, the two terminals of the inductance coil are welded on an electrode frame, when the metal magnetic powder and the inductance coil are pressed in a mixed manner, the metal magnetic powder is wrapped outside the coil, the use of a magnetic core inside the coil is not mentioned, the same needs to be pressed first to form, the process is complex, two steps are needed to complete, and a complete integrated inductor cannot be formed.
In summary, for the manufacturing and forming of the inductor, it is necessary to select a suitable manner, so that the step of pressing the magnetic core can be omitted, the magnetic core can be formed by one-step pressing, and meanwhile, the strength of the coil is ensured, and the performance of the inductor is improved.
Disclosure of Invention
The invention aims to provide an inductor and a compression molding method thereof, wherein the inductor is prepared by one-step compression molding, a magnetic core of an inductance coil and an outer side molding part are integrally molded, the step of independently pressing the magnetic core is reduced, the strength of the inductor can be improved, the space utilization rate of coil winding is improved, and the miniaturization development of the inductor is facilitated.
In order to achieve the purpose, the invention adopts the following technical scheme:
in one aspect, the present invention provides a method of press forming an inductor, the method comprising the steps of:
(1) placing the inductance coil in a mold, then adding magnetic powder to fill the inside and the outside of the inductance coil, and performing compression molding in the mold to obtain a molded part;
(2) and (3) curing the formed part obtained in the step (1) and then carrying out insulation treatment to obtain the inductor.
According to the invention, the inductor is prepared in a one-step compression molding manner, after the inductor coil is placed in a mold, magnetic powder is filled in the inductor coil and outside the inductor coil, and all parts form a whole in a compression molding manner, so that the problem of unstable structure of the inductor coil is avoided, the high strength of the inductor is ensured, and the performance of the inductor is excellent; the method simplifies the preparation process of the inductor, does not need to press the magnetic core and the outer side forming piece in a grading way, and meanwhile, the connection between the coil end and the electrode plate is placed on the outer side of the inductor without the design of a complex structure in the inductor; the space utilization rate of the inductor coil during winding is high, and the miniaturization development of the inductor is facilitated.
The following technical solutions are preferred technical solutions of the present invention, but not limited to the technical solutions provided by the present invention, and technical objects and advantageous effects of the present invention can be better achieved and achieved by the following technical solutions.
As a preferable technical scheme of the invention, the inductance coil in the step (1) is made into a spiral shape by winding an enameled wire.
Preferably, the helical king post shape comprises a circle or an ellipse.
Preferably, two terminals are arranged on two sides of one end of the inductance coil, and the two terminals are parallel to or perpendicular to a radial plane of the inductance coil.
The enameled wire for winding the inductance coil is mainly made of copper, polyimide is coated on the outer side of the enameled wire, the wire is a flat wire or a round wire, the width of the flat wire is about 0.2-1.0 mm, the thickness of the flat wire is about 0.05-0.25 mm, the diameter of the round wire is about 0.1-0.8 mm, and the shape of the coil can be kept without a magnetic core.
As a preferable technical scheme of the invention, the size of the die in the step (1) is larger than that of the inductance coil.
Preferably, the inductor coil has a radial plane area of 35% to 45%, for example 35%, 36%, 38%, 40%, 42%, 44% or 45% of the transverse cross-sectional area of the die, but not limited to the values recited, and other values not recited within this range of values are equally applicable.
In the invention, the inductance coil is generally circular, the cross section of the die is generally square, the die with corresponding size is selected according to the size of the column in the coil and the thickness of the enameled wire on the outer side, for example, the die with 4mm by 4mm is selected, wherein the inner diameter of the coil, namely the diameter of the center column, is 1.9mm, the enameled wire is a flat wire with 0.8mm by 0.25mm, and a certain distance is left between the outer side of the coil and the edge of the inner cavity of the die.
Preferably, the bottom of the die in step (1) is provided with fixing slots or through holes for fixing or penetrating out terminals of the inductance coil.
According to the invention, the arrangement of the fixing groove at the bottom of the die is matched with the size of the inductance coil terminal, so that magnetic powder is prevented from entering the fixing groove, the molded coil terminal is exposed, and the subsequent operation is convenient.
In a preferred embodiment of the present invention, the magnetic powder in step (1) is formed by coating a binder on the outer side of the metal particles.
Preferably, the average particle size of the magnetic powder in step (1) is 60 to 150 mesh, for example, 60 mesh, 80 mesh, 100 mesh, 120 mesh, 140 mesh, 150 mesh, etc., but the average particle size is not limited to the recited values, and other values not recited in the range of the values are also applicable.
Preferably, the metal particles comprise alloyed iron powder and/or carbonyl iron powder.
Preferably, the alloyed iron powder comprises any one of or a combination of at least two of iron-silicon-chromium alloy, iron-silicon-aluminum alloy, or iron-silicon alloy, as typical but non-limiting examples: combinations of iron-silicon-chromium alloys and iron-silicon-aluminum alloys, combinations of iron-silicon-aluminum alloys and iron-silicon alloys, combinations of iron-silicon-chromium alloys, iron-silicon-aluminum alloys and iron-silicon alloys, and the like.
In the present invention, the alloy iron powder may be classified from the above-described elemental composition, and may also be classified from the crystal type, for example, into amorphous powder, nanocrystalline powder, and the like.
Preferably, the binder comprises any one of, or a combination of at least two of, epoxy, silicone or amino resins, typical but non-limiting examples of which are: combinations of epoxy and silicone resins, combinations of silicone and amino resins, combinations of epoxy, silicone and amino resins, and the like.
In the invention, because the inductor is formed by one-step pressing, higher strength can be ensured, the content of the required binder does not need to be excessively high, the content of the corresponding magnetic metal particles can be improved, and the performance of the inductor can be improved, wherein the content of the used binder is 0.8-3.5 wt% of the magnetic powder, such as 0.8 wt%, 1 wt%, 1.5 wt%, 2 wt%, 2.5 wt%, 3 wt% or 3.5 wt%, and the like, but is not limited to the recited values, and other values in the numerical value range are also applicable.
In a preferred embodiment of the present invention, the pressure for press molding after filling the magnetic powder in step (1) is 600 to 1000MPa, for example, 600MPa, 650MPa, 700MPa, 750MPa, 800MPa, 850MPa, 900MPa, 950MPa, or 1000MPa, but the pressure is not limited to the above-mentioned values, and other values not listed in the above-mentioned range are also applicable.
Preferably, the temperature of the press molding in step (1) is 100 to 180 ℃, for example, 100 ℃, 110 ℃, 120 ℃, 130 ℃, 140 ℃, 150 ℃, 160 ℃, 170 ℃ or 180 ℃, but not limited to the recited values, and other values not recited in the range of the values are also applicable.
Preferably, the molded part in the step (1) is taken out of the mold by ejecting the molded part by a demolding mechanism.
In a preferred embodiment of the present invention, the curing in step (2) is baking.
Preferably, the baking temperature is 150 to 180 ℃, for example 150 ℃, 155 ℃, 160 ℃, 165 ℃, 170 ℃, 175 ℃ or 180 ℃, but not limited to the recited values, and other values not recited in the range of values are also applicable.
Preferably, the baking time is 60-400 min, such as 60min, 120min, 180min, 240min, 300min, 360min or 400min, but not limited to the recited values, and other values not recited in the range of values are also applicable.
In a preferable technical scheme of the invention, the insulation treatment in the step (2) is to coat a layer of insulation material on the surface of the formed part.
In the present invention, the insulating material is often used with an insulating varnish, and epoxy resin, polyester resin, or the like may be selected in addition to the insulating varnish.
Preferably, the coating means is spraying or coating.
And (3) peeling off the insulating layer of the terminal which is not wrapped in the inductance coil after the step (2) is finished, and preparing to form an electrode or a connecting electrode plate.
Preferably, after the inductor is prepared, the terminal is bent to be parallel to the cross section of the inductor body.
As a preferred technical scheme of the invention, the method comprises the following steps:
(1) placing an inductance coil in a mold, wherein the inductance coil is wound into a spiral shape by an enameled wire, two terminals are arranged on two sides of one end of the inductance coil, the two terminals are parallel to or perpendicular to a radial plane of the inductance coil, the size of the mold is larger than that of the inductance coil, the radial plane sectional area of the inside of the inductance coil is 35% -45% of the transverse sectional area of the mold, a fixing groove or a through hole is formed in the bottom of the mold and used for fixing or penetrating out the terminals of the inductance coil, then, magnetic powder is added to fill the inside and the outside of the inductance coil, the magnetic powder is formed by coating a binder on the outer side of metal particles, the average particle size of the magnetic powder is 60-150 meshes, the magnetic powder is pressed and molded in the mold, the pressure of the pressing and molding is 600-1000 MPa;
(2) and (2) carrying out insulation treatment on the formed part obtained in the step (1) after curing, wherein the curing mode is baking, the baking temperature is 150-180 ℃, the baking time is 60-400 min, the insulation treatment is to coat a layer of insulating material on the surface of the formed part, the coating mode is spraying or coating, an inductor is obtained, then the insulating layer of the terminal which is not coated in the inductance coil is stripped, and an electrode or a connecting electrode piece is prepared.
In another aspect, the invention provides an inductor prepared by the method.
Compared with the prior art, the invention has the following beneficial effects:
(1) according to the method, the inductor is prepared in a one-step compression molding mode, and the magnetic core of the inductance coil and the outer side molding part are integrally molded to form a whole, so that the problem of unstable structure of the inductance coil is solved, the high strength of the inductor is ensured, and the performance of the inductor is excellent;
(2) the method simplifies the preparation process of the inductor, does not need to press the magnetic core and the outer side forming part in a sub-division manner, has high space utilization rate when the coil of the inductor is wound, and is favorable for the miniaturization development of the inductor.
Detailed Description
In order to better illustrate the present invention and facilitate the understanding of the technical solutions of the present invention, the present invention is further described in detail below. However, the following examples are only simple examples of the present invention and do not represent or limit the scope of the present invention, which is defined by the claims.
The invention provides, in part, a method of press forming an inductor, the method comprising the steps of:
(1) placing the inductance coil in a mold, then adding magnetic powder to fill the inside and the outside of the inductance coil, and performing compression molding in the mold to obtain a molded part;
(2) and (3) curing the formed part obtained in the step (1) and then carrying out insulation treatment to obtain the inductor.
The following are typical but non-limiting examples of the invention:
example 1:
the embodiment provides a method for pressing and forming an inductor, which comprises the following steps:
(1) placing an inductance coil in a mould, wherein the inductance coil is wound into a spiral shape by an enameled wire, the shape of a center column is circular, two terminals are arranged on two sides of one end of the inductance coil, the two terminals are parallel to the radial plane of the inductance coil, the inner radial sectional area of the inductance coil is 40% of the transverse sectional area of the mould, a fixing groove is formed in the bottom of the mould and used for fixing the terminals of the inductance coil, then, magnetic powder is added to fill the inner side and the outer side of the inductance coil, the magnetic powder is formed by coating epoxy resin adhesive on the outer sides of iron-silicon-chromium alloy and carbonyl iron powder particles, the adhesive accounts for 2.0 wt% of the magnetic powder, the average particle size of the magnetic powder is 100 meshes, and the magnetic powder is subjected to compression molding in the mould under the pressure of 800MPa and at the temperature of;
(2) and (2) carrying out insulation treatment on the formed part obtained in the step (1) after curing, wherein the curing mode is baking, the baking temperature is 160 ℃, the baking time is 180min, the insulation treatment is to coat a layer of insulating paint on the surface of the formed part, the coating mode is spraying, so as to obtain an inductor, and then stripping the enameled wire insulating layer of the terminal which is not coated in the inductance coil, so as to prepare the formed electrode.
In the embodiment, the inductor prepared by the method has high strength and high inductance performance, the inductance value reaches 0.47 muH when the inductor is used, and the direct current resistance DCR is 3.9m omega.
Example 2:
the embodiment provides a method for pressing and forming an inductor, which comprises the following steps:
(1) placing an inductance coil in a mold, wherein the inductance coil is wound into a spiral shape by an enameled wire, a center column is in an oval shape, two terminals are arranged on two sides of one end of the inductance coil, the two terminals are perpendicular to a radial plane of the inductance coil, the inner radial sectional area of the inductance coil is 35% of the transverse sectional area of the mold, a through hole is formed in the bottom of the mold and used for penetrating out the terminals of the inductance coil, then magnetic powder is added to fill the inside and the outside of the inductance coil, the magnetic powder is formed by coating silicon resin binder on the outer side of carbonyl iron powder particles, the binder accounts for 3.0 wt% of the magnetic powder, the average particle size of the magnetic powder is 75 meshes, and the inductance coil is pressed and molded in the mold, the pressure and the temperature of the pressing and molding are controlled;
(2) and (2) carrying out insulation treatment on the formed part obtained in the step (1) after curing, wherein the curing mode is baking, the baking temperature is 180 ℃, the baking time is 120min, the insulation treatment is to coat a layer of insulating paint on the surface of the formed part, the coating mode is coating, so as to obtain an inductor, and then stripping the enameled wire insulating layer of the terminal which is not coated in the inductance coil to prepare the formed electrode.
In the embodiment, the inductor prepared by the method has high strength and high inductance performance, the inductance value reaches 0.44 muH when the inductor is used, and the direct current resistance DCR is 3.9m omega.
Example 3:
the embodiment provides a method for pressing and forming an inductor, which comprises the following steps:
(1) placing an inductance coil in a mould, wherein the inductance coil is wound into a spiral shape by an enameled wire, a center column is circular, two terminals are arranged on two sides of one end of the inductance coil, the two terminals are parallel to a radial plane of the inductance coil, the inner radial sectional area of the inductance coil is 45% of the transverse sectional area of the mould, a fixing groove is formed in the bottom of the mould and used for fixing the terminals of the inductance coil, then magnetic powder is added to fill the inner side and the outer side of the inductance coil, the magnetic powder is formed by coating amino resin binder on the outer side of iron-silicon-chromium alloy iron powder particles, the binder accounts for 1.0 wt% of the magnetic powder, the average particle size of the magnetic powder is 140 meshes, and the magnetic powder is pressed and molded in the mould, the pressure of the pressing and molding is 1000MPa, and the temperature is;
(2) and (2) carrying out insulation treatment on the formed part obtained in the step (1) after curing, wherein the curing mode is baking, the baking temperature is 150 ℃, the baking time is 360min, the insulation treatment is to coat a layer of epoxy resin insulation material on the surface of the formed part, the coating mode is spraying, so as to obtain an inductor, and then stripping off the enameled wire insulation layer of the terminal which is not coated in the inductance coil, so as to connect an electrode plate for use.
In the embodiment, the inductor prepared by the method has high strength and high inductance performance, the inductance value reaches 0.51 muH when the inductor is used, and the direct current resistance DCR is 3.9m omega.
Example 4:
the embodiment provides a method for pressing and forming an inductor, which comprises the following steps:
(1) placing an inductance coil in a mold, wherein the inductance coil is wound into a spiral shape by an enameled wire, a center pillar is in an oval shape, two terminals are arranged on two sides of one end of the inductance coil, the two terminals are perpendicular to a radial plane of the inductance coil, the inner radial sectional area of the inductance coil is 40% of the transverse sectional area of the mold, a through hole is formed in the bottom of the mold and used for penetrating out the terminals of the inductance coil, then magnetic powder is added to fill the inner side and the outer side of the inductance coil, the magnetic powder is formed by coating silicon resin adhesive on the outer sides of iron-silicon-aluminum alloy and carbonyl iron powder particles, the adhesive accounts for 1.5 wt% of the magnetic powder, the average particle size of the magnetic powder is 120 meshes, and the magnetic powder is subjected to compression molding in the mold, the pressure of the compression molding is 900 MPa;
(2) and (2) carrying out insulation treatment on the formed part obtained in the step (1) after curing, wherein the curing mode is baking, the baking temperature is 170 ℃, the baking time is 150min, the insulation treatment is to coat a layer of insulating paint on the surface of the formed part, the coating mode is coating, so as to obtain an inductor, and then stripping the enameled wire insulating layer of the terminal which is not coated in the inductance coil to prepare the formed electrode.
In the embodiment, the inductor prepared by the method has high strength and high inductance performance, the inductance value reaches 0.48 muH when the inductor is used, and the direct current resistance DCR is 3.95m omega.
Example 5:
the embodiment provides a method for pressing and forming an inductor, which comprises the following steps:
(1) placing an inductance coil in a mould, wherein the inductance coil is wound into a spiral shape by an enameled wire, a center column is circular, two terminals are arranged on two sides of one end of the inductance coil, the two terminals are parallel to a radial plane of the inductance coil, the inner radial sectional area of the inductance coil is 40% of the transverse sectional area of the mould, a fixing groove is formed in the bottom of the mould and used for fixing the terminals of the inductance coil, then, magnetic powder is added to fill the inner side and the outer side of the inductance coil, the magnetic powder is formed by coating epoxy resin adhesive on the outer side of iron-silicon-aluminum alloy iron powder particles, the adhesive accounts for 2.5 wt% of the magnetic powder, the average particle size of the magnetic powder is 90 meshes, the magnetic powder is subjected to compression molding in the mould, the pressure of the compression molding is 700MPa, and the temperature;
(2) and (2) carrying out insulation treatment on the formed part obtained in the step (1) after curing, wherein the curing mode is baking, the baking temperature is 165 ℃, the baking time is 240min, the insulation treatment is to coat a layer of polyester resin insulation material on the surface of the formed part, the coating mode is spraying, so as to obtain an inductor, and then stripping off the enameled wire insulation layer of the terminal which is not coated in the inductance coil, so as to connect an electrode plate for use.
In the embodiment, the inductor prepared by the method has high strength and high inductance performance, the inductance value reaches 0.46 muH when the inductor is used, and the direct current resistance DCR is 3.85m omega.
According to the embodiment, the inductor is prepared in a one-step compression molding mode, and the magnetic core of the inductance coil and the outer side molding part are integrally molded to form a whole, so that the problem of unstable structure of the inductance coil is solved, the high strength of the inductor is ensured, and the performance of the inductor is excellent; the method simplifies the preparation process of the inductor, the magnetic core and the outer side forming part do not need to be pressed in a sub-step mode, the space utilization rate of the inductor coil during winding is high, and the miniaturization development of the inductor is facilitated.
The applicant states that the present invention is illustrated in detail by the above examples, but the present invention is not limited to the above detailed methods, i.e. it is not meant that the present invention must rely on the above detailed methods for its implementation. It will be apparent to those skilled in the art that any modifications to the present invention, equivalents of the method of the present invention and additions of ancillary steps, selection of specific means, etc., are within the scope and disclosure of the present invention.
Claims (10)
1. A method of compression molding an inductor, the method comprising the steps of:
(1) placing the inductance coil in a mold, then adding magnetic powder to fill the inside and the outside of the inductance coil, and performing compression molding in the mold to obtain a molded part;
(2) and (3) curing the formed part obtained in the step (1) and then carrying out insulation treatment to obtain the inductor.
2. The method of claim 1, wherein step (1) said inductor coil is wound from an enameled wire into a spiral shape;
preferably, the helical king post shape comprises a circle or an ellipse;
preferably, two terminals are arranged on two sides of one end of the inductance coil, and the two terminals are parallel to or perpendicular to a radial plane of the inductance coil.
3. The method of claim 1 or 2, wherein the size of the mold of step (1) is larger than the size of the inductor coil;
preferably, the inner radial sectional area of the inductance coil is 35-45% of the transverse sectional area of the die;
preferably, the bottom of the die in step (1) is provided with fixing slots or through holes for fixing or penetrating out terminals of the inductance coil.
4. The method according to any one of claims 1 to 3, wherein the magnetic powder in step (1) is formed by coating a binder on the outer side of the metal particles;
preferably, the particle size of the magnetic powder in the step (1) is 60-150 meshes;
preferably, the metal particles comprise alloyed iron powder and/or carbonyl iron powder;
preferably, the alloy iron powder comprises any one or a combination of at least two of iron-silicon-chromium alloy, iron-silicon-aluminum alloy, iron-silicon alloy, amorphous powder or nanocrystalline powder;
preferably, the binder comprises any one of epoxy resin, silicone resin or amino resin or a combination of at least two of the epoxy resin, the silicone resin or the amino resin;
preferably, the binder accounts for 0.8-3.5 wt% of the magnetic powder.
5. The method according to any one of claims 1 to 4, wherein the pressure for press forming after filling the magnetic powder in the step (1) is 600 to 1000 MPa;
preferably, the temperature of the compression molding in the step (1) is 100-180 ℃;
preferably, the molded part in the step (1) is taken out of the mold by ejecting the molded part by a demolding mechanism.
6. The method according to any one of claims 1 to 5, wherein the curing in step (2) is by baking;
preferably, the baking temperature is 150-180 ℃;
preferably, the baking time is 60-400 min.
7. The method according to any one of claims 1 to 6, wherein the insulation treatment of step (2) is to coat the surface of the molded part with a layer of insulation material;
preferably, the coating means is spraying or coating.
8. The method according to any one of claims 1 to 7, wherein the insulation layer of the terminal not covered in the inductor coil is peeled off after the step (2) is completed to prepare the electrode or the connection electrode sheet;
preferably, after the inductor is prepared, the terminal is bent to be parallel to the cross section of the inductor.
9. Method according to any of claims 1-8, characterized in that the method comprises the steps of:
(1) placing an inductance coil in a mold, wherein the inductance coil is wound into a spiral shape by an enameled wire, two terminals are arranged on two sides of one end of the inductance coil, the two terminals are parallel to or perpendicular to a radial plane of the inductance coil, the size of the mold is larger than that of the inductance coil, the radial plane sectional area of the inside of the inductance coil is 35% -45% of the transverse sectional area of the mold, a fixing groove or a through hole is formed in the bottom of the mold and used for fixing or penetrating out the terminals of the inductance coil, then, magnetic powder is added to fill the inside and the outside of the inductance coil, the magnetic powder is formed by coating a binder on the outer side of metal particles, the particle size of the magnetic powder is 60-150 meshes, the magnetic powder is pressed and molded in the mold, the pressure of the pressing and molding is 600-1000 MPa;
(2) and (2) carrying out insulation treatment on the formed part obtained in the step (1) after curing, wherein the curing mode is baking, the baking temperature is 150-180 ℃, the baking time is 60-400 min, the insulation treatment is to coat a layer of insulating material on the surface of the formed part, the coating mode is spraying or coating, an inductor is obtained, then the insulating layer of the terminal which is not coated in the inductance coil is stripped, and an electrode or a connecting electrode piece is prepared.
10. An inductor produced by the method of any one of claims 1 to 9.
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN113488305A (en) * | 2021-06-08 | 2021-10-08 | 昆山磁通新材料科技有限公司 | Adhesive, integrally-formed inductor and preparation method |
| CN114558717A (en) * | 2022-01-24 | 2022-05-31 | 山东恒瑞磁电科技有限公司 | Paint spraying equipment and paint spraying method for integrally formed carbonyl inductor |
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| US20150162122A1 (en) * | 2013-12-09 | 2015-06-11 | Joinset Co., Ltd. | Surface mount device type inductor and method of manufacturing the same |
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| CN101567246A (en) * | 2008-04-23 | 2009-10-28 | 深圳感通科技有限公司 | Integrally-forming compacting inductor and fabricating method thereof |
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