CN114512309A - Cylindrical inductor precursor and preparation method and application thereof - Google Patents
Cylindrical inductor precursor and preparation method and application thereof Download PDFInfo
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- H01F27/00—Details of transformers or inductances, in general
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- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/30—Fastening or clamping coils, windings, or parts thereof together; Fastening or mounting coils or windings on core, casing, or other support
- H01F27/306—Fastening or mounting coils or windings on core, casing or other support
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- 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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Abstract
The invention provides a cylindrical inductor precursor and a preparation method and application thereof, wherein the cylindrical inductor is prepared from the cylindrical inductor precursor, the cylindrical inductor precursor comprises a cylindrical magnetic core and a coil arranged in the cylindrical magnetic core, two grooves are formed in the surface of one side of the cylindrical magnetic core, a convex surface is formed in the surface of the other side of the cylindrical magnetic core, and two terminals of the coil are respectively pulled to two sides of the convex surface through the two grooves. According to the invention, the coil is placed in the cylindrical magnetic core, the coil is limited by the side wall of the cylindrical magnetic core and the two grooves to obtain the cylindrical inductance precursor, the structural strength is not required to be larger, the characteristics of the formed powder are better, the performance of the material is greatly exerted, and the cost of the material is saved.
Description
Technical Field
The invention belongs to the technical field of electronic equipment, and relates to a cylindrical inductor precursor, and a preparation method and application thereof.
Background
An inductor is a basic component constituting an electronic circuit, and has a wide range of applications in electronic circuits. In an ac circuit, the inductor can block the ac current, while in a dc circuit it does not contribute to the dc current, except for the dc resistance of the coil itself; therefore, the inductor has the functions of choke flow, voltage reduction, cross-linking coupling and the like, and is widely applied to the fields of medical use, vehicle-mounted use, aerospace aviation and the like.
At present, the types of inductance elements in the market are more, and are classified according to the manufacturing method: one is a molded inductor, and the other is an integrally formed T-core inductor. The existing integrally formed molded inductor in the market needs to weld a wound coil on a conductor electrode, for example, the CN202183292U patent provides an improved integrally formed inductor which comprises a coil, a magnetic solid body and two electrode pins, the inductor is processed by adopting the general processes of spot welding of the coil, molding and the like, the appearance of the inductor is improved, but the welding in the patent can generate contact impedance, meanwhile, the coil has no positioning protection, the coil is easy to deviate and deform during molding, so that the impedance is further increased, the characteristics and the quality are influenced, and the market competitiveness of the product is poor due to the factors; in addition, automotive products have high quality requirements, and the problem of large coil deformation is difficult to accept by customers.
In the prior art, the coil of the T-core inductor is integrally formed, and the T-core is used as a support, so that the deformation of the coil in the inductor is improved to a certain extent. CN108648901A provides an integrally formed inductor, which adopts a T-core process, the patent firstly presses the T-core, then winds the wire on the T-core center post, and obtains the integrally formed T-core inductor by the general processes of mould pressing and the like; although the T-core process is adopted in the patent, the coil is wound on the T-core center column, the deformation of the coil is small due to the protection of the T-core during hot pressing, but the T-core needs high strength (the coil is wound on the T-core subsequently) and precision, particularly, the requirements on the equipment precision and powder characteristics (such as spherical degree, fluidity and the like) are high along with the reduction of the product size, and the T-core is not suitable for the production of inductors with smaller sizes, so that the further application of the T-core is limited.
In summary, in the prior art, a molded inductor and an integrally formed T-core inductor are generally adopted, and the molded inductor has a simple process, but the coil has large deformation, poor product characteristics and no guarantee of quality; the integrally formed T-core inductor has high precision requirement, high equipment dependence and high investment and cannot meet the requirement of products with smaller sizes. Therefore, it is of great significance to develop an inductor with high characteristics and easy realization of industrial production.
Disclosure of Invention
Aiming at the problems in the prior art, the invention aims to provide a cylindrical inductor precursor and a preparation method and application thereof. According to the invention, the coil is placed in the cylindrical magnetic core, the coil is limited by the side wall of the cylindrical magnetic core and the two grooves to obtain the cylindrical inductance precursor, the structural strength is not required to be larger, the characteristics of the formed powder are better, the performance of the material is greatly exerted, and the cost of the material is saved.
In order to achieve the purpose, the invention adopts the following technical scheme:
in a first aspect, the invention provides a cylindrical inductance precursor, which comprises a cylindrical magnetic core and a coil arranged inside the cylindrical magnetic core, wherein two grooves are formed in the surface of one side of the cylindrical magnetic core, a convex surface is formed in the surface of the other side of the cylindrical magnetic core, and two terminals of the coil are respectively pulled to two sides of the convex surface through the two grooves.
According to the invention, the coil is placed in the cylindrical magnetic core, the coil is limited through the side wall of the cylindrical magnetic core and the two grooves, two terminals of the coil respectively extend out through the two grooves, are folded to the other side surface of the cylindrical magnetic core, and are finally attached to two sides of the convex surface of the other side surface, so that the cylindrical inductance precursor is obtained. The side surface (curved surface) and the plane where the convex surface of the cylindrical inductor precursor is located have certain thickness, different thicknesses can be designed according to the requirements of products, and the cylindrical inductor precursor can be widely applied.
The cylindrical inductor precursor is different from a T-core inductor, and the T-core inductor needs great structural strength. Meanwhile, when the inductor is used for powder molding, a certain amount of glue is generally required to be added for improving the strength of a product, but the addition of the glue can reduce the electrical property of the product.
Preferably, the distance between the two grooves is 1.2-1.4 mm, such as 1.2mm, 1.25mm, 1.3mm, 1.35mm or 1.4 mm.
The cylindrical magnetic core is provided with the two grooves for limiting the coil, when the distance between the two grooves is within the range of 1.2-1.4 mm, the limiting effect is the best, the range is that the series from 2012 to 3225 can be used universally, if the distance between the grooves is larger than 1.4mm, the lead is leaked outside after hot pressing, and if the distance is smaller than 1.2mm, the lead is raised after line turning, so that paint stripping cannot be positioned.
The size of the cylindrical magnetic core is not particularly limited, the size of the cylindrical magnetic core can be adjusted according to actual application requirements, but the comprehensive effect is best when the distance between the two grooves of the cylindrical magnetic cores with different sizes is within the range of 1.2-1.4 mm.
Preferably, the two grooves are symmetrically distributed, so that when two terminals of the coil are led out from the grooves, the two terminals are pulled to two sides of the convex surface one by one, in the subsequent pressing process, the two terminals respectively enable two lead grooves to be formed on two sides of the convex surface, and the terminals are located in the lead grooves.
In a second aspect, the present invention provides a method for preparing the cylindrical inductor precursor according to the first aspect, the method comprising:
(1) mixing the magnetic powder and glue, granulating, and performing primary pressing to obtain a cylindrical magnetic core;
(2) and (2) placing a coil in the cylindrical magnetic core obtained in the step (1), leading out two terminals of the coil through a groove on one side of the cylindrical magnetic core, and turning over the two terminals to the surface on the other side of the cylindrical magnetic core to obtain a cylindrical inductance precursor.
The preparation method disclosed by the invention is simple in preparation process and low in equipment requirement, the cylindrical magnetic core obtained by pressing and the coil are orderly combined to obtain the cylindrical inductor precursor, and the prepared cylindrical inductor precursor has better performance and application.
Preferably, the magnetic powder of step (1) includes amorphous powder and/or alloy powder.
Illustratively, the amorphous powder in the present invention includes any one of iron-silicon-boron amorphous powder, iron-nickel-boron amorphous powder, or iron-chromium-boron amorphous powder, or a combination of at least two of them, for example, a combination of iron-silicon-boron amorphous powder and iron-nickel-boron amorphous powder, a combination of iron-nickel-boron amorphous powder and iron-chromium-boron amorphous powder, or a combination of iron-silicon-boron amorphous powder, iron-nickel-boron amorphous powder and iron-chromium-boron amorphous powder, or the like.
Preferably, the glue of step (1) comprises epoxy resin.
Preferably, the mass ratio of the amorphous powder to the alloy powder is 1:10 to 10:1, and may be, for example, 1:10, 1:8, 1:5, 3:8, 1:2, 1:1, 6:5, 2:1, 4:1, 6:1, 8:1, or 10:1, and the ratio of the amorphous powder to the alloy powder may be adjusted according to product characteristics, and is preferably 3:8 to 6: 5.
Preferably, the mass of the glue accounts for 0-10% of the total mass of the magnetic powder and the glue, and does not contain 0%, and for example, the mass may be 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, or the like, and preferably 1-4%.
In the invention, glue with less content is preferably adopted for coating granulation, and the requirement on the strength of the cylindrical inductor precursor is not high, so that the requirement can be met by less glue content, and the characteristic of the prepared cylindrical inductor can be improved.
Preferably, the method further comprises the operation of sieving after the granulation and before the primary pressing in the step (1).
Preferably, the mesh number of the screening is 50 to 300 meshes, for example, 50 meshes, 80 meshes, 100 meshes, 120 meshes, 140 meshes, 160 meshes, 180 meshes, 200 meshes, 220 meshes, 240 meshes, 260 meshes, 280 meshes, 300 meshes, or the like can be adopted.
Preferably, the method further comprises the step of drying after the screening and before the primary pressing.
Preferably, the drying temperature is 50-60 ℃, for example, 50 ℃, 52 ℃, 54 ℃, 56 ℃, 58 ℃ or 60 ℃, and the drying time is 1.5-2.5 h, for example, 1.5h, 1.8h, 2h, 2.2h or 2.5 h.
As a preferable embodiment of the method for preparing the cylindrical inductor precursor according to the present invention, the pressure of the primary pressing in step (1) is 10 to 500MPa, and may be, for example, 10MPa, 20MPa, 40MPa, 60MPa, 80MPa, 100MPa, 150MPa, 200MPa, 300MPa, 400MPa, or 500 MPa.
Preferably, the time of the primary pressing in the step (1) is 9-11 s, for example, 9s, 9.5s, 10s, 10.5s or 11 s.
The one-time pressing in the invention can be carried out at normal temperature.
Preferably, the step (1) further comprises a baking operation after the primary pressing.
Preferably, the baking temperature is 200-220 ℃, for example, 200 ℃, 205 ℃, 210 ℃, 215 ℃ or 220 ℃.
In a third aspect, the present invention provides a cylindrical inductor, which is prepared from the cylindrical inductor precursor according to the first aspect.
The cylindrical inductor precursor has a specific structure, does not need great structural strength when used for preparing the cylindrical inductor, has better powder forming property, greatly exerts the performance of materials, saves the cost of the materials, has higher inductance value, lower direct current resistance and higher saturation current, has high property and is easy for industrial production.
In a fourth aspect, the present invention provides a method for manufacturing a cylindrical inductor according to the third aspect, the method comprising:
and filling powder into the cylindrical inductor precursor and performing secondary pressing to obtain the cylindrical inductor.
According to the invention, the semi-finished product obtained by the preparation, namely the cylindrical inductor precursor, is filled in a mold cavity with a certain volume and quantity, and then powder is filled for secondary pressing, so that the cylindrical inductor with high characteristics can be obtained.
Preferably, the powder used for powder filling comprises magnetic powder and glue.
Preferably, the magnetic powder includes amorphous powder and/or alloy powder.
Preferably, the glue comprises an epoxy resin.
Illustratively, the powder material used for powder filling is the same as the powder material obtained after granulation and screening in the step (1) of the preparation method of the cylindrical inductor precursor.
Preferably, the temperature of the secondary pressing is 170 to 200 ℃, for example, 170 ℃, 175 ℃, 180 ℃, 185 ℃, 190 ℃, 195 ℃ or 200 ℃, preferably 180 to 190 ℃.
Preferably, the time of the secondary pressing is 2-3 min, for example, 2min, 2.4min, 2.5min, 2.6min or 3min, and preferably 2.4-2.6 min.
Preferably, the pressure of the secondary pressing is 20 to 300MPa, for example, 20MPa, 40MPa, 80MPa, 100MPa, 120MPa, 140MPa, 150MPa, 160MPa, 180MPa, 200MPa, 250MPa or 300MPa, and the like, preferably 100 to 150 MPa.
Compared with the prior art, the invention has the following beneficial effects:
the cylindrical inductor precursor is different from a T-core inductor, and the T-core inductor needs great structural strength. Meanwhile, when the inductor is used for powder molding, a certain amount of glue is generally required to be added for improving the strength of a product, but the addition of the glue can reduce the electrical property of the product.
Drawings
Fig. 1 is a bottom view of a cylindrical inductor precursor in an embodiment of the present invention.
Fig. 2 is a perspective view of a cylindrical inductor precursor in an embodiment of the present invention.
Fig. 3 is a front view of a cylindrical inductor precursor in an embodiment of the present invention.
Fig. 4 is a schematic structural diagram of a cylindrical inductor precursor in an embodiment of the present invention.
Fig. 5 is a bottom view of the core of the T-core inductor of comparative example 1 of the present invention.
Fig. 6 is a top view of the magnetic core of the T-core inductor of comparative example 1 of the present invention.
Fig. 7 is a bottom view of the T-core inductor precursor of comparative example 1 of the present invention.
Fig. 8 is a top view of the T-core inductor precursor of comparative example 1 of the present invention.
Wherein, 1-cylindrical magnetic core; 2-a coil; 11 a-a first groove, 11 b-a second groove; 12-convex surface; 21 a-a first terminal; 21 b-second terminal.
Detailed Description
The technical solution of the present invention is further explained by the following embodiments. It should be understood by those skilled in the art that the examples are only for the understanding of the present invention and should not be construed as the specific limitation of the present invention.
The embodiment of the invention provides a cylindrical inductor precursor, which has a schematic structural diagram shown in fig. 4, and includes a cylindrical magnetic core 1 and a coil 2 arranged inside the cylindrical magnetic core 1, a bottom view of the cylindrical inductor precursor is shown in fig. 1, an inner circle represents the coil 2, the coil 2 is externally provided with the cylindrical magnetic core 1, one side surface of the cylindrical magnetic core 1 is provided with a first groove 11a and a second groove 11b, the other side surface is provided with a convex surface 12, and as shown in fig. 2 and fig. 3, a first terminal 21a and a second terminal 21b of the coil 2 are respectively drawn to two sides of the convex surface 12 through the first groove 11a and the second groove 11 b.
In some embodiments, the first groove 11a and the second groove 11b have a distance of 1.2-1.4 mm.
In some embodiments, the first grooves 11a and the second grooves 11b are symmetrically distributed.
The embodiment of the invention also provides a preparation method of the cylindrical inductor precursor, which comprises the following steps:
(1) mixing the magnetic powder and glue, granulating, and performing primary pressing to obtain a cylindrical magnetic core 1;
(2) and (2) placing the coil 2 in the cylindrical magnetic core 1 obtained in the step (1), leading out the first terminal 21a and the second terminal 21b of the coil 2 through the first groove 11a and the second groove 11b on one side of the cylindrical magnetic core 1 respectively, and turning over the two terminals to the surface on the other side of the cylindrical magnetic core 1 to obtain the cylindrical inductance precursor.
In some embodiments, the magnetic powder of step (1) comprises an amorphous powder and/or an alloy powder.
In some embodiments, the glue of step (1) comprises an epoxy resin.
In some embodiments, the mass ratio of the amorphous powder to the alloy powder is 1:10 to 10:1, preferably 3:8 to 6: 5.
In some embodiments, the mass of the glue accounts for 0-10%, preferably 1-4% of the total mass of the magnetic powder and the glue.
In some embodiments, the granulation in step (1) further comprises a sieving operation after the granulation and before the primary pressing.
In some embodiments, the screen mesh number of the screen is 50 to 300 mesh.
In some embodiments, the drying operation is further included after the screening and before the primary pressing.
In some embodiments, the drying temperature is 50-60 ℃, and the drying time is 1.5-2.5 h.
In some embodiments, the pressure of the primary pressing in the step (1) is 10 to 500 MPa.
In some embodiments, the time for the primary pressing in the step (1) is 9 to 11 seconds.
In some embodiments, the step (1) further comprises a baking operation after the primary pressing.
In some embodiments, the baking temperature is 200 to 220 ℃.
The embodiment of the invention also provides a cylindrical inductor, and the cylindrical inductor is prepared by adopting the cylindrical inductor precursor.
The embodiment of the invention also provides a preparation method of the cylindrical inductor, which comprises the following steps:
and filling powder into the cylindrical inductor precursor and performing secondary pressing to obtain the cylindrical inductor.
In some embodiments, the temperature of the secondary pressing is 170 to 200 ℃, preferably 180 to 190 ℃.
In some embodiments, the time for the secondary pressing is 2 to 3min, preferably 2.4 to 2.6 min.
In some embodiments, the pressure of the secondary pressing is 20 to 300MPa, preferably 100 to 150 MPa.
Example 1
The embodiment provides a cylinder formula inductance precursor, as shown in fig. 4, cylinder formula inductance precursor includes cylinder type magnetic core 1 and sets up 1 inside coil 2 of cylinder type magnetic core, one side surface of cylinder type magnetic core 1 is provided with first recess 11a and second recess 11b, and the opposite side surface is provided with convex surface 12, and first recess 11a and second recess 11b are the symmetric distribution, and the interval of first recess 11a and second recess 11b is 1.3mm, first terminal 21a and second terminal 21b of coil 2 pull extremely through first recess 11a and second recess 11b respectively the both sides of convex surface 12.
The embodiment also provides a cylindrical inductor and a preparation method thereof, wherein the cylindrical inductor is prepared by adopting the cylindrical inductor precursor, and the preparation method comprises the following steps:
(1) preparing a cylindrical inductor precursor: mixing and granulating magnetic powder and epoxy resin glue (PH glue), screening and granulating the granules by using a 200-mesh sieve, placing the granules in an oven at 55 ℃ and baking for 2 hours to obtain granulated powder, pressing the granulated powder into a cylindrical magnetic core 1 by using a one-step forming machine, wherein the one-step pressing pressure is 200MPa, the temperature is normal temperature, and the time is 10s, the pressed cylindrical magnetic core 1 is combined with a coil 2 after being cured at high temperature, the high-temperature curing mode is that the cylindrical magnetic core 1 is baked for 2 times in a Reflow furnace at 210 ℃, and a first terminal 21a and a second terminal 21b at two ends of the coil 2 are bent to two sides of a convex surface 12 of the cylindrical magnetic core 1 to obtain a cylindrical inductance precursor;
wherein the PH glue accounts for 2.2% of the total mass of the magnetic powder and the PH glue, and the magnetic powder is a mixture of amorphous powder and alloy powder in a mass ratio of 3: 7;
(2) and (2) filling powder into the cylindrical inductor precursor obtained in the step (1) in a secondary forming press, performing secondary pressing, wherein the powder used for powder filling is the same as the powder granulated in the step (1), the secondary pressing temperature is 180 ℃, the time is 2min, and the pressure is 125MPa, and the cylindrical inductor is obtained by processing the cylindrical inductor precursor through general processes such as baking, rolling spraying, laser, electroplating and the like after pressing.
Example 2
The embodiment provides a cylinder formula inductance precursor, as shown in fig. 4, cylinder formula inductance precursor includes cylinder type magnetic core 1 and sets up 1 inside coil 2 of cylinder type magnetic core, one side surface of cylinder type magnetic core 1 is provided with first recess 11a and second recess 11b, and the opposite side surface is provided with convex surface 12, and first recess 11a and second recess 11b are the symmetric distribution, and the interval of first recess 11a and second recess 11b is 1.3mm, first terminal 21a and second terminal 21b of coil 2 pull extremely through first recess 11a and second recess 11b respectively the both sides of convex surface 12.
The embodiment also provides a cylindrical inductor and a preparation method thereof, wherein the cylindrical inductor is prepared by adopting the cylindrical inductor precursor, and the preparation method comprises the following steps:
(1) preparing a cylindrical inductor precursor: mixing and granulating magnetic powder and PH glue, screening and granulating the granules by using a 200-mesh sieve, placing the granules in an oven at 55 ℃ and baking for 2 hours to obtain granulated powder, pressing the granulated powder into a cylindrical magnetic core 1 by using a one-step forming machine, wherein the pressure of the one-step pressing is 200MPa, the temperature is normal temperature, the time is 10s, the pressed cylindrical magnetic core 1 is combined with a coil 2 after high-temperature curing, the high-temperature curing mode is that the cylindrical magnetic core 1 is baked for 2 times in a Reflow furnace at 210 ℃, and a first terminal 21a and a second terminal 21b at two ends of the coil 2 are bent to two sides of a convex surface 12 of the cylindrical magnetic core 1 to obtain a cylindrical inductance precursor;
wherein the PH glue accounts for 2.4% of the total mass of the magnetic powder and the PH glue, and the magnetic powder is a mixture of amorphous powder and alloy powder in a mass ratio of 4: 6;
(2) and (2) filling powder into the cylindrical inductor precursor obtained in the step (1) in a secondary forming press, performing secondary pressing, wherein the powder used for powder filling is the same as the powder granulated in the step (1), the secondary pressing temperature is 185 ℃, the time is 2min, and the pressure is 120MPa, and the cylindrical inductor is obtained by processing the cylindrical inductor precursor through general processes such as baking, rolling spraying, laser, electroplating and the like after pressing.
Example 3
The embodiment provides a cylinder formula inductance precursor, as shown in fig. 4, cylinder formula inductance precursor includes cylinder type magnetic core 1 and sets up 1 inside coil 2 of cylinder type magnetic core, one side surface of cylinder type magnetic core 1 is provided with first recess 11a and second recess 11b, and the opposite side surface is provided with convex surface 12, and first recess 11a and second recess 11b are the symmetric distribution, and the interval of first recess 11a and second recess 11b is 1.3mm, first terminal 21a and second terminal 21b of coil 2 pull extremely through first recess 11a and second recess 11b respectively the both sides of convex surface 12.
The embodiment also provides a cylindrical inductor and a preparation method thereof, wherein the cylindrical inductor is prepared by adopting the cylindrical inductor precursor, and the preparation method comprises the following steps:
(1) preparing a cylindrical inductor precursor: mixing and granulating magnetic powder and PH glue, screening and granulating the granules by using a 200-mesh sieve, placing the granules in an oven at 55 ℃ and baking for 2 hours to obtain granulated powder, pressing the granulated powder into a cylindrical magnetic core 1 by using a one-step forming machine, wherein the pressure of the one-step pressing is 200MPa, the temperature is normal temperature, the time is 10s, the pressed cylindrical magnetic core 1 is combined with a coil 2 after high-temperature curing, the high-temperature curing mode is that the cylindrical magnetic core 1 is baked for 2 times in a Reflow furnace at 210 ℃, and a first terminal 21a and a second terminal 21b at two ends of the coil 2 are bent to two sides of a convex surface 12 of the cylindrical magnetic core 1 to obtain a cylindrical inductance precursor;
wherein the PH glue accounts for 2.6% of the total mass of the magnetic powder and the PH glue, and the magnetic powder is a mixture of amorphous powder and alloy powder in a mass ratio of 5: 5;
(2) and (2) filling powder into the cylindrical inductor precursor obtained in the step (1) in a secondary forming press, performing secondary pressing, wherein the powder used for powder filling is the same as the powder granulated in the step (1), the secondary pressing temperature is 190 ℃, the time is 1.5min, and the pressure is 140MPa, and after pressing, performing general processing procedures such as baking, rolling spraying, laser, electroplating and the like to obtain the cylindrical inductor.
Example 4
The same as in embodiment 1 except that the pitch of the first grooves 11a and the second grooves 11b was 2 mm.
Example 5
The same as in embodiment 1 except that the pitch of the first grooves 11a and the second grooves 11b was 0.5 mm.
Comparative example 1
The present embodiment provides a T-core inductor and a method for manufacturing the same, where a bottom view and a top view of a magnetic core of the T-core inductor are respectively shown in fig. 5 and 6, and the method for manufacturing the T-core inductor includes:
(1) preparing a T-core inductor precursor: mixing and granulating magnetic powder and epoxy resin glue (PH glue), then screening and granulating the granules by using a 200-mesh sieve, placing the granules in an oven at 55 ℃ and baking for 2h to obtain granulated powder, pressing the granulated powder into a magnetic core by using a one-step forming machine, wherein the one-step pressing pressure is 200MPa, the temperature is normal temperature, and the time is 10s, as shown in fig. 5 and 6, the whole magnetic core is square, two grooves are reserved at two corners of the square on the same side, a magnetic column for winding a coil is arranged on the top surface of the magnetic core, a convex surface is arranged on the bottom surface of the magnetic core, the pressed cylindrical magnetic core is combined with the coil after high-temperature curing, terminals at two ends of the coil are bent to the back surface through the grooves and placed on two sides of the convex surface, as shown in fig. 7 and 8, the high-temperature curing mode is that the magnetic core is baked for 2 times in a Reflow furnace at 210 ℃ to obtain a T-core inductance precursor;
wherein the PH glue accounts for 3.0% of the total mass of the magnetic powder and the PH glue, and the magnetic powder is a mixture of amorphous powder and alloy powder in a mass ratio of 5: 5;
(2) and (2) filling powder into the T-core inductor precursor obtained in the step (1) in a secondary forming press, performing secondary pressing, wherein the powder used for powder filling is the same as the powder granulated in the step (1), the secondary pressing temperature is 190 ℃, the secondary pressing time is 1.5min, and the pressure is 140MPa, and after pressing, performing general processing procedures such as baking, rolling spraying, laser, electroplating and the like to obtain the T-core inductor.
The cylindrical inductor and the T-core inductor prepared by the invention are subjected to inductance, Direct Current Resistance (DCR) and saturation current tests, and the test results are shown in Table 1.
TABLE 1
| Sensory value (μ A) | DCR(mΩ) | Saturation current (A) | |
| Example 1 | 2.22 | 206 | 1.90 |
| Example 2 | 2.16 | 203 | 1.85 |
| Example 3 | 2.14 | 205 | 1.80 |
| Example 4 | 2.09 | 258 | 1.65 |
| Example 5 | 2.05 | 263 | 1.60 |
| Comparative example 1 | 2.11 | 321 | 1.55 |
To sum up, the embodiments 1 to 5 show that the coil is placed in the cylindrical magnetic core, and the coil is limited by the side wall of the cylindrical magnetic core and the two grooves to obtain the cylindrical inductor precursor, so that the structural strength is not required to be large, the characteristics of the formed powder are excellent, the performance of the material is greatly exerted, and the cost of the material is saved.
As can be seen from comparison between example 1 and examples 4 to 5, the present invention is most effective when the distance between the first groove 11a and the second groove 11b is about 1.3mm, when the distance is too large, the lead may leak, the inductance may be decreased due to the magnetic flux leakage, and when the distance is too small, the lead may be pressed to the coil when the lead is turned over, the lead may be bumped, the stripping may be poor, and the appearance requirement may not be satisfied, so that the performance and appearance of examples 4 to 5 are slightly inferior to those of example 1.
It can be known from the comparison between the example 1 and the comparative example 1 that, in the present invention, the cylindrical inductor is used and the specific groove is used to limit the coil, so that the characteristics of the molding powder can be better, and the performance of the material can be greatly exerted, and in the comparative example 1, because the T-core inductor is used, the required strength and precision of the T-core inductor are higher, and in order to maintain sufficient strength performance, the content of part of glue needs to be properly increased, which reduces the inductance value and the saturation current of the inductor, and increases the dc resistance of the inductor, therefore, the magnetic powder compositions of the comparative example 1 and the example 3 are the same, and the pressing parameters are also the same, but the dc resistance value of the comparative example 1 is 321m Ω, which is significantly higher than 205m Ω in the example 3, and the inductance value and the saturation current of the comparative example 1 are also lower than that of the example 3 of the present invention.
The above description is only for the specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto, and it should be understood by those skilled in the art that any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention are within the protection scope and the disclosure of the present invention.
Claims (10)
1. The utility model provides a cylinder formula inductance precursor, its characterized in that, cylinder formula inductance precursor includes the cylinder type magnetic core and sets up the inside coil of cylinder type magnetic core, one side surface of cylinder type magnetic core is provided with two recesses, and the opposite side surface is provided with the convex surface, two terminals of coil draw extremely through two recesses respectively the both sides of convex surface.
2. The cylinder type inductor precursor as claimed in claim 1, wherein the distance between the two grooves is 1.2-1.4 mm.
3. The cylindrical inductor precursor as claimed in claim 1 or 2, wherein the two grooves are symmetrically distributed.
4. A method for preparing a cylindrical inductor precursor according to any one of claims 1 to 3, comprising:
(1) mixing the magnetic powder and glue, granulating, and performing primary pressing to obtain a cylindrical magnetic core;
(2) and (2) placing a coil in the cylindrical magnetic core obtained in the step (1), leading out two terminals of the coil through a groove on one side of the cylindrical magnetic core, and turning over the terminals to the surface on the other side of the cylindrical magnetic core to obtain a cylindrical inductance precursor.
5. The method for preparing a cylindrical inductor precursor according to claim 4, wherein the magnetic powder of step (1) comprises amorphous powder and/or alloy powder;
preferably, the glue of step (1) comprises epoxy resin;
preferably, the mass ratio of the amorphous powder to the alloy powder is 1: 10-10: 1, and preferably 3: 8-6: 5;
preferably, the mass of the glue accounts for 0-10% of the total mass of the magnetic powder and the glue, and does not contain 0%, and preferably accounts for 1-4%.
6. The method for preparing the cylindrical inductor precursor according to claim 4 or 5, further comprising a sieving operation after the granulating and before the primary pressing in step (1);
preferably, the mesh number of the screened screen is 50-300 meshes;
preferably, the method further comprises the operation of drying after screening and before primary pressing;
preferably, the drying temperature is 50-60 ℃, and the drying time is 1.5-2.5 h.
7. The method for preparing the cylindrical inductor precursor according to any one of claims 4 to 6, wherein the pressure of the primary pressing in the step (1) is 10 to 500 MPa;
preferably, the time for the primary pressing in the step (1) is 9-11 s;
preferably, the step (1) further comprises a baking operation after the primary pressing;
preferably, the baking temperature is 200-220 ℃.
8. A cylindrical inductor, characterized in that it is produced using a cylindrical inductor precursor according to any one of claims 1 to 3.
9. A method for manufacturing the cylindrical inductor according to claim 8, wherein the method comprises:
and filling powder into the cylindrical inductor precursor and performing secondary pressing to obtain the cylindrical inductor.
10. The method according to claim 9, wherein the powder used for filling comprises magnetic powder and glue;
preferably, the magnetic powder includes amorphous powder and/or alloy powder;
preferably, the glue comprises an epoxy resin;
preferably, the temperature of the secondary pressing is 170-200 ℃, and preferably 180-190 ℃;
preferably, the time for the secondary pressing is 2-3 min, preferably 2.4-2.6 min;
preferably, the pressure of the secondary pressing is 20-300 MPa, and preferably 100-150 MPa.
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| CN114898998A (en) * | 2022-05-27 | 2022-08-12 | 横店集团东磁股份有限公司 | Cross-shaped magnetic core inductor and preparation method and application thereof |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN114898998A (en) * | 2022-05-27 | 2022-08-12 | 横店集团东磁股份有限公司 | Cross-shaped magnetic core inductor and preparation method and application thereof |
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