CN114141520A - Manufacturing method of sheet-shaped power inductor - Google Patents
Manufacturing method of sheet-shaped power inductor Download PDFInfo
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- CN114141520A CN114141520A CN202111360436.8A CN202111360436A CN114141520A CN 114141520 A CN114141520 A CN 114141520A CN 202111360436 A CN202111360436 A CN 202111360436A CN 114141520 A CN114141520 A CN 114141520A
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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
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/005—Impregnating or encapsulating
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/076—Forming taps or terminals while winding, e.g. by wrapping or soldering the wire onto pins, or by directly forming terminals from the wire
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Abstract
The invention relates to the field of manufacturing of inductors, and discloses a method for manufacturing a sheet-shaped power inductor, which comprises the following steps: s1, preparing a T-shaped sintered blank; s2, winding; s3, preparing a cup-shaped sintered blank; s4, hot-press forming; s5 spraying; and S6, manufacturing electrodes to obtain the chip power inductor. The inductor is prepared by combining and pressing the prefabricated T-shaped and cup-shaped blanks, the method for directly filling powder in the existing manufacturing process is replaced, the filling density of the inductor can be effectively improved, the coil can be protected, and the coil is prevented from being exposed, deformed and even broken in the hot pressing process, so that the shielding performance and the inductance value of the inductor are ensured, the comprehensive performance of the product is improved, and the product performance is more excellent.
Description
Technical Field
The invention relates to the field of manufacturing of inductors, in particular to a method for manufacturing a sheet-shaped power inductor.
Background
With the rapid development of the electronic information industry, downstream electronic devices and communication equipment are gradually developed towards high frequency, small size, low voltage and large current, the traditional plug-in inductor cannot meet the requirements of a downstream electronic complete machine, and the chip inductor which has the advantages of small size, low cost, excellent shielding performance, high reliability and suitability for high-density surface mounting is widely applied in the fields of mobile communication, computers, automotive electronics, high-resolution televisions, broadcasting satellites and the like and gradually becomes the mainstream of the inductor market.
At present, chip power inductors are manufactured in more processes, but the basic method is as follows: (1) pre-winding an air core coil, placing the air core coil into a mold cavity of a mold, filling prepared soft magnetic alloy powder into the mold, pressing to obtain a blank of the sheet power inductor, and then performing subsequent steps of curing, manufacturing electrodes and the like (such as patents CN111210986A, CN107689280A and the like); or (2) prefabricating the magnetic core, then manufacturing a combination of the magnetic core and the coil, putting the combination of the magnetic core and the coil into a mold, then filling powder into the mold, carrying out compression molding to obtain an inductance blank, and then carrying out subsequent steps of curing, manufacturing electrodes and the like (such as patents CN104616878A, CN107768069A and the like).
In order to meet the development requirements of the current power inductor for miniaturization, high frequency and large current, the size of an internal coil of the power inductor is closer to the size of a finished inductor product, namely, in the compression molding process, the space between the coil and the side wall of a mold cavity is smaller, which provides higher requirements for the manufacturing process of the power inductor, and the manufacturing process of the conventional chip inductor is difficult to meet the current requirements, and mainly has the following defects:
(1) the gap between the coil and the die cavity wall is too small, so that the powder filling in the die is not uniform due to direct powder filling, the phenomenon that the powder filling density on the side wall of the inductor is low and even the coil is exposed is easily caused, and the shielding performance and the inductance value of the inductor finished product are obviously reduced;
(2) when a product is pressed and formed, enough pressure needs to be applied to obtain high compaction density, but the coil wound on the blank body is easily punctured by powder due to overhigh pressure, so that the interlayer insulation is poor, and the coil is deformed in the pressing process, so that the coil has large variation; too low pressure will result in a lower inductor density for powder compaction, and ultimately a lower inductance value, which affects the performance of the back end product.
Therefore, it is desirable to further improve the current chip power inductor manufacturing method against the shortcomings.
Disclosure of Invention
The invention provides a manufacturing method of a sheet power inductor, aiming at the problems in the prior art, the invention adopts the mode of prefabricating T-shaped and cup-shaped blanks, then combining the T-shaped and cup-shaped blanks and then carrying out hot press molding, thus obtaining the sheet power inductor with excellent performance.
A manufacturing method of a sheet power inductor specifically comprises the following steps:
s1, preparing a T-shaped sintered blank: processing the soft magnetic alloy powder to prepare a T-shaped sintered blank;
s2, winding: winding an enameled wire by the columnar bulge of the T-shaped sintered blank prepared in the step S1, bending pins at two ends, and attaching the bent pins to the bottom surface of the flat plate of the T-shaped sintered blank to obtain a wound T-shaped sintered blank;
s3, preparing a cup-shaped blank: filling soft magnetic alloy powder into a cup-shaped die for pressing and forming to obtain a cup-shaped blank, wherein the cup-shaped blank is not demoulded and enters the next step along with the die;
s4, hot press forming: placing the cup-shaped blank prepared in the step S3 with an upward opening along with a mold, implanting the T-shaped sintered blank of the winding prepared in the step S2 into a mold cavity with the cup-shaped blank according to a downward convex part, and then performing hot press molding to obtain a first inductance blank and baking the first inductance blank to obtain a cured inductance blank;
s5, spraying: spraying an insulating resin protective material on the surface of the inductor blank prepared in the step S4 to obtain a sheet-shaped power inductor semi-finished product;
s6, electrode preparation: and (5) stripping the insulating protective material and the copper wire enamel at the copper electrode of the semi-finished product of the chip power inductor prepared in the step (S5), and electroplating the electrode at the enamel stripping position to obtain the chip power inductor.
Preferably, the method for preparing the T-shaped sintered body in step S1 includes: and (3) filling the soft magnetic alloy powder into a T-shaped die with a preset structure and size for compression molding, and then demolding and compacting to obtain a T-shaped sintered blank.
Preferably, the method for preparing the T-shaped sintered compact in step S1 may also include: the soft magnetic alloy powder is put into a block-shaped die with a preset structure and size for compression molding, then demoulding and sintering are carried out, and then a T-shaped sintering blank is obtained by adopting a machining cutting mode;
preferably, the soft magnetic alloy powder in steps S1 and S3 includes soft magnetic alloy powder, binder, lubricant and other raw materials, and is prepared by mixing, granulating and sieving the raw materials.
The binder comprises at least one of epoxy resin, polyurethane, silicone resin, organic silicon resin, amino resin, polyimide, phenolic resin, cyanate ester and acrylic resin; the content of the binder is 1-5% of the total mass of the soft magnetic alloy powder.
The lubricant comprises at least one of zinc stearate, magnesium stearate, aluminum stearate, calcium stearate, graphite powder and graphene; the content of the lubricant is 0.1-1% of the total mass of the soft magnetic alloy powder.
Preferably, the soft magnetic alloy powder comprises 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.
Preferably, in the step S1 and the step S3, the compression molding is cold press molding by using a high-precision servo molding press, and the cold press pressure is 2t/cm2-15t/cm2The pressure maintaining time is 0.3s-30 s; the sintering temperature of the green body is 400-700 ℃, and the sintering time is 1-8 h. By adopting high-temperature sintering, part of organic matters in the powder can be carbonized and volatilized, the strength of a blank body is improved, and the high-strength inductor is finally prepared.
Preferably, in step S2, a precision winding machine is used to precisely wind an enameled wire on the columnar protrusion of the T-shaped sintered blank.
Preferably, the hot press molding is performed in step S4The pressure is 0.5t/cm2-10t/cm2The dwell time is 1s-200 s.
Preferably, in step S5, spraying is performed by using a constant-temperature heating spraying device, and the coating material can be cured by baking after spraying; the baking temperature is 80-200 ℃, and the baking time is 0.5-5 h.
The insulating resin protective material comprises at least one of epoxy resin, phenolic resin, glass reinforced polyester, silicone resin, polyester resin and organic silicone resin.
Preferably, in step S6, the insulating resin protective material and the copper wire enamel at the copper electrode of the inductor semi-finished product are stripped by using a laser paint stripping device.
Compared with the prior art, the invention mainly has the following advantages:
(1) the inductor is prepared by combining and pressing the prefabricated T-shaped and cup-shaped blanks, the method for directly filling powder in the existing manufacturing process is replaced, the filling density of soft magnetic powder in the inductor can be effectively improved, the coil can be protected, and the coil is prevented from being exposed, deformed and even broken in the hot pressing process, so that the shielding performance and the inductance value of the inductor are ensured, and the comprehensive performance of a product is improved; the cup-shaped blank is not demoulded, and when the cup-shaped blank is combined with the T-shaped blank, the process flow can be shortened, the time can be saved, and the production efficiency can be improved.
(2) The T-shaped blank is obtained by cold pressing and sintering, so that the density and the inductance of the soft magnetic material and the strength of the inductance blank are improved, and the product performance is more excellent.
Drawings
Fig. 1 is a flow chart of a method for manufacturing a chip power inductor according to an embodiment of the invention;
fig. 2 is a schematic diagram of cold press forming of a T-shaped blank of a chip power inductor according to an embodiment of the present invention;
fig. 3 is a perspective view of a T-shaped blank in the chip power inductor after cold press molding according to the embodiment of the invention;
FIG. 4 is a perspective view of a T-shaped sintered blank in a chip power inductor after being wound;
fig. 5 is a schematic diagram of cold press molding of a cup-shaped blank of a chip power inductor according to an embodiment of the invention;
FIG. 6 is a perspective view of a cup-shaped blank of a chip power inductor according to an embodiment of the present invention;
fig. 7 is a schematic view illustrating a hot press molding of a chip power inductor according to an embodiment of the invention;
FIG. 8 is a schematic structural diagram of a chip power inductor product according to an embodiment of the invention;
FIG. 9 is a schematic diagram of the formation of a sheet-like power inductor prepared in a comparative example;
the figures are numbered: 11. punching the cold press forming die; 12. cold-pressing a middle die of a forming die; 13. punching a cold press forming die; 2. t-shaped sintered green bodies; 21. a first T-shaped blank; 22. a columnar bulge; 23. the bottom surface of the blank body; 3. a cup-shaped green body; 41. punching a hot-pressing forming die; 42. a middle mold base; 5. a coil; 6. a copper wire pin; 61. an electrode; 7. soft magnetic alloy powder; 8. an insulating protective material; the arrow direction in the figure is the stamping direction of the upper punch of the cold-pressing forming die and the upper punch of the hot-pressing forming die.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
It should be noted that the embodiments and features of the embodiments may be combined with each other without conflict.
The invention is further described with reference to the following drawings and specific examples, which are not intended to be limiting.
The invention provides a manufacturing method of a sheet power inductor, belongs to the field of manufacturing of inductors, and aims to solve the problems of low powder filling density, exposed coils, low inductance and the like of side walls of the inductor in the prior art; the prefabricated T-shaped blank is obtained by cold pressing and sintering, the density and the inductance of the soft magnetic material and the strength of the inductor blank are improved, only small forming pressure is needed for preparing the inductor with the same density, the inductor is prepared by adopting the T-shaped blank and the cup-shaped blank, the coil can be protected, the coil is prevented from deforming and breaking in the hot pressing process, the use stability of the inductor is ensured, and the comprehensive performance of the product is improved. Fig. 1 is a flow chart of a method for manufacturing a chip power inductor according to the present invention.
Example 1
In this embodiment, the soft magnetic alloy powder is a composite powder formed by mixing Fe-Ni soft magnetic alloy powder and iron powder, the binder is epoxy resin and sodium silicate, the lubricant is zinc stearate, the Fe-Ni soft magnetic alloy powder and the iron powder are uniformly mixed according to a preset first mass ratio of 5:5 to form powder, the binder, the lubricant and acetone are uniformly mixed according to a preset second mass ratio of 100:3:0.1:12 to form granules, and the powder with the particle size of-80 meshes to +200 meshes is screened out by an ultrasonic vibration screen, so as to obtain the target soft magnetic powder, wherein the preparation method of the power inductor in this embodiment specifically comprises the following steps:
s1, preparing a T-shaped sintered blank: as shown in fig. 2, the screened soft magnetic alloy powder is loaded into a T-shaped die with a preset structure and size, which is composed of a cold-pressing forming die middle die 12 and a cold-pressing forming die lower punch 13, the cold-pressing forming die upper punch 11 of a high-precision servo forming press is started to punch and form downwards (as shown by an arrow in fig. 2), ultrasonic vibration is applied, then demoulding is carried out, a first T-shaped blank 21 (as shown in fig. 3) composed of a columnar bulge 22 and a blank bottom surface 23 is obtained, the first T-shaped blank 21 is placed into a vacuum heat treatment furnace to be sintered and densified, a T-shaped sintered blank 2 is obtained, and the weight and the appearance of the T-shaped sintered blank are detected;
wherein the cold pressing pressure adopted when the first T-shaped blank body 21 is pressed is 6T/cm2, and the dwell time is 1 s; the sintering temperature for sintering the first T-shaped blank body 21 is 450 ℃, and the sintering time is 4 h.
S2, winding: and (2) precisely winding the coil 5 on the columnar protrusion 22 of the T-shaped sintered blank 2 which is obtained by sintering in the step S1 and is qualified in weight and appearance detection by adopting a precise winding machine, bending the copper wire pins 6 at two ends and attaching the bent copper wire pins to the flat bottom surface of the T-shaped sintered blank 2 to obtain the wound T-shaped sintered blank 2 (as shown in figure 4).
S3, preparing a cup-shaped blank: as shown in fig. 5, the screened soft magnetic alloy powder is loaded into a cup-shaped die with a preset structure and size, which is composed of a middle die 12 of a cold press forming die and a lower die 13 of the cold press forming die, an upper die 11 of the cold press forming die of a high-precision servo forming press is started to perform downward punch forming (as shown by an arrow in fig. 5), ultrasonic vibration is applied to the downward punch forming (as shown by an arrow in fig. 5), a cup-shaped blank body 3 with a groove is obtained (as shown in fig. 6), the cup-shaped blank body 3 is not separated from the middle die 12 of the cold press forming die, and the cup-shaped blank body enters the next step along with the die;
wherein the cold pressing pressure adopted when pressing into the cup-shaped blank body is 3t/cm2The dwell time was 1 s.
S4, hot press forming: as shown in fig. 7, placing the cup-shaped blank 3 obtained in step S3 with the opening facing upward on the middle mold 12, fixing the cup-shaped blank on the middle mold base 42, placing the columnar protrusion 22 of the T-shaped sintered blank 2 with the coil 5 wound thereon obtained in step S2 downward into the mold cavity of the middle mold 12 with the cup-shaped blank 3, then starting the upper punch 41 of the hot-press forming mold to punch downward (as shown by the arrow in fig. 7) to obtain a first inductor blank, and baking the first inductor blank to obtain a cured inductor blank;
wherein the hot pressing pressure adopted in the hot pressing is 3t/cm2And keeping the pressure for 150s, baking and curing the first inductor blank, specifically, baking the first inductor blank in a baking oven to enable resin inside the cup-shaped blank in the first inductor blank to perform a curing reaction to obtain the inductor blank. The resin adopted here is epoxy resin, and only has small volume shrinkage during curing, so that the inductance blank body is not deformed after curing and molding. Specifically, the baking curing temperature is 150 ℃, baking equipment with a temperature rise and fall stepped curve can be selected, heat preservation is carried out for 3 hours, and finally an inductor semi-finished product is obtained, wherein the size of the inductor semi-finished product is the same as that of the inductor semi-finished product2.0 mm. times.1.6 mm. times.1.0 mm.
S5, spraying: and (4) spraying a layer of epoxy resin protective material on the surface of the inductor blank prepared in the step S4 by adopting constant-temperature heating spraying equipment, and then baking the sprayed inductor semi-finished product to cure the epoxy resin on the surface of the inductor semi-finished product. Wherein, the baking conditions are as follows: baking at 150 ℃ for 2h to cure the resin on the surface of the semi-finished inductor and obtain certain strength.
S6, electrode preparation: and (3) stripping the epoxy resin protective material and the copper wire enamel at the copper electrode of the semi-finished inductor product prepared in the step (S5), namely the copper wire pin 6 by using laser paint stripping equipment to expose the copper electrode at the bottom, and electroplating a copper layer, a nickel layer and a tin layer at the paint stripping position to realize the leading-out of the electrode 61 and obtain the sheet power inductor. As shown in fig. 8, which is a schematic structural diagram of a finished chip power inductor, the soft magnetic alloy powder 7 coats the enameled coil 5 inside, two electrodes 61 arranged in parallel are arranged on the upper portion of a plane perpendicular to the upper end face of the enameled coil 5, and an insulating protective material 8 is sprayed on the outside of the power inductor, wherein the insulating protective material is epoxy resin.
Testing the prepared power inductor, setting the standard inductance of the inductor to be 1 muH, and testing the inductance value L under the conditions of 1V and 1MHz by using an impedance analyzers0.998 muH, direct current resistance RdcIs 31.1 m.OMEGA.; saturation current IsatIt was 4.87A.
Comparative example 1:
the comparative example uses the same soft magnetic alloy powder as the example 1, and the specific preparation steps are as follows:
s1, making T-shaped sintered green body as S1 in example 1;
s2, winding wire as in S2 of example 1, and obtaining a T-shaped sintered green body 2 of the winding wire.
S3, hot press forming: as shown in fig. 5, the screened soft magnetic alloy powder 7 is filled into the T-shaped sintered blank 2 and the top of the coil 5 in the mold 42 of the hot press forming mold and the gap formed by the coil and the side wall of the mold cavity, the upper punch 41 of the hot press forming mold is started to punch downwards (as shown by the arrow in fig. 9) to obtain a first inductor blank, and then the first inductor blank is baked to obtain a cured inductor blank;
wherein the hot pressing pressure adopted in the hot pressing is 3t/cm2And keeping the pressure for 150s, baking and curing the first inductor blank, specifically, putting the first inductor blank into a baking oven for heating and raising the temperature, so that the resin in the first inductor blank is subjected to a curing reaction to obtain the inductor blank. The resin adopted here is epoxy resin, and only has small volume shrinkage during curing, so that the inductance blank body is not deformed after curing and molding. Specifically, the baking curing temperature is 150 ℃, baking equipment with a temperature rise and drop step curve can be selected here, heat preservation is carried out for 3 hours, and finally an inductance semi-finished product is obtained, wherein the size of the inductance semi-finished product is 2.0mm multiplied by 1.6mm multiplied by 1.0 mm.
S4, spraying is carried out as in S5 of example 1.
S5, electrode preparation is as in example S6. The performance parameters obtained using the same performance test conditions as in example 1 are shown in table 1.
Comparative example 2:
selecting the same soft magnetic alloy powder as in example 1, only baking the prepared T-shaped blank in baking equipment with a temperature rise and fall step curve at 180 ℃ for 30min, without sintering, selecting the same method as in example 1 to prepare a cup-shaped blank, and obtaining the sheet-shaped power inductor with the same manufacturing method, steps and process parameters as in example 1. The performance parameters obtained using the same performance test conditions as in example 1 are shown in table 1.
Comparative example 3:
selecting the same soft magnetic alloy powder as in example 1, only baking the prepared T-shaped blank in baking equipment with a temperature rise and fall step curve at 180 ℃ for 30min without sintering treatment and preparing a cup-shaped blank 3, wherein the rest manufacturing methods, steps and process parameters are the same as those of comparative example 1, and the sheet-shaped power inductor is obtained. The performance parameters obtained using the same performance test conditions as in example 1 are shown in table 1.
Thus, the performance parameters obtained for example 1 and comparative examples 1-3 above are shown in Table 1 below:
TABLE 1 Performance parameters of chip Power inductors obtained in example 1 and comparative examples 1 to 3
Example 2:
in the embodiment, the soft magnetic alloy powder is a composite powder formed by mixing Fe-Si-B-Nb-Cu nanocrystalline soft magnetic alloy powder and iron powder, and the rest of the manufacturing method, steps and process parameters are the same as those in the embodiment 1, so that the sheet-shaped power inductor is obtained. The performance parameters obtained using the same performance test conditions as in example 1 are shown in table 2.
Comparative example 4:
the same soft magnetic alloy powder as that in the embodiment 2 is selected, and the manufacturing method, the steps and the process parameters as those in the comparative example 1 are adopted to manufacture the sheet power inductor. The performance parameters obtained using the same performance test conditions as in example 1 are shown in table 2.
Comparative example 5:
the same soft magnetic alloy powder as that in the embodiment 2 is selected, and the manufacturing method, the steps and the process parameters as those in the comparative example 2 are adopted to manufacture the sheet power inductor. The performance parameters obtained using the same performance test conditions as in example 1 are shown in table 2.
Comparative example 6:
the same soft magnetic alloy powder as that in the embodiment 2 is selected, and the manufacturing method, the steps and the process parameters as those in the comparative example 3 are adopted to manufacture the sheet power inductor. The performance parameters obtained using the same performance test conditions as in example 1 are shown in table 2.
Thus, the performance parameters obtained for example 2 above and comparative examples 4-6 are shown in Table 2 below:
TABLE 2 Performance parameters of chip Power inductors obtained in example 2 and comparative examples 4 to 6
Tables 1 and 2 include the differences in the manufacturing processes of chip power inductors of examples 1 to 2 and comparative examples 1 to 6d.C. resistance R of chip power inductordc(m.OMEGA.) saturation Current Isat(A) Inductance Ls(μH)。
By comparing the manufacturing processes and performance parameters of the embodiment 1, the comparative examples 2 and 3, and the embodiment 2, the comparative examples 5 and 6, it is determined that sintering densification of the T-shaped blank in the blank preparation process can significantly improve the permeability performance of the inductor product, which is that the sintering process increases the densification of the powder, so that higher permeability is obtained, i.e. the inductance is greatly improved.
By comparing the manufacturing processes and performance parameters of the embodiment 1, the comparative examples 1 and 3, and the embodiment 2, the comparative examples 4 and 6, it is determined that the inductance and the saturation current of the inductor product can be effectively improved by using the combination of the prefabricated cup-shaped blank and the T-shaped blank, on one hand, the prefabricated blank has higher density than the direct powder filling, on the other hand, the internal coil can be effectively protected, the deformation of the coil in the compression molding process is reduced, so that the use stability of the inductor is ensured, and the comprehensive performance of the product is improved.
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 (10)
1. A method for manufacturing a sheet-shaped power inductor is characterized by comprising the following steps:
s1, preparing a T-shaped sintered blank: processing the soft magnetic alloy powder to prepare a T-shaped sintered blank;
s2, winding: winding an enameled wire by the columnar bulge of the T-shaped sintered blank prepared in the step S1, bending pins at two ends, and attaching the bent pins to the bottom surface of the flat plate of the T-shaped sintered blank to obtain a wound T-shaped sintered blank;
s3, preparing a cup-shaped blank: filling soft magnetic alloy powder into a cup-shaped die for pressing and forming to obtain a cup-shaped blank, wherein the cup-shaped blank is not demoulded and enters the next step along with the die;
s4, hot press forming: placing the cup-shaped blank prepared in the step S3 with an upward opening along with a mold, implanting the T-shaped sintered blank of the winding prepared in the step S2 into a mold cavity with the cup-shaped blank according to a downward convex part, and then performing hot press molding to obtain a first inductance blank and baking the first inductance blank to obtain a cured inductance blank;
s5, spraying: spraying an insulating protection material on the surface of the inductor blank prepared in the step S4 to obtain a sheet-shaped power inductor semi-finished product;
s6, electrode preparation: and (5) stripping the insulating protective material and the copper wire enamel at the copper electrode of the semi-finished product of the chip power inductor prepared in the step (S5), and electroplating the electrode at the enamel stripping position to obtain the chip power inductor.
2. The method for manufacturing a chip power inductor according to claim 1, wherein the method for preparing the T-shaped sintered body in step S1 comprises: and (3) filling the soft magnetic alloy powder into a T-shaped die with a preset structure and size for compression molding, and then demolding and sintering to obtain a T-shaped sintered blank.
3. The method for manufacturing a chip power inductor according to claim 1, wherein the method for preparing the T-shaped sintered body in step S1 comprises: soft magnetic alloy powder is put into a block-shaped die with a preset structure and size for compression molding, and then is demoulded and sintered, and then a T-shaped sintered blank is obtained by adopting a machining cutting mode.
4. The method for manufacturing a chip power inductor according to claim 1, wherein the soft magnetic alloy powder comprises soft magnetic alloy powder, a binder and a lubricant, and is prepared by mixing, granulating and screening raw materials.
5. The method of claim 4, wherein the soft magnetic alloy powder comprises 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.
6. The method for manufacturing a chip power inductor according to claim 1, wherein the step S1 and the step S3 are performed by cold press molding with a high precision servo molding press, and the cold press pressure is 2t/cm2-15t/cm2The pressure maintaining time is 0.3s-30 s;
the sintering temperature of the green body is 400-700 ℃, and the sintering time is 1-8 h.
7. The method for manufacturing a chip power inductor according to claim 1, wherein in step S2, a precision winding machine is used to precisely wind an enameled wire on the columnar protrusion of the T-shaped sintered blank.
8. The method as claimed in claim 1, wherein the hot press molding pressure in step S4 is 0.5t/cm2-10t/cm2The dwell time is 1s-200 s.
9. The method for manufacturing a chip power inductor according to claim 1, wherein the step S5 is performed by spraying with a constant temperature heating spraying device, and the coating material is cured by baking after spraying; the baking temperature is 80-200 ℃, and the baking time is 0.5-5 h.
10. The method for manufacturing a chip power inductor according to claim 1, wherein the insulating protective material and the copper wire enamel at the copper electrode of the inductor semi-finished product are stripped by a laser paint stripping device in step S6.
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| CN114758881A (en) * | 2022-04-18 | 2022-07-15 | 宁波中科毕普拉斯新材料科技有限公司 | Preparation method of chip inductor |
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