CN113539668A - Coil packaging manufacturing method of inductor - Google Patents
Coil packaging manufacturing method of inductor Download PDFInfo
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- CN113539668A CN113539668A CN202110681458.8A CN202110681458A CN113539668A CN 113539668 A CN113539668 A CN 113539668A CN 202110681458 A CN202110681458 A CN 202110681458A CN 113539668 A CN113539668 A CN 113539668A
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- 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
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Abstract
The invention provides a coil packaging manufacturing method of an inductor, which comprises the steps of firstly implanting a magnetic core blank wound with a coil in advance into a mold cavity of a forming mold, and screening to obtain a first powder and a second powder, wherein the average particle size of the first powder is smaller than that of the second powder; then filling the first powder material into a gap between the coil of the magnetic core blank and the side wall of the mold cavity, and filling the second powder material into the top of the magnetic core blank; and finally, moving the forming die carrying the magnetic core blank, the first powder and the second powder to a forming press for pressing and then demolding to finish coil packaging to obtain a semi-finished inductor product. The invention has the beneficial effects that: the density of the side wall of the integrally formed inductor finished product is effectively improved, the phenomena of exposed coils and powder bridging are avoided, the inductance performance is remarkably improved and stabilized, high frequency and miniaturization of an inductor are greatly facilitated, and more possibilities are provided for targeted design and material selection of a rear-end inductor.
Description
Technical Field
The invention relates to the technical field of inductor manufacturing, in particular to a coil packaging manufacturing method of an inductor.
Background
The chip inductor is widely applied to the fields of mobile communication, computers, automotive electronics, high-resolution televisions, broadcasting satellites and the like, wherein the integrally formed inductor has shielding effect and stability which are incomparable with those of the traditional wound inductor because the coil of the integrally formed inductor is completely wrapped and packaged by soft magnetic powder.
At present, the coil of the integrated inductor is usually packaged by a one-step powder filling device, and the production process thereof includes: (1) pressing the proportioned powder into a T-shaped green body; (2) precisely winding an enameled wire at the columnar bulge of the T-shaped blank body; (3) putting the T-shaped blank body wound with the coil into a mold cavity of a mold for primary powder filling and pressing forming; (4) and demolding after compression molding to obtain the integrally molded inductor.
At present along with the continuous promotion of application occasions such as smart mobile phone, intelligent wearing product to the miniaturized, high frequency and the great current-ization of integrated into one piece inductance, its inside coil size is more and more close with the finished size of inductance, promptly at the compression molding in-process, and the space between coil and the die cavity lateral wall is more and more littleer, and this package to soft-magnetic powder material has proposed higher requirement. The above-mentioned existing integrally formed inductor coil packaging technology is not suitable for the manufacture of small-size, large-current integrally formed inductor, and mainly has the following problems: the gap between the coil and the die cavity wall is too small, if the filling powder is not distinguished, the powder is still packaged by uniformly granulated large-particle powder, so that the powder filling density on the side wall of the inductor is low, even the coil is exposed, and the shielding performance and the inductance value of the inductor finished product are obviously reduced; if the fine particle powder is completely used for filling and packaging, the yield of the fine particle powder is low, the manufacturing cost is obviously improved, the powder on the top of the inductor is not compacted enough easily, and the performance of the inductor finished product is also affected.
Therefore, a further improvement is needed to overcome the shortcomings of the conventional method for integrally forming the inductor coil package.
Disclosure of Invention
In view of the above problems in the prior art, it is an object of the present invention to provide a method for manufacturing a coil package of an inductor, so as to improve the powder filling density and the inductance performance of the inductor and reduce the production cost.
The specific technical scheme is as follows:
a method for packaging and manufacturing a coil of an inductor comprises the steps of firstly, implanting a magnetic core blank wound with the coil in advance into a mold cavity of a forming mold, and screening to obtain a first powder and a second powder, wherein the average particle size of the first powder is smaller than that of the second powder; then filling the first powder material into a gap between the coil of the magnetic core blank and the side wall of the mold cavity, and filling the second powder material into the top of the magnetic core blank; and finally, moving the forming die carrying the magnetic core blank, the first powder and the second powder to a forming press for pressing, and then demolding to finish coil packaging to obtain a semi-finished inductor product.
Preferably, a powder filling device is configured in advance, and the magnetic core blank is encapsulated by the powder filling device, and the powder filling device includes:
at least one first powder filling box for loading the first powder material;
at least one second powder filling box for loading the second powder material;
the powder filling machine is characterized in that a quantitative powder filling jig is correspondingly arranged below the first powder filling box and the second powder filling box respectively, at least one powder guide hole is formed in the quantitative powder filling jig along the vertical direction, an aligning device which is used for installing the forming die and driving the forming die to move is arranged below the quantitative powder filling jig, and the aligning device is connected with a control system.
Preferably, when the powder filling device is used for packaging the magnetic core blank, the method includes the following steps:
step S1, preliminary preparation: respectively loading the first powder material and the second powder material obtained by screening into the first powder filling box and the second powder filling box, implanting the magnetic core blank into the mold cavity of the forming mold, and then installing and fixing the forming mold on the alignment device of the powder filling device;
the average particle size of the first powder is smaller than that of the second powder;
step S2, first powder filling: starting the alignment device to drive the mold to be attached to the bottom of the quantitative powder filling jig corresponding to the first powder filling box, aligning the mold cavity with the powder guide hole, and then controlling the first powder to fall into the accommodating space between the side wall of the mold cavity and the magnetic core blank through the powder guide hole to finish primary powder filling;
step S3, second powder filling: starting the alignment device to drive the mold to be attached to the bottom of the quantitative powder filling jig corresponding to the second powder filling box, aligning the mold cavity with the powder guide hole, and then controlling the second powder to fall into the accommodating space at the top of the magnetic core blank in the mold cavity through the powder guide hole to finish secondary powder filling;
step S4, pressing and demolding: and moving the forming die carrying the magnetic core blank, the first powder and the second powder to a forming press for pressing, and then demolding to finish coil packaging to obtain the semi-finished inductor.
Preferably, the bottom of the first powder filling box is provided with corresponding first powder filling holes according to the number and positions of the mold cavities in the forming mold, and before the step S2 is executed, the method further includes:
the control system controls the quantitative powder filling jig corresponding to the lower part of the first powder filling box to move, so that the first powder filling hole is communicated with the powder guiding hole, and then the first powder material is controlled to be quantitatively filled into the corresponding quantitative powder filling jig through the first powder filling hole.
Preferably, if the second powder filling box bottom is provided with corresponding second powder filling holes according to the number and positions of the mold cavities in the forming mold, before the step S3 is executed, the method further includes:
the control system controls the quantitative powder filling jig corresponding to the lower part of the second powder filling box to move, so that the second powder filling hole is communicated with the powder guide hole, and then the second powder material is controlled to be quantitatively filled into the corresponding quantitative powder filling jig through the second powder filling hole.
Preferably, after the quantitative powder filling jig is filled with the first powder or the second powder, the quantitative powder filling jig further comprises:
the control system controls the quantitative powder filling jig to move, so that the powder guide hole is staggered with the corresponding first powder filling hole or the corresponding second powder filling hole.
Preferably, a control valve is arranged in the powder guide hole and connected with the control system, after the mold cavity is aligned with the corresponding powder guide hole, the control system controls the control valve to open, so that the powder guide hole is communicated with the mold cavity, and the first powder or the second powder falls into the mold cavity through the powder guide hole.
Preferably, a first vibrator is arranged below the mold and connected with the control system, and the control system controls the first vibrator to start in the process that the first powder or the second powder falls into the mold cavity.
Preferably, a second vibrator is arranged on the side wall of the first powder filling box and connected with the control system, the first powder material is filled into the corresponding quantitative powder filling jig through the first powder filling hole, and the control system controls the second vibrator to be started.
Preferably, a third vibrator is arranged on the side wall of the second powder filling box, the third vibrator is connected with the control system, the second powder material is filled into the corresponding quantitative powder filling jig through the second powder filling hole, and the control system controls the third vibrator to be started.
Preferably, the first powder is prepared by proportionally mixing the magnetically soft alloy powder, the binder, the lubricant and the curing agent, kneading by granulation equipment and granulating, and the particle size is 50-180 mu m.
Preferably, the second powder is prepared by proportionally mixing the soft magnetic alloy powder, the binder, the lubricant and the curing agent, kneading by granulation equipment and granulating, and the particle size is 100-350 μm.
Preferably, the soft magnetic alloy powder is at least one of amorphous soft magnetic alloy powder, nanocrystalline soft magnetic alloy powder, iron-silicon-aluminum alloy powder, iron-silicon-chromium alloy powder, iron-silicon-nickel alloy powder, iron-silicon-aluminum-nickel alloy powder, iron-nickel-aluminum alloy powder and carbonyl iron powder.
The positive effects of the technical scheme are as follows:
(1) when the coil is packaged, powder materials with corresponding particle sizes are respectively selected for filling according to different powder material requirements on the side wall and the top of the inductor, so that the density of the side wall of a finished inductor product is effectively improved, the inductance performance of the inductor is remarkably improved and stable, and meanwhile, the production yield of the finished inductor product is effectively improved;
(2) aiming at the side wall and the top of the inductor, when the inductor is filled, powder materials with corresponding particle sizes are divided twice to respectively fill the side wall and the top, so that the powder material density of the side wall of the inductor is improved, the condition that a coil is exposed due to the fact that the side wall of the inductor is thin is reduced, the compaction density of the top of the inductor is improved, the phenomenon of bridging caused by the difference of the particle sizes of the powder materials can be avoided, high frequency and miniaturization of an inductor device are facilitated greatly, and more possibilities are provided for targeted design and material selection of a rear-end inductor device.
Drawings
Fig. 1 is a schematic flow chart of a method for manufacturing a coil package of an inductor according to the present invention;
FIG. 2 is a schematic structural diagram of a powder filling device according to the present invention;
FIG. 3 is a cross-sectional view of the mold cavity after a first powder fill of the present invention;
FIG. 4 is a cross-sectional view of the mold cavity after a second powder fill in accordance with the present invention;
FIG. 5 is a schematic cross-sectional view of a powder guiding hole of a quantitative powder filling jig corresponding to the first powder filling box according to the present invention;
FIG. 6 is a schematic cross-sectional view of a powder guiding hole of a quantitative powder filling jig corresponding to a second powder filling box according to the present invention;
FIG. 7 is a schematic diagram of the control principle of the present invention;
fig. 8 is a cross-sectional view of a die cavity for making an inductor using uniformly granulated large particle powder.
In the drawings: 1. a first powder filling box; 1-1, a first powder filling hole; 2. a first powder material; 3. a second powder filling box; 3-1, a second powder filling hole; 4. a second powder material; 5. a quantitative powder filling jig; 5-1, powder guide holes; 6. a mold; 6-1, a mold cavity; 7. a control system; 8. a blank; 8-1, a coil; 9. a control valve; 10. a first vibrator; 11. a second vibrator; 12. a third vibrator; 13. a mold base; 14. a working platform; 15. a platform base; 16. a ball screw; 17. a nut assembly; 18. a slide rail; 19. a first slider; 20. a first driver; 21. a second driver; 22. a guide rail; 23. a second slider; 24. a fixing plate; 25. and a third driver.
Detailed Description
In order to make the technical means, the creation features, the achievement purposes and the effects of the present invention easy to understand, the following embodiments specifically describe the technical solutions provided by the present invention with reference to fig. 1 to 8, but the following contents are not to be taken as limitations of the present invention.
The method for manufacturing the coil package of the inductor provided by the embodiment comprises the following steps: as shown in fig. 1 to 7, a powder filling device is configured in advance, and the powder filling device includes a powder filling box, a quantitative powder filling jig 5 and an alignment device for driving a mold 6 to move;
the powder filling box is provided with two powder filling boxes, the two powder filling boxes are respectively defined as a first powder filling box 1 and a second powder filling box 3 according to the fact that the two powder filling boxes are respectively filled with powder with different particle sizes, a quantitative powder filling jig 5 is correspondingly arranged below each of the first powder filling box 1 and the second powder filling box 3, each quantitative powder filling jig 5 is provided with at least one powder guide hole 5-1 along the vertical direction, an aligning device used for installing a forming mold 6 and driving the mold 6 to move is arranged below each quantitative powder filling jig 5, and the aligning device is connected with a control system 7.
The coil package manufacturing method includes the steps of:
step S1, preliminary preparation: respectively loading a first powder material 2 and a second powder material 4 obtained by screening into a first powder filling box 1 and a second powder filling box 3, implanting a magnetic core blank 8 with a coil 8-1 wound in advance into a mold cavity 6-1 of a forming mold 6, and then installing and fixing the forming mold 6 on an alignment device of a powder filling device;
the average particle size of the first powder 2 is smaller than the average particle size of the second powder 4;
step S2, first powder filling: starting an alignment device to drive a mold 6 to be attached to the bottom of a quantitative powder filling jig 5 corresponding to the first powder filling box 1, aligning the mold cavity 6-1 to a powder guide hole 5-1, and then controlling the first powder 2 to fall into a containing space between the side wall of the mold cavity 6-1 and the magnetic core blank 8 through the powder guide hole 5-1 to finish primary powder filling;
step S3, second powder filling: starting the alignment device to drive the mold 6 to be attached to the bottom of the quantitative powder filling jig 5 corresponding to the second powder filling box 3, aligning the mold cavity 6-1 to the powder guide hole 5-1, and then controlling the second powder 4 to fall into the accommodating space at the top of the mold cavity 6-1 and the magnetic core blank 8 through the powder guide hole 5-1 to complete secondary powder filling;
step S4, pressing and demolding: and (3) moving the die 6 carrying the magnetic core blank 8, the first powder material 2 and the second powder material 4 to a forming press for pressing, and then demolding to finish coil packaging to obtain a semi-finished inductor product.
Specifically, in this embodiment, when the magnetic core blank 8 is pressed and packaged, powder is filled twice, the first powder filling fills the first powder material 2 with a relatively small particle size into the accommodating space between the sidewall of the mold cavity 6-1 and the magnetic core blank 8, the second powder filling fills the second powder material 4 with a relatively large particle size into the accommodating space between the mold cavity 6-1 and the top of the magnetic core blank 8, and after the powder filling twice, the mold 6 is moved to a molding press for press molding to obtain the inductance semi-finished product. Through the first powder filling, the powder density of the side wall of the prepared inductor semi-finished product is improved, the condition that a coil is exposed due to the fact that the side wall of the inductor is thin is reduced, the compaction density of the top of the inductor semi-finished product is improved through the second powder filling, and the reliability of the inductor is further improved. Further preferably, through setting up two powder filling boxes, first powder filling box 1 and second powder filling box 3, realize that same powder filling device can satisfy the different powder material demands at inductance lateral wall and top.
More specifically, before step S2 is executed, that is, before the powder filling operation is performed, first, powder filling preparation needs to be performed, including screening the first powder material 2 and the second powder material 4 with appropriate particle sizes, and the particle size of the first powder material 2 is smaller than that of the second powder material 4, and then the first powder material 2 is loaded into the first powder filling box 1, and the second powder material 4 is loaded into the second powder filling box 3 for use in a subsequent powder filling operation. Before the powder filling operation, the method also comprises the step of implanting the magnetic core blank 8 with the coil 8-1 wound in advance into the mold cavity 6-1, wherein the operation of implanting the magnetic core blank 8 into the mold cavity 6-1 and the operation of screening the powder and filling the screened powder with the corresponding particle size into the corresponding powder filling box can be executed in an order which is not distinguished. Preferably, the first powder 2 and the second powder 4 are soft magnetic alloy powders including, but not limited to, amorphous soft magnetic alloy powders, nanocrystalline soft magnetic alloy powders, iron-silicon-aluminum alloy powders, iron-silicon-chromium alloy powders, iron-silicon-nickel alloy powders, iron-silicon-aluminum-nickel alloy powders, iron-nickel-aluminum alloy powders, and carbonyl iron powders. More preferably, the first powder 2 can be prepared by proportionally mixing the magnetically soft alloy powder, the binder, the lubricant and the curing agent, kneading by granulation equipment and granulating, and the particle size can be in the range of 50-180 μm; the second powder 4 can be prepared by mixing the soft magnetic alloy powder, the binder, the lubricant and the curing agent in proportion, kneading the mixture by granulation equipment and granulating, and the particle size can be in the range of 100-350 mu m.
As a preferred embodiment, the powder filling preparation further includes obtaining the amount of powder required by the powder filling operation by performing the size and structural design processing of the inductor prepared in advance according to the need, where the amount of powder comprises a first amount of powder 2 required to be filled for the first powder filling and a second amount of powder 4 required to be filled for the second powder filling, and then selecting a quantitative powder filling jig 5 corresponding to the first powder filling box 1 according to the first amount of powder, where the quantitative powder filling jig 5 has a powder capacity corresponding to the first amount of powder, and selecting a quantitative powder filling jig 5 corresponding to the second powder filling box 3 according to the second amount of powder, where the quantitative powder filling jig 5 has a powder capacity corresponding to the second amount of powder, so as to ensure the quantitative powder filling in the subsequent powder filling operation.
Further, after the powder filling preparation is completed, a powder filling operation may be performed, which includes the first powder filling in step S2 and the second powder filling in step S3. After the first powder filling, the first powder 2 is filled into the accommodating space between the side wall of the mold cavity 6-1 and the magnetic core blank 8, that is, into the gap between the side wall of the mold cavity 6-1 and the magnetic core blank 8, and is in a filling state as shown in fig. 3 after the first powder filling is completed, it can be seen that the first powder 2 is filled into the gap between the side wall of the mold cavity 6-1 and the magnetic core blank 8, wherein the magnetic core blank 8 is wound with the coil 8-1 in advance; then, performing secondary powder filling to fill the second powder material 4 into the accommodating space at the top of the mold cavity 6-1 and the magnetic core blank 8, wherein the second powder filling is in a filling state as shown in fig. 4; as can be seen from fig. 4, after two powder filling operations, the first powder 2 and the second powder 4 are tightly filled without the phenomena of exposed coil and bridging, but the invention is not limited thereto.
More specifically, during the first powder filling, the control system 7 is first required to start the alignment device to accurately position the mold cavity 6-1 and the powder guide hole 5-1 of the quantitative powder filling jig 5 corresponding to the lower portion of the first powder filling box 1, so that the first powder 2 can fall into the accommodating space between the sidewall of the mold cavity 6-1 and the magnetic core blank 8 through the powder guide hole 5-1. Preferably, before the first powder filling, the first powder material 2 in the first powder filling box 1 may be loaded into the adaptive quantitative powder filling jig 5 according to the set quality, as a preferred embodiment, the bottom of the first powder filling box 1 is provided with corresponding first powder filling holes 1-1 according to the number and the position of the mold cavities 6-1 in the forming mold 6, and before the step S2 is executed, that is, before the first powder filling, the method further includes:
the control system 7 controls the quantitative powder filling jig 5 corresponding to the first powder filling box 1 to move, so that the first powder filling hole 1-1 is communicated with the powder guiding hole 5-1, and then the first powder material 2 is controlled to be filled into the corresponding quantitative powder filling jig 5 through the first powder filling hole 1-1. In this embodiment, a plurality of first powder filling holes 1-1 may be provided, so that a plurality of inductor blanks are filled at a time, and the production efficiency is improved. In order to realize that the first powder 2 can fall into the accommodating space between the side wall of the mold cavity 6-1 and the magnetic core blank 8 through the powder guide hole 5-1, in the embodiment, the cross-sectional shape of the powder guide hole 5-1 of the quantitative powder filling jig 5 corresponding to the first powder filling box 1 is designed to be adapted to the shape of the accommodating space between the mold cavity 6-1 and the side wall of the magnetic core blank 8, as shown in fig. 5, and correspondingly, the cross-sectional shape of the first powder filling hole 1-1 is the same as the cross-sectional shape of the powder guide hole 5-1.
Further preferably, after the first powder material 2 is filled into the quantitative powder filling jig 5, the quantitative powder filling jig 5 can be controlled to move by the control system 7, so that the powder guide hole 5-1 and the corresponding first powder filling hole 1-1 are dislocated, the quantitative filling of the first powder material 2 in the quantitative powder filling jig 5 for the first powder filling is completed, and then the control system 7 starts the alignment device to realize the alignment between the mold cavity 6-1 and the powder guide hole 5-1 of the quantitative powder filling jig 5 corresponding to the first powder filling box 1.
Similarly, when filling powder for the second time, the control system 7 is required to start the alignment device to accurately position the powder guide hole 5-1 on the quantitative powder filling jig 5 corresponding to the mold cavity 6-1 and the second powder filling box 3, so that the second powder 4 can fall into the accommodating space at the top of the mold cavity 6-1 and the magnetic core blank 8 through the powder guide hole 5-1. Preferably, before the second powder filling, the second powder material 4 in the second powder filling box 3 may be loaded into the adaptive quantitative powder filling jig 5 according to the set quality, as a preferred embodiment, the bottom of the second powder filling box 3 is provided with corresponding second powder filling holes 3-1 according to the number and the positions of the mold cavities 6-1 in the forming mold 6, and before the step S3 is executed, that is, before the second powder filling, the method further includes:
the control system 7 controls the quantitative powder filling jig 5 corresponding to the second powder filling box 3 to move, so that the second powder filling hole 3-1 is communicated with the powder guide hole 5-1, and then the second powder material 4 is controlled to be filled into the corresponding quantitative powder filling jig 5 through the second powder filling hole 3-1. A plurality of second powder filling holes 3-1 can be arranged, so that a plurality of inductance blanks can be filled at one time, and the production efficiency is improved. In order to make the second powder 4 fall into the accommodating space at the top of the mold cavity 6-1 and the magnetic core blank 8 through the powder guiding hole 5-1, in the embodiment, the cross-sectional shape of the powder guiding hole 5-1 of the quantitative powder filling jig 5 corresponding to the second powder filling box 3 is designed to be adapted to the shape of the accommodating space at the top of the mold cavity 6-1 and the magnetic core blank 8, as shown in fig. 6, and accordingly, the cross-sectional shape of the second powder filling hole 3-1 is the same as the cross-sectional shape of the powder guiding hole 5-1.
Similarly, after the second powder material 4 is filled into the quantitative powder filling jig 5, the quantitative powder filling jig 5 can be controlled to move by the control system 7, so that the powder guide hole 5-1 and the corresponding second powder filling hole 3-1 are dislocated, the quantitative filling of the second powder material 4 in the quantitative powder filling jig 5 for the second powder filling is completed, and then the control system 7 starts the alignment device to realize the alignment between the mold cavity 6-1 and the powder guide hole 5-1 of the quantitative powder filling jig 5 corresponding to the second powder filling box 3.
In a preferred embodiment, a control valve 9 is arranged in the powder guide hole 5-1 and connected with the control system 7, after the mold cavity 6-1 is aligned with the corresponding powder guide hole 5-1, the control system 7 controls the control valve 9 to open, so that the powder guide hole 5-1 is communicated with the mold cavity 6-1, and the first powder 2 or the second powder 4 falls into the mold cavity 6-1 through the powder guide hole 5-1. In this embodiment, the control valve 9 is controlled to be in a closed state when the first powder 2 or the second powder 4 falls into the powder guide hole 5-1, and the control valve 9 is controlled to be in an open state when the powder filling operation is performed, so that the powder falls into the cavity 6-1 from the powder guide hole 5-1.
In a preferred embodiment, at least one first vibrator 10 is arranged below the mold 6, the first vibrator 10 is connected with the control system 7, and the control system 7 controls the first vibrator 10 to be started during the process that the first powder 2 or the second powder 4 falls into the mold cavity 6-1. The first vibrator 10 can be an ultrasonic vibrator, and the first vibrator 10 is controlled to start to vibrate in the powder filling process, so that the first powder 2 or the second powder 4 filled into the die cavity 6-1 is more uniform and compact, the particle gap of the powder is small, the compaction density of the inductor is increased, the magnetic conductivity is further improved, and the product performance is more excellent.
As a preferred embodiment, at least one second vibrator 11 is arranged on the side wall of the first powder container 1, the second vibrator 11 is connected to the control system 7, and the control system 7 controls the second vibrator 11 to start in the process that the first powder material 2 is filled into the corresponding quantitative powder filling jig 5 through the first powder filling hole 9. The second vibrator 11 can be an ultrasonic vibrator, and the second vibrator 11 is controlled to start to vibrate in the process that the first powder material 2 is filled into the quantitative powder filling jig 5 from the first powder filling box 1, so that the first powder material 2 filled into the quantitative powder filling jig 5 is more uniform and compact, and the first powder material 2 filled into the mold cavity 6-1 subsequently is more uniform and compact.
In a preferred embodiment, at least one third vibrator 12 is disposed on a side wall of the second powder container 3, the third vibrator 12 is connected to the control system 7, and the control system 7 controls the third vibrator 12 to start in the process that the second powder material 4 is filled into the corresponding quantitative powder filling jig 5 through the second powder filling hole 10. The third vibrator 12 may be an ultrasonic vibrator, and the third vibrator 12 is controlled to start to vibrate in the process that the second powder material 4 is filled into the quantitative powder filling jig 5 from the second powder filling box 3, so that the second powder material 4 filled into the quantitative powder filling jig 5 is more uniform and dense, and further the second powder material 4 subsequently filled into the mold cavity 6-1 is more uniform and dense.
The coil packaging manufacturing method provided by the invention can be realized based on a pre-configured powder filling device, wherein the number of the powder filling boxes in the powder filling device can be more than two, so that powder materials with different particle sizes can be filled in the die 6 for packaging the coil for many times according to specific powder filling requirements according to the inductor design.
As a preferred embodiment, the aligning device in the powder filling device may include:
the transverse driving device is connected with a platform base 15, the die 6 is installed and fixed in a working platform 14 above the platform base 15 through a die base 13, and the control system 7 is connected with the transverse driving device and controls the transverse driving device to drive the platform base 15 to enable the working platform 14 to slide along the horizontal direction, so that the die 6 is driven to move along the horizontal direction;
the longitudinal driving device is arranged above the platform base 15 and connected with the mold base 13 used for fixing the mold 6, and the control system 7 is connected with the longitudinal driving device and controls the longitudinal driving device to drive the mold base 13 to lift along the vertical direction, so that the mold 6 is driven to move along the vertical direction.
Based on the structure of the alignment device, when powder is filled for the first time, the control system 7 can respectively control the transverse driving device and the longitudinal driving device to realize alignment between the mold cavity 6-1 and the powder guide hole 5-1 of the quantitative powder filling jig 5 corresponding to the first powder filling box 1.
At the moment of finishing the first powder filling, the die cavity 6-1 and the powder guide hole 5-1 of the quantitative powder filling jig 5 corresponding to the first powder filling box 1 are still in a joint and aligned state, so that after the first powder filling is finished, the aligning device can be controlled to drive the die 6 to be away from the powder guide hole 5-1 of the quantitative powder filling jig 5 corresponding to the first powder filling box 1, and then the transverse driving device and the longitudinal driving device are respectively controlled to realize the alignment between the die cavity 6-1 and the powder guide hole 5-1 of the quantitative powder filling jig 5 corresponding to the second powder filling box 3, so as to carry out the second powder filling.
The control of the alignment device to drive the mold 6 to be away from the powder guide hole 5-1 of the quantitative powder filling jig 5 corresponding to the first powder filling box 1 may be to control only the longitudinal driving device to drive the mold to move away from the first powder filling box 1 along the vertical direction, so that a gap is formed between the mold 6 and the powder guide hole 5-1 in the vertical direction, and then control the transverse driving device and the longitudinal driving device respectively to achieve alignment between the mold cavity 6-1 and the powder guide hole 5-1 of the quantitative powder filling jig 5 corresponding to the second powder filling box 3; the aligning device may drive the mold 6 to be away from the powder guiding hole 5-1 of the quantitative powder filling jig 5 corresponding to the first powder filling box 1, or the aligning device may drive the mold 6 to return to an initial position by pre-configuring the initial position, and then control the transverse driving device and the longitudinal driving device to align the mold cavity 6-1 with the powder guiding hole 5-1 of the quantitative powder filling jig 5 corresponding to the second powder filling box 3. The initial position may be a position where the mold 6 is located before the first powder filling, in other words, the initial position is also used as a starting point at the first powder filling, and the initial position is used as an end point after the first powder filling is completed, that is, the mold 6 is returned to the initial position, and then the initial position is used as a starting point at the second powder filling, and so on.
As a preferred embodiment, the transverse driving device may include a ball screw 16 for driving the mold 6 to slide along the horizontal direction, a nut assembly 17 sleeved on the ball screw 16, and four first sliding blocks 19 sleeved on the two sliding rails 18 and fixedly connected to the platform base 15, wherein a first driver 20 is connected to the ball screw 16, the first driver 20 is connected to the control system 7 by using a servo motor, the control system 7 controls the first driver 20 to drive the working platform 14 to slide along the extending direction of the ball screw 16, the mold 6 slides along with the first driver, the nut assembly 17 is fixedly connected to the lower portion of the platform base 15, and when the working platform 14 slides, the first sliding blocks 19 slide along the extending direction of the sliding rails 18 to ensure the stable movement of the working platform 14, thereby reducing the probability of the position deviation of the mold 6.
The longitudinal driving means may be a second driver 21. The second driver 21 is fixed on the platform base 15, the second driver 21 can select the air cylinder, the output shaft of the air cylinder is vertically upwards arranged, and one end of the output shaft is welded and fixed at the bottom of the mold base 13. The control system 7 controls the output shaft of the cylinder to reciprocate along the vertical direction, and further controls the mold base 13 to reciprocate along the vertical direction.
The longitudinal driving device can further comprise at least two guide rails 22 arranged in the vertical direction, the guide rails 22 are oppositely arranged on the platform base 15, the end faces of the guide rails 22 are respectively provided with a second sliding block 23, the second sliding blocks 23 are provided with sliding holes in the vertical direction, and the guide rails 22 are respectively sleeved with the second sliding blocks 23. When the second driver 21 controls the mold 6 to move in the vertical direction, the second slider 23 slides relative to the guide rail 22, so that the mold base 13 is fixed relative to the platform base 15 in the horizontal direction, the stability of the mold base 13 during lifting is enhanced, and the probability of position deviation of the mold base 13 when the cylinder drives the mold base 13 to move in the vertical direction is reduced.
In a preferred embodiment, the powder filling device further comprises a fixing plate 24 for mounting the first powder filling box 1 and the second powder filling box 3, and the fixing plate 24 is fixed on the ground or the base of the powder filling device through a supporting column. Preferably, the first powder filling box 1 and the second powder filling box 3 can be respectively provided with a buckle, the first powder filling box 1 and the second powder filling box 3 are fixed on the fixing plate 24 through the buckle, and correspondingly, two clamping grooves for clamping the buckle are respectively formed in the end surface, away from the quantitative powder filling jig 5, of the fixing plate 24. When the first powder filling box 1 and the second powder filling box 3 are installed on the fixing plate 24, the buckle is clamped in the clamping groove to fix the first powder filling box 1 and the second powder filling box 3.
In a preferred embodiment, the powder filling device further comprises a transverse driving structure for driving the quantitative powder filling jig 5 to move, the transverse driving structure is connected with the control system 7, and the control system 7 controls the transverse driving structure to drive the quantitative powder filling jig 5 to move, so that the relative positions of the first powder filling hole 1-1 or the second powder filling hole 3-1 and the corresponding powder guiding hole 5-1 are adjusted respectively.
Further, the transverse driving mechanism may be a third driver 25 connected to the sidewall of the quantitative powder-filling jig 5, the third driver 25 may be an air cylinder, the cylinder can be fixed at the lower end of the fixing plate 24 through bolts, the cylinder can be connected with the side wall of the quantitative powder filling jig 5 through a guide post, a sliding groove parallel to the extending direction of the sliding rail 18 is arranged between the fixing plate 24 and the quantitative powder filling jig 5, the sliding chute can be fixed at the lower end of the fixing plate 24 through bolts, a sliding sheet of the sliding chute can be fixed at the upper end of the quantitative powder filling jig 5 through bolts, the sliding sheet is clamped in the sliding chute, the sliding sheet and the sliding chute can slide relatively, under the driving action of the cylinder, the sliding sheet slides in the sliding groove to realize the transverse movement of the quantitative powder filling jig 5, so that the relative positions of the first powder filling hole 1-1 or the second powder filling hole 3-1 and the corresponding powder guide hole 5-1 are respectively adjusted.
As a preferable embodiment, the mold 6 is further provided with a positioning structure, in this embodiment, the positioning structure is a positioning protrusion, so as to realize accurate butt joint between the powder guide hole 5-1 and the mold cavity 6-1. The positioning bulge is integrally formed at the upper part of the left side of the mold 6, the quantitative powder filling jig 5 is provided with a groove for the insertion of the positioning bulge, and the second driver 21 controls the mold 6 to be lifted towards the quantitative powder filling jig 5, so that the positioning bulge is inserted into the groove, the powder guide hole 5-1 is aligned with the mold cavity 6-1 more accurately, the powder cannot fall into the mold cavity 6-1 from the powder guide hole 5-1 because the powder guide hole 5-1 and the mold cavity 6-1 are not in a coaxial state, the probability that part of the powder is remained in a space formed by the powder guide hole 5-1 and the end face, close to the quantitative powder filling jig 5, of the mold 6 is reduced, and the precision in powder filling is improved.
Example 1
In a preferred embodiment of the present invention, the coil package manufacturing method of the present invention can be used to manufacture an inductor having a standard inductance of 0.47 muH and a size of 2.0mm × 1.2mm × 1.0 mm. In this embodiment, the first powder 2 and the second powder 4 are soft magnetic powders, the soft magnetic powder is a composite powder formed by mixing Fe-Si-B amorphous soft magnetic alloy powder and carbonyl iron powder, the binder is epoxy resin, the lubricant is graphene, the first powder 2 and the second powder 4 are granulated powders having particle sizes of 100 to 180 μm and 150 to 300 μm, and the granulation powders are granulated after being proportioned and mixed and screened out in two particle size ranges.
After the first powder 2 and the second powder 4 are obtained by screening, the inductor is obtained by sequentially performing the steps S1 to S4 of the coil package manufacturing method of the present invention, wherein in the step S4, the following pressing parameters are adopted during powder filling pressing: applying ultrasonic vibration with frequency of 20KHz and pressure maintaining of 6t/cm2Dwell time 120s, dwell temperature 170 ℃. And (3) after demolding, keeping the temperature for 5 hours in an oven at 180 ℃ under an inert atmosphere, cooling to normal temperature, and taking out to obtain a solidified semi-finished inductor sample.
After the powder filling and pressing are finished, the obtained inductance sample is subjected to electrical performance testing, an impedance analyzer can be selected for the electrical performance testing, the inductance average value Ls of the inductance sample is 0.488 muH under the conditions of 1V and 1MHz, and the preparation requirement is met.
Comparative example 1
In comparative example 1, the same inductor having a standard inductance of 0.47. mu.H and a size of 2.0 mm. times.1.2 mm. times.1.0 mm was prepared by a conventional powder filling method. The same coil and magnetic core blank as in example 1, the same formula and soft magnetic powder material with the particle size range of only 150-300 μm as conventional ones are adopted, powder filling and packaging are carried out in a one-time powder filling manner, namely, the powder material which is uniformly granulated is adopted to fill the powder material into the accommodating space between the magnetic core blank 8 and the side wall of the mold cavity 6-1 and the accommodating space between the top of the magnetic core blank 8 and the mold cavity 6-1 at one time, and the same pressing parameters as in example 1 are adopted during pressing. The cross section of the mold 6 after the powder filling is completed is shown in fig. 8, and it can be seen that the powder material gap is large by directly filling the powder at one time. The obtained inductance sample is further subjected to electrical performance test, an impedance analyzer is selected, the inductance average value Ls of the obtained inductance sample is 0.431 mu H under the conditions of 1V and 1MHz, and the specific performance parameters are shown in Table 1.
Table 1 performance parameters of inductor samples obtained in example 1 and comparative example 1
Example 2
As another preferred embodiment of the present invention, an inductor having a standard inductance of 1 μ H and dimensions of 2.0mm by 1.2mm by 1.0mm is manufactured by the coil package manufacturing method of the present invention. In a preferred embodiment, the first powder 2 and the second powder 4 are soft magnetic powders, the soft magnetic powders are composite powders formed by mixing Fe-Si-B amorphous soft magnetic alloy powders and carbonyl iron powders, the binder is epoxy resin, the lubricant is graphene, the first powder 2 is granulated and has a particle size of 50-150 μm, and the second powder 4 is granulated and has a particle size of 150-250 μm.
After the first powder 2 and the second powder 4 are obtained by screening, the inductor is obtained by sequentially performing the steps S1 to S4 of the coil package manufacturing method of the present invention, wherein in the step S4, the following pressing parameters are adopted during powder filling pressing: applying ultrasonic vibration with frequency of 20KHz and pressure maintaining of 6t/cm2Dwell time 120s, dwell temperature 170 ℃. And (3) after demolding, keeping the temperature for 5 hours in an oven at 180 ℃ in a nitrogen atmosphere, cooling to normal temperature, and taking out to obtain a cured semi-finished inductor sample.
After the powder filling and pressing are finished, the obtained inductor is subjected to electrical performance testing, an impedance analyzer can be selected for the electrical performance testing, and the inductance Ls of the obtained inductor is 1.133 muH under the conditions of 1V and 1MHz, so that the preparation requirement is met.
Comparative example 2
Comparative example 2 the same inductor having a standard inductance of 1 muh and dimensions of 2.0mm x 1.2mm x 1.0mm was prepared using a conventional powder filling method. The same coil and magnetic core blank as in example 2, the same formula and soft magnetic powder material with the particle size range of only 150-250 μm as conventional soft magnetic powder material are adopted, powder filling and packaging are carried out in a one-time powder filling mode, namely, the accommodating space between the magnetic core blank 8 and the side wall of the mold cavity 6-1 and the accommodating space between the top of the magnetic core blank 8 and the mold cavity 6-1 are filled with powder by uniformly granulated powder material at one time, and the same pressing parameters as in example 2 are adopted during pressing. The obtained inductance sample is further subjected to electrical performance test, an impedance analyzer is selected, the average value Ls of the inductance of the obtained inductance sample is 0.996 mu H under the conditions of 1V and 1MHz, and the specific performance parameters are shown in Table 2.
Table 2 performance parameters of inductor samples obtained in example 2 and comparative example 2
Example 3
As still another preferred embodiment of the present invention, an inductor having a standard inductance of 1 μ H and dimensions of 2.5mm by 2.0mm by 1.0mm is manufactured by the coil package manufacturing method of the present invention. In a preferred embodiment, the first powder 2 and the second powder 4 are soft magnetic powder materials, the soft magnetic powder materials are composite powder materials formed by mixing Fe-Si-B amorphous soft magnetic alloy powder and carbonyl iron powder, the used binder is epoxy resin, the used lubricant is graphene, and the first powder 2 and the second powder 4 are granulated powders with particle sizes of 100-180 μm and 200-350 μm, and are granulated powders with particle sizes in two particle size ranges after being proportioned and mixed.
After the first powder 2 and the second powder 4 are obtained by screening, the method of the present invention is performed in sequenceIn the coil package manufacturing method, the inductor is obtained in steps S1 to S4, wherein in step S4, the following pressing parameters are adopted during powder filling and pressing: applying ultrasonic vibration with frequency of 20KHz and pressure maintaining of 6t/cm2Dwell time 120s, dwell temperature 170 ℃. And (3) after demolding, keeping the temperature for 5 hours in an oven at 180 ℃ in a nitrogen atmosphere, cooling to normal temperature, and taking out to obtain a cured semi-finished inductor sample. After the powder filling and pressing are finished, the obtained inductor is subjected to electrical performance testing, an impedance analyzer can be selected for the electrical performance testing, and the inductance Ls of the obtained inductor is 1.087 mu H under the conditions of 1V and 1MHz, so that the preparation requirement is met.
Comparative example 3
In comparative example 3, when an inductor with the same standard inductance of 1 muh and the same size of 2.0mm × 1.2mm × 1.0mm is prepared by using a conventional powder filling method, the soft magnetic powder material which has the same coil and magnetic core blank and the same formula as those in example 3 but has the particle size range of only 200 to 350 μm is used for powder filling and packaging in a one-time powder filling manner, that is, the powder material which is uniformly granulated is used for filling the powder in the accommodating space between the magnetic core blank 8 and the side wall of the mold cavity 6-1 and the accommodating space between the top of the magnetic core blank 8 and the mold cavity 6-1 at one time, and the same pressing parameters as those in example 3 are used for pressing. The obtained inductance sample is further subjected to electrical performance test, an impedance analyzer is selected, the inductance average value Ls of the obtained inductance sample is 0.975 muH under the conditions of 1V and 1MHz, and specific performance parameters are shown in Table 3.
Table 3 inductance performance parameters obtained by different powder filling methods of soft magnetic powder of example 3 and comparative example 3
As can be seen from tables 1, 2 and 3, when different soft magnetic powder materials are used for preparing inductors with different specifications, the inductance of the inductor can be improved by packaging the coil by using a secondary powder filling device and method, which also indicates that the secondary powder filling design is separately performed on the soft magnetic powder material with large particle size and the soft magnetic powder material with small particle size, so that the powder material filling is more uniform, the coil is more completely coated, and the problems of powder material bridging and coil exposure are solved; secondly, ultrasonic vibration applied in the process of filling powder enables gaps among powder particles in the inductor to be obviously reduced, the density is greatly improved, finally, the inductance is obviously improved, high-frequency and miniaturization of the inductor are facilitated, and more possibilities are provided for targeted design and material selection of the rear-end inductor.
While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.
Claims (12)
1. A coil packaging manufacturing method of an inductor is characterized in that a magnetic core blank wound with a coil in advance is implanted into a mold cavity of a forming mold, and a first powder and a second powder are obtained through screening, wherein the average particle size of the first powder is smaller than that of the second powder; then filling the first powder material into a gap between the coil of the magnetic core blank and the side wall of the mold cavity, and filling the second powder material into the top of the magnetic core blank; and finally, moving the forming die carrying the magnetic core blank, the first powder and the second powder to a forming press for pressing, and then demolding to finish coil packaging to obtain a semi-finished inductor product.
2. The coil package manufacturing method according to claim 1, wherein a powder filling device is previously provided, and the magnetic core blank is packaged by the powder filling device, the powder filling device including:
at least one first powder filling box for loading the first powder material;
at least one second powder filling box for loading the second powder material;
the powder filling machine is characterized in that a quantitative powder filling jig is correspondingly arranged below the first powder filling box and the second powder filling box respectively, at least one powder guide hole is formed in the quantitative powder filling jig along the vertical direction, an aligning device which is used for installing the forming die and driving the forming die to move is arranged below the quantitative powder filling jig, and the aligning device is connected with a control system.
3. The coil package manufacturing method according to claim 2, comprising the steps of:
step S1, preliminary preparation: respectively loading the first powder material and the second powder material obtained by screening into the first powder filling box and the second powder filling box, implanting the magnetic core blank into the mold cavity of the forming mold, and then installing and fixing the forming mold on the alignment device of the powder filling device;
the average particle size of the first powder is smaller than that of the second powder;
step S2, first powder filling: starting the alignment device to drive the mold to be attached to the bottom of the quantitative powder filling jig corresponding to the first powder filling box, aligning the mold cavity with the powder guide hole, and then controlling the first powder to fall into the accommodating space between the side wall of the mold cavity and the magnetic core blank through the powder guide hole to finish primary powder filling;
step S3, second powder filling: starting the alignment device to drive the mold to be attached to the bottom of the quantitative powder filling jig corresponding to the second powder filling box, aligning the mold cavity with the powder guide hole, and then controlling the second powder to fall into the accommodating space at the top of the magnetic core blank in the mold cavity through the powder guide hole to finish secondary powder filling;
step S4, pressing and demolding: and moving the forming die carrying the magnetic core blank, the first powder and the second powder to a forming press for pressing, and then demolding to finish coil packaging to obtain the semi-finished inductor.
4. The method for manufacturing a coil package according to claim 3, wherein the bottom of the first powder filling box is provided with corresponding first powder filling holes according to the number and positions of the mold cavities in the molding mold, and before the step S2 is executed, the method further comprises:
the control system controls the quantitative powder filling jig corresponding to the lower part of the first powder filling box to move, so that the first powder filling hole is communicated with the powder guiding hole, and then the first powder material is controlled to be quantitatively filled into the corresponding quantitative powder filling jig through the first powder filling hole.
5. The method for manufacturing a coil package according to claim 3, wherein the second powder filling box bottom is provided with corresponding second powder filling holes according to the number and positions of the mold cavities in the forming mold, and before the step S3 is executed, the method further comprises:
the control system controls the quantitative powder filling jig corresponding to the lower part of the second powder filling box to move, so that the second powder filling hole is communicated with the powder guide hole, and then the second powder material is controlled to be quantitatively filled into the corresponding quantitative powder filling jig through the second powder filling hole.
6. The method for manufacturing a coil package according to claim 4 or 5, wherein after the first powder or the second powder is filled in the quantitative powder filling jig, the method further comprises:
the control system controls the quantitative powder filling jig to move, so that the powder guide hole is staggered with the corresponding first powder filling hole or the corresponding second powder filling hole.
7. The method for manufacturing a coil package according to claim 3, wherein a control valve is disposed in the powder guide hole, the control valve is connected to the control system, and after the mold cavity is aligned with the corresponding powder guide hole, the control system controls the control valve to open so that the powder guide hole is communicated with the mold cavity, and the first powder or the second powder falls into the mold cavity through the powder guide hole.
8. The method for manufacturing a coil package according to claim 3, wherein a first vibrator is disposed below the mold, the first vibrator is connected to the control system, and the control system controls the first vibrator to be activated during the process that the first powder or the second powder falls into the mold cavity.
9. The method for manufacturing the coil package according to claim 3, wherein a second vibrator is disposed on a side wall of the first powder filling box, the second vibrator is connected to the control system, and the control system controls the second vibrator to start up when the first powder material is filled into the corresponding quantitative powder filling jig through the first powder filling hole.
10. The method for manufacturing the coil package according to claim 3, wherein a third vibrator is disposed on a side wall of the second powder filling box, the third vibrator is connected to the control system, and the control system controls the third vibrator to start up when the second powder material is filled into the corresponding quantitative powder filling jig through the second powder filling hole.
11. The method for manufacturing a coil package according to claim 1, wherein the first powder is prepared by proportionally mixing the soft magnetic alloy powder, the binder, the lubricant and the curing agent, kneading the mixture by a granulating device, and granulating the mixture, and the particle size of the first powder is 50-180 μm.
12. The coil package manufacturing method according to claim 1, wherein the second powder is prepared by proportionally mixing the soft magnetic alloy powder, the binder, the lubricant and the curing agent, kneading the mixture by a granulating device, and granulating the mixture, and the particle size of the second powder is 100 to 350 μm.
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