CN114898998A - Cross-shaped magnetic core inductor and preparation method and application thereof - Google Patents
Cross-shaped magnetic core inductor and preparation method and application thereof Download PDFInfo
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- 238000004804 winding Methods 0.000 claims abstract description 18
- 239000003292 glue Substances 0.000 claims description 20
- 239000002243 precursor Substances 0.000 claims description 18
- 238000000034 method Methods 0.000 claims description 16
- 238000001035 drying Methods 0.000 claims description 13
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- 239000006247 magnetic powder Substances 0.000 claims description 12
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- 238000009713 electroplating Methods 0.000 claims description 9
- 238000002156 mixing Methods 0.000 claims description 9
- 238000005096 rolling process Methods 0.000 claims description 9
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- 229910000519 Ferrosilicon Inorganic materials 0.000 claims description 2
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- 238000012216 screening Methods 0.000 claims description 2
- 238000013386 optimize process Methods 0.000 abstract description 2
- XWHPIFXRKKHEKR-UHFFFAOYSA-N iron silicon Chemical compound [Si].[Fe] XWHPIFXRKKHEKR-UHFFFAOYSA-N 0.000 description 17
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/24—Magnetic cores
- H01F27/255—Magnetic cores made from particles
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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
- H01F27/2823—Wires
- H01F27/2828—Construction of conductive connections, of leads
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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
- H01F41/02—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
Abstract
The invention relates to a cross-shaped magnetic core inductor and a preparation method and application thereof, wherein the preparation method comprises the following steps: (1) placing the horizontal winding type coil in a cross-shaped magnetic core, and folding and fixing a coil lead outside the cross-shaped magnetic core for at least four times to obtain a cross-shaped magnetic core combined coil; (2) and (2) performing powder filling, compression molding and post-treatment on the cross-shaped magnetic core combined coil obtained in the step (1) to obtain the cross-shaped magnetic core inductor. According to the cross-shaped magnetic core inductor and the preparation method thereof, the coil winding design of at least four turns is adopted, quality risks caused by poor lead upwarp, lead deflection or broken wire and the like are prevented, and the manufactured cross-shaped magnetic core inductor coil has good quality and low direct current impedance by matching with optimized process parameters of the cross-shaped magnetic core.
Description
Technical Field
The invention belongs to the field of inductance elements, relates to an inductor and a preparation method and application thereof, and particularly relates to a cross-shaped magnetic core inductor and a preparation method and application thereof.
Background
Inductors are widely used in electronic circuit products as one of basic components of electronic circuits. The traditional inductor mainly forms a wire-wound inductor by winding an enameled wire outside a magnetizer, but the inductor of the type has the defects of poor direct current saturation resistance, low inductance value and the like. The integrally formed inductor has the advantages of lowest direct current impedance in the same size, good noise reduction effect, capability of ensuring smooth reduction of the current-resistant inductance value and the like due to powder pressing forming of the integrally formed inductor, and is widely applied to the fields of automobiles, Internet of things and electronic equipment.
CN 208596602U discloses a thermal shrinkage epoxy encapsulation i-shaped inductor, which comprises an inductor main body, a movable pin, a coil, an adjusting cavity, an adjusting bolt, a sliding part, a conductive sleeve and a fixed pin; a coil is arranged in the inductor main body, a fixed pin is arranged at the bottom of the inductor main body, and an adjusting cavity is arranged at one side of the inductor main body; a sliding rail is arranged on the wall of the adjusting cavity; the sliding rail is provided with a threaded hole and an adjusting bolt; the adjusting bolt is provided with a sliding part, and the front end of the adjusting bolt is provided with a conductive sleeve; the conductive sleeve is connected with the movable pin. However, the I-shaped inductor has higher requirements on equipment precision and powder characteristics, and is not suitable for the production of small-size inductors.
CN 213124033U discloses an integral type inductance electronic component, including the magnetic core, the inside of magnetic core is equipped with the coil, is equipped with the alloy filler between magnetic core and the coil, and the outside cladding of magnetic core has insulating housing, and the inside of magnetic core is equipped with U type groove, and the lower extreme in U type groove is equipped with the bottom plate, and the tip of two lead wires of coil is the electrode foot, and two lead wires of coil are bending structure. The utility model discloses a bend the back of magnetic core with two lead wires of coil, lateral wall and bottom plate through the magnetic core carry on spacingly to the coil, nevertheless buckle its off-the-shelf characteristic of coil twice especially direct current impedance and still remain to improve.
CN 202183292U discloses an improved integrally formed inductor, which comprises a coil, a magnetic solid body and two electrode pins, wherein the coil is embedded in the magnetic solid body, one end of the electrode pin is a first end, the other end of the electrode pin is a second end, the first ends of the two electrode pins are respectively embedded in the magnetic solid body, and the two electrode pins are respectively welded with two ends of the coil. However, the utility model discloses an adopt coil spot welding back hot pressing, because of the coil does not have the location, the coil takes place the skew very easily and warp during the hot pressing, and has the quality risk of pseudo-soldering, puncture or broken foot.
In view of the deficiencies of the prior art, it is desirable to provide an inductor with low dc resistance and less deformation of the winding.
Disclosure of Invention
The invention aims to provide a cross-shaped magnetic core inductor and a preparation method and application thereof.
In order to achieve the purpose, the invention adopts the following technical scheme:
in a first aspect, the present invention provides a method for preparing a cross-shaped magnetic core inductor, wherein the method comprises the following steps:
(1) placing the horizontal winding type coil in a cross-shaped magnetic core, and folding and fixing a coil lead outside the cross-shaped magnetic core for at least four times to obtain a cross-shaped magnetic core combined coil;
(2) and (2) performing powder filling, compression molding and post-treatment on the cross-shaped magnetic core combined coil obtained in the step (1) to obtain the cross-shaped magnetic core inductor.
According to the preparation method of the cross-shaped magnetic core inductor, the coil winding design of at least four turns is adopted, the cross-shaped magnetic core inductor can be fixed and wrapped around the cross-shaped magnetic core, quality risks caused by poor quality such as lead tilting, lead deflection or wire breakage are prevented, and the cross-shaped magnetic core inductor prepared by matching with powder filling and pressing and other treatment is good in quality and low in direct current impedance.
Preferably, the folding step in step (1) is: two leads of the coil are respectively turned over to the side face of the cross-shaped magnetic core once through the grooves of the cross-shaped magnetic core, turned over to the bottom face of the cross-shaped magnetic core twice, turned over to the opposite side face of the cross-shaped magnetic core for three times and turned over to the surface of the coil body for four times.
Preferably, the horizontally wound coil in the step (1) comprises a circular bar type or a track type.
Preferably, the number of turns of the horizontal winding coil in step (1) is 2.75 to 15.75Ts, such as 2.75Ts, 3.75Ts, 4.75Ts, 5.75Ts, 6.75Ts, 7.75Ts, 8.75Ts, 9.75Ts, 10.75Ts, 11.75Ts, 12.75Ts, 13.75Ts, 14.75Ts or 15.75Ts, but not limited to the enumerated values, and other unrecited values in the numerical range are also applicable.
The horizontally wound coil is designed into one layer, the risk of upper and lower layering of the traditional two layers can be effectively avoided, different wire diameters and turns can be designed, the high-inductance requirement can be met, the low-inductance requirement can be met, and the turns of the horizontally wound coil are not integers due to the fact that the tail ends of two leads of the coil are not crossed.
Preferably, the pressure for the press forming in step (2) is 25-200MPa, such as 25MPa, 50MPa, 100MPa, 120MPa, 140MPa, 160MPa or 200MPa, but not limited to the values listed, and other values not listed in the numerical range are also applicable, preferably 120-160 MPa.
The pressure of the compression molding is too large or too small, and the obtained cross-shaped magnetic core has the problems of uneven internal structure or low compactness, so that the direct-current impedance of the manufactured inductor is negatively influenced.
Preferably, the temperature for the press forming in step (2) is 170-.
Preferably, the pressing time in step (2) is 1-3min, such as 1min, 1.5min, 2min, 2.5min or 3min, but not limited to the recited values, and other values not recited in the range of values are equally applicable, preferably 1.5-2.5 min.
Preferably, the post-treatment in the step (2) comprises baking, rolling spraying, laser and electroplating treatment which are sequentially carried out.
Preferably, the cross-shaped magnetic core in the step (1) is prepared by the following method:
(a) uniformly mixing the magnetic powder and glue, and sequentially granulating, sieving and drying to obtain a cross-shaped magnetic core precursor;
(b) and (b) sequentially carrying out compression molding and baking on the precursor of the cross-shaped magnetic core obtained in the step (a) to obtain the cross-shaped magnetic core.
Preferably, the magnetic powder material in step (a) comprises nanocrystalline powder and alloy powder in a mass ratio of (0.125-8):1, which may be, for example, 0.125:1, 0.5:1, 0.8:1, 1.25:1, 2:1, 3:1, 4:1, 5:1, 6:1, 7:1 or 8:1, but is not limited to the recited values, and other values not recited in the numerical range are equally applicable, preferably (0.5-2): 1.
The proportion of the nanocrystalline powder and the alloy powder is in a reasonable range, the prepared cross-shaped magnetic core inductor has lower direct current impedance and proper inductance value, the mass ratio is too high or too low, and the characteristics of a finished product are adversely affected.
Preferably, the mass of the glue of step (a) is 1-5 wt% of the mass of the magnetic powder, for example 1 wt%, 2 wt%, 3 wt%, 3.5 wt%, 4 wt% or 5 wt%, but not limited to the recited values, and other values in the range of values not recited are equally applicable, preferably 2-3.5 wt%.
Preferably, the glue of step (a) comprises an epoxy resin and/or a phenolic resin.
Preferably, the nanocrystalline powder comprises fesibbcu and/or FeSiGrBC.
Preferably, the alloy powder comprises ferrosilicon powder and/or ferrosilicon-aluminum powder.
Preferably, the mesh size of the screen used for the screening in step (a) is 50 to 300 mesh, for example 50 mesh, 100 mesh, 150 mesh, 200 mesh, 250 mesh or 300 mesh, but is not limited to the values listed, and other values not listed within the range of values are equally applicable.
Preferably, the powder used for powder filling in the step (2) is the same as the powder obtained after granulation and sieving in the step (a).
Preferably, the drying temperature in step (a) is 50-60 ℃, for example 50 ℃, 52 ℃, 55 ℃, 58 ℃ or 60 ℃, but not limited to the recited values, and other values not recited in the numerical ranges are equally applicable.
Preferably, the drying time in step (a) is 1.5 to 2.5h, for example 1.5h, 1.8h, 2h, 2.2h or 2.5h, but not limited to the recited values, and other values not recited in the range of values are equally applicable.
The pressure for the press molding in step (b) is 20 to 480MPa, and may be, for example, 20MPa, 50MPa, 100MPa, 150MPa, 200MPa, 250MPa, 300MPa, 350MPa, 400MPa, 450MPa or 480MPa, but is not limited to the values listed, and other values not listed in the numerical range are also applicable, and preferably 50 to 150 MPa.
Preferably, the temperature of the press forming in step (b) is 20-25 ℃, for example 20 ℃, 21 ℃, 22 ℃, 23 ℃, 24 ℃ or 25 ℃, but not limited to the recited values, and other values not recited in the range of values are equally applicable.
Preferably, the press forming time in step (b) is 8-12s, for example 8s, 9s, 10s, 11s or 12s, but not limited to the recited values, and other values not recited in the range of values are equally applicable.
Preferably, the temperature of the baking in step (b) is 200-220 ℃, for example, 200 ℃, 205 ℃, 210 ℃, 215 ℃ or 220 ℃, but not limited to the recited values, and other unrecited values within the range of values are equally applicable.
Preferably, the baking of step (b) is repeated 2-3 times.
Preferably, the baking time in step (b) is 7-10min, and the interval between two adjacent times of repeated baking is 4-6 min.
The baking time is 7-10min, such as 7min, 7.5min, 8min, 8.5min, 9min, 9.5min or 10min, but not limited to the recited values, and other values not recited in the range of values are equally applicable, preferably 8-9 min.
The interval between two adjacent times of the repeated baking is 4-6min, such as 4min, 4.5min, 5min, 5.5min or 6min, but not limited to the recited values, and other values not recited in the range of values are also applicable.
As a preferable technical solution of the preparation method provided by the first aspect of the present invention, the preparation method comprises the steps of:
(1) placing the horizontal winding type coil in a cross-shaped magnetic core, and folding and fixing a coil lead outside the cross-shaped magnetic core for at least four times to obtain a cross-shaped magnetic core combined coil;
the turning steps are as follows: two leads of the coil are respectively turned over to the side surface of the cross-shaped magnetic core once through the grooves of the cross-shaped magnetic core, turned over to the bottom surface of the cross-shaped magnetic core for the second time, turned over to the opposite side surface of the cross-shaped magnetic core for the third time and turned over to the surface of the coil body for the fourth time;
(2) filling powder into the cross-shaped magnetic core combined coil obtained in the step (1), performing compression molding for 1-3min at the temperature of 170-190 ℃ under the pressure of 25-200MPa, and performing baking, rolling spraying, laser and electroplating treatment to obtain a cross-shaped magnetic core inductor;
the cross-shaped magnetic core in the step (1) is prepared by adopting the following method:
(a) uniformly mixing the magnetic powder and the glue, granulating, sieving with a 50-300 mesh sieve, and drying at 50-60 ℃ for 1.5-2.5h to obtain a cross-shaped magnetic core precursor;
the magnetic powder comprises nanocrystalline powder and alloy powder in a mass ratio of (0.125-8) to 1; the mass of the glue is 1-5 wt% of that of the magnetic powder;
(b) and (c) performing compression molding on the precursor of the cross-shaped magnetic core obtained in the step (a) at 20-25 ℃ under 20-480MPa for 8-12s, baking at 200-220 ℃ for 7-10min, and repeating baking for 2-3 times to obtain the cross-shaped magnetic core.
In a second aspect, the invention provides a cross-shaped magnetic core inductor, which is prepared by the preparation method in the first aspect.
In a third aspect, the invention provides an application of the cross-shaped magnetic core inductor according to the second aspect, wherein the cross-shaped magnetic core inductor is used in the fields of vehicle electronic equipment, communication equipment or internet of things.
Compared with the prior art, the invention has the following beneficial effects:
according to the cross-shaped magnetic core inductor and the preparation method and application thereof, the coil winding design of at least four turns is adopted, quality risks caused by poor lead upwarp, lead deflection or wire breakage and the like are prevented, the manufactured cross-shaped magnetic core inductor coil is not easy to deform and good in quality by matching with optimized technological parameters of the cross-shaped magnetic core, the direct-current impedance is less than or equal to 7.2m omega, and the cross-shaped magnetic core inductor can be used in the fields of automotive electronic equipment, communication equipment or internet of things.
Drawings
FIG. 1 is a schematic structural view of a cross-shaped magnetic core provided in embodiment 1 of the present invention;
fig. 2 is a schematic view of a coil lead wire being folded once according to embodiment 1 of the present invention;
fig. 3 is a schematic view of a coil lead double fold provided in embodiment 1 of the present invention;
fig. 4 is a schematic diagram of a coil lead folded three times according to embodiment 1 of the present invention;
fig. 5 is a schematic view of four turns of the coil lead according to embodiment 1 of the present invention.
Wherein: 1, leading wires; 2, a groove; 3, side surface; 4, a bottom surface; 5, opposite side faces; and 6, coil body surface.
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 limitations of the present invention.
Example 1
The embodiment provides a cross-shaped magnetic core inductor, and a preparation method of the cross-shaped magnetic core inductor comprises the following steps:
(1) placing the horizontal winding type coil in a cross-shaped magnetic core as shown in fig. 1, and folding and fixing a coil lead wire 1 outside the cross-shaped magnetic core for four times to obtain a cross-shaped magnetic core combined coil;
the turning steps are as follows: two lead wires 1 of the coil are respectively turned over to the side surface 3 of the cross-shaped magnetic core shown in fig. 2 once through the groove 2 of the cross-shaped magnetic core, turned over to the bottom surface 4 of the cross-shaped magnetic core shown in fig. 3 twice, turned over to the opposite side surface 5 of the cross-shaped magnetic core shown in fig. 4 three times, and turned over to the coil body surface 6 shown in fig. 5 four times;
(2) filling powder into the cross-shaped magnetic core combined coil obtained in the step (1), performing compression molding for 2min at 180 ℃ under 140MPa, and performing baking, rolling spraying, laser and electroplating treatment to obtain a cross-shaped magnetic core inductor;
the cross-shaped magnetic core in the step (1) is prepared by adopting the following method:
(a) uniformly mixing FeSiNbBCu nanocrystalline powder, iron silicon powder and epoxy resin glue, granulating, sieving with a 180-mesh sieve, and drying at 55 ℃ for 2h to obtain a cross-shaped magnetic core precursor;
the mass ratio of the FeSiNbBCu nanocrystalline powder to the iron silicon powder is 1.25: 1; the mass of the epoxy resin glue is 2.5 wt% of the total mass of the nanocrystalline powder and the iron silicon powder;
(b) and (b) pressing and molding the precursor of the cross-shaped magnetic core obtained in the step (a) at 23 ℃ under 250MPa for 10s, baking at 210 ℃ for 8.5min, and repeatedly baking for 2 times with the time interval of 5min to obtain the cross-shaped magnetic core.
Example 2
The embodiment provides a cross-shaped magnetic core inductor, and a preparation method of the cross-shaped magnetic core inductor comprises the following steps:
(1) placing the horizontal winding type coil in a cross-shaped magnetic core, and folding and fixing a coil lead 1 outside the cross-shaped magnetic core for four times to obtain a cross-shaped magnetic core combined coil;
the turning steps are as follows: two lead wires 1 of the coil are respectively turned over to the side surface 3 of the cross-shaped magnetic core once through the groove 2 of the cross-shaped magnetic core, turned over to the bottom surface 4 of the cross-shaped magnetic core for the second time, turned over to the opposite side surface 5 of the cross-shaped magnetic core for the third time, and turned over to the coil body surface 6 for the fourth time;
(2) filling powder into the cross-shaped magnetic core combined coil obtained in the step (1), performing compression molding for 1.5min at 175 ℃ under 160MPa, and performing baking, rolling spraying, laser and electroplating treatment to obtain a cross-shaped magnetic core inductor;
the cross-shaped magnetic core in the step (1) is prepared by adopting the following method:
(a) uniformly mixing FeSiNbBCu nanocrystalline powder, iron silicon powder and epoxy resin glue, granulating, sieving with a 100-mesh sieve, and drying at 52 ℃ for 2.2h to obtain a cross-shaped magnetic core precursor;
the mass ratio of the FeSiNbBCu nanocrystalline powder to the iron silicon powder is 0.5: 1; the mass of the epoxy resin glue is 2 wt% of the total mass of the nanocrystalline powder and the iron-silicon powder;
(b) and (b) performing compression molding on the precursor of the cross-shaped magnetic core obtained in the step (a) at 24 ℃ under 100MPa for 9s, baking at 215 ℃ for 8min, and repeating the baking for 2 times, wherein the time interval of the 2 times is 4.5min, so as to obtain the cross-shaped magnetic core.
Example 3
The embodiment provides a cross-shaped magnetic core inductor, and a preparation method of the cross-shaped magnetic core inductor comprises the following steps:
(1) placing the horizontal winding type coil in a cross-shaped magnetic core, and folding and fixing a coil lead 1 outside the cross-shaped magnetic core for four times to obtain a cross-shaped magnetic core combined coil;
the turning steps are as follows: two lead wires 1 of the coil are respectively turned over to the side surface 3 of the cross-shaped magnetic core once through the groove 2 of the cross-shaped magnetic core, turned over to the bottom surface 4 of the cross-shaped magnetic core for the second time, turned over to the opposite side surface 5 of the cross-shaped magnetic core for the third time, and turned over to the coil body surface 6 for the fourth time;
(2) filling powder into the cross-shaped magnetic core combined coil obtained in the step (1), performing compression molding for 2.5min at 185 ℃ under 120MPa, and performing baking, rolling spraying, laser and electroplating treatment to obtain a cross-shaped magnetic core inductor;
the cross-shaped magnetic core in the step (1) is prepared by adopting the following method:
(a) uniformly mixing FeSiNbBCu nanocrystalline powder, iron silicon powder and epoxy resin glue, granulating, sieving with a 250-mesh sieve, and drying at 58 ℃ for 1.8h to obtain a cross-shaped magnetic core precursor;
the mass ratio of the FeSiNbBCu nanocrystalline powder to the iron silicon powder is 2: 1; the mass of the epoxy resin glue is 3.5 wt% of the total mass of the nanocrystalline powder and the iron silicon powder;
(b) and (b) performing compression molding on the precursor of the cross-shaped magnetic core obtained in the step (a) at 21 ℃ under 350MPa for 11s, baking at 205 ℃ for 9min, and repeating the baking for 2 times, wherein the time interval of the 2 times is 5.5min, so as to obtain the cross-shaped magnetic core.
Example 4
The embodiment provides a cross-shaped magnetic core inductor, and a preparation method of the cross-shaped magnetic core inductor comprises the following steps:
(1) placing the horizontal winding type coil in a cross-shaped magnetic core, and folding and fixing a coil lead 1 outside the cross-shaped magnetic core for four times to obtain a cross-shaped magnetic core combined coil;
the turning steps are as follows: two lead wires 1 of the coil are respectively turned over to the side surface 3 of the cross-shaped magnetic core once through the groove 2 of the cross-shaped magnetic core, turned over to the bottom surface 4 of the cross-shaped magnetic core for the second time, turned over to the opposite side surface 5 of the cross-shaped magnetic core for the third time, and turned over to the coil body surface 6 for the fourth time;
(2) filling powder into the cross-shaped magnetic core combined coil obtained in the step (1), pressing and forming for 1min at 170 ℃ under 200MPa, and then baking, rolling and spraying, laser and electroplating to obtain a cross-shaped magnetic core inductor;
the cross-shaped magnetic core in the step (1) is prepared by adopting the following method:
(a) uniformly mixing FeSiNbBCu nanocrystalline powder, iron silicon powder and epoxy resin glue, granulating, sieving with a 50-mesh sieve, and drying at 50 ℃ for 2.5 hours to obtain a cross-shaped magnetic core precursor;
the mass ratio of the FeSiNbBCu nanocrystalline powder to the iron silicon powder is 0.125: 1; the mass of the epoxy resin glue is 1 wt% of the total mass of the nanocrystalline powder and the iron-silicon powder;
(b) and (b) performing compression molding on the precursor of the cross-shaped magnetic core obtained in the step (a) at 25 ℃ under 20MPa for 8s, baking at 220 ℃ for 7min, and repeating the baking for 2 times, wherein the time interval of the 2 times is 4min, so as to obtain the cross-shaped magnetic core.
Example 5
The embodiment provides a cross-shaped magnetic core inductor, and a preparation method of the cross-shaped magnetic core inductor comprises the following steps:
(1) the horizontal winding type coil is placed in the cross-shaped magnetic core, and a coil lead 1 is turned over and fixed outside the cross-shaped magnetic core for four times to obtain a cross-shaped magnetic core combined coil;
the turning steps are as follows: two lead wires 1 of the coil are respectively turned over to the side surface 3 of the cross-shaped magnetic core once through the groove 2 of the cross-shaped magnetic core, turned over to the bottom surface 4 of the cross-shaped magnetic core for the second time, turned over to the opposite side surface 5 of the cross-shaped magnetic core for the third time, and turned over to the coil body surface 6 for the fourth time;
(2) filling powder into the cross-shaped magnetic core combined coil obtained in the step (1), performing compression molding for 3min at 190 ℃ under 25MPa, and performing baking, rolling spraying, laser and electroplating treatment to obtain a cross-shaped magnetic core inductor;
the cross-shaped magnetic core in the step (1) is prepared by adopting the following method:
(a) uniformly mixing FeSiNbBCu nanocrystalline powder, iron silicon powder and epoxy resin glue, granulating, sieving with a 300-mesh sieve, and drying at 60 ℃ for 1.5h to obtain a cross-shaped magnetic core precursor;
the mass ratio of the FeSiNbBCu nanocrystalline powder to the iron silicon powder is 8: 1; the mass of the epoxy resin glue is 5 wt% of the total mass of the nanocrystalline powder and the iron silicon powder;
(b) and (b) performing compression molding on the precursor of the cross-shaped magnetic core obtained in the step (a) at the temperature of 20 ℃ under 480MPa for 12s, baking at the temperature of 200 ℃ for 10min, and repeating the baking for 2 times, wherein the time interval of 2 times is 6min, so as to obtain the cross-shaped magnetic core.
Example 6
This example provides a cross-shaped core inductor, which is prepared by a method different from that of example 1 in that the pressure of the press molding in step (2) is 10MPa, and the rest is the same as that of example 1.
Example 7
This example provides a cross-shaped core inductor, which is prepared by a method different from that of example 1 in that the pressure of the press molding in step (2) is 250MPa, and the rest is the same as that of example 1.
Example 8
The embodiment provides a cross-shaped magnetic core inductor, and the preparation method of the cross-shaped magnetic core inductor is different from that of embodiment 1 in that the mass ratio of the fesibbcu nanocrystalline powder to the iron silicon powder in step (a) is 0.1:1, and the rest is the same as that of embodiment 1.
Example 9
The embodiment provides a cross-shaped magnetic core inductor, and the preparation method of the cross-shaped magnetic core inductor is different from that of embodiment 1 in that the mass ratio of the fesibbcu nanocrystalline powder to the iron silicon powder in step (a) is 9:1, and the rest is the same as that of embodiment 1.
Comparative example 1
The present comparative example provides a T-shaped magnetic core inductor, and the manufacturing method of the T-shaped magnetic core inductor is different from that of example 1 in that step (1) is: the horizontal winding type coil is placed in a T-shaped magnetic core, two leads of the coil are respectively turned over to the side face of the T-shaped magnetic core for the first time through a groove of the T-shaped magnetic core, and are turned over to the bottom face of the T-shaped magnetic core for the second time, and the T-shaped magnetic core combined coil is obtained; the cross-shaped core was replaced with a T-shaped core, and the rest was the same as in example 1.
The end product characteristics of the cross-core inductors provided in examples 1-9 and comparative example 1 are shown in table 1.
TABLE 1
As can be seen from table 1, as can be seen from comparison between example 1 and examples 2 to 9, the dc impedance of the inductor is greatly affected by the raw material ratio and the pressure of the compression molding, and the cross-shaped magnetic core inductor has lower dc impedance and higher saturation current due to the selection of the reasonable raw material ratio and the molding pressure; as can be seen from comparison between example 1 and comparative example 1, when the coil lead wire is fixed outside the magnetic core by only twice folding, the coil may be deformed or shifted, and the dc impedance of the inductor is high and the saturation current is low.
In summary, according to the cross-shaped magnetic core inductor and the preparation method thereof provided by the invention, the coil winding design of at least four turns is adopted, quality risks caused by poor lead upwarp, lead skew or wire breakage and the like are prevented, and the prepared cross-shaped magnetic core inductor coil is not easy to deform and has good quality, the direct current impedance is less than or equal to 7.2m Ω by matching with the optimized process parameters of the cross-shaped magnetic core, and the cross-shaped magnetic core inductor can be used in the fields of automotive electronic equipment, communication equipment or internet of things.
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. A preparation method of a cross-shaped magnetic core inductor is characterized by comprising the following steps:
(1) placing the horizontal winding type coil in a cross-shaped magnetic core, and folding and fixing a coil lead outside the cross-shaped magnetic core for at least four times to obtain a cross-shaped magnetic core combined coil;
(2) and (2) performing powder filling, compression molding and post-treatment on the cross-shaped magnetic core combined coil obtained in the step (1) to obtain the cross-shaped magnetic core inductor.
2. The method for preparing according to claim 1, wherein the folding step of step (1) is: two leads of the coil are respectively turned over to the side surface of the cross-shaped magnetic core once through the grooves of the cross-shaped magnetic core, turned over to the bottom surface of the cross-shaped magnetic core for the second time, turned over to the opposite side surface of the cross-shaped magnetic core for the third time and turned over to the surface of the coil body for the fourth time;
preferably, the horizontally wound coil in the step (1) comprises a circular bar type or a track type.
3. The production method according to claim 1 or 2, wherein the pressure for the press molding in the step (2) is 25 to 200MPa, preferably 120 to 160 MPa;
preferably, the temperature for the compression molding in the step (2) is 170-;
preferably, the time for the compression molding in the step (2) is 1-3min, preferably 1.5-2.5 min;
preferably, the post-treatment in the step (2) comprises baking, rolling spraying, laser and electroplating treatment which are sequentially carried out.
4. The method according to any one of claims 1 to 3, wherein the cross-shaped magnetic core in the step (1) is prepared by:
(a) uniformly mixing the magnetic powder and glue, and sequentially granulating, sieving and drying to obtain a cross-shaped magnetic core precursor;
(b) and (b) sequentially carrying out compression molding and baking on the precursor of the cross-shaped magnetic core obtained in the step (a) to obtain the cross-shaped magnetic core.
5. The method according to claim 4, wherein the magnetic powder of step (a) comprises nanocrystalline powder and alloy powder in a mass ratio of (0.125-8):1, preferably (0.5-2): 1;
preferably, the mass of the glue in the step (a) is 1-5 wt% of the mass of the magnetic powder, and preferably 2-3.5 wt%;
preferably, the glue of step (a) comprises an epoxy resin and/or a phenolic resin;
preferably, the nanocrystalline powder comprises FeSiNbBCu and/or FeSiGrBC;
preferably, the alloy powder comprises ferrosilicon powder and/or ferrosilicon-aluminum powder.
6. The method according to claim 4 or 5, wherein the mesh size of the screen used for the screening in the step (a) is 50 to 300 mesh;
preferably, the temperature of the drying of step (a) is 50-60 ℃;
preferably, the drying time in step (a) is 1.5-2.5 h.
7. The production method according to any one of claims 4 to 6, wherein the pressure for the press-molding in step (b) is 20 to 480MPa, preferably 50 to 150 MPa;
preferably, the temperature of the press forming in the step (b) is 20-25 ℃;
preferably, the time for the press forming of step (b) is 8-12 s;
preferably, the temperature of the baking in the step (b) is 200-220 ℃;
preferably, the baking of step (b) is repeated 2-3 times;
preferably, the baking time in step (b) is 7-10min, preferably 8-9min, and the interval between two adjacent times of repeated baking is 4-6 min.
8. The production method according to any one of claims 1 to 7, characterized by comprising the steps of:
(1) placing the horizontal winding type coil in a cross-shaped magnetic core, and folding and fixing a coil lead outside the cross-shaped magnetic core for at least four times to obtain a cross-shaped magnetic core combined coil;
the turning steps are as follows: two leads of the coil are respectively turned over to the side surface of the cross-shaped magnetic core once through the grooves of the cross-shaped magnetic core, turned over to the bottom surface of the cross-shaped magnetic core for the second time, turned over to the opposite side surface of the cross-shaped magnetic core for the third time and turned over to the surface of the coil body for the fourth time;
(2) filling powder into the cross-shaped magnetic core combined coil obtained in the step (1), performing compression molding for 1-3min at the temperature of 170-190 ℃ under the pressure of 25-200MPa, and performing baking, rolling spraying, laser and electroplating treatment to obtain a cross-shaped magnetic core inductor;
the cross-shaped magnetic core in the step (1) is prepared by adopting the following method:
(a) uniformly mixing the magnetic powder and the glue, granulating, sieving with a 50-300 mesh sieve, and drying at 50-60 ℃ for 1.5-2.5h to obtain a cross-shaped magnetic core precursor;
the magnetic powder comprises nanocrystalline powder and alloy powder in a mass ratio of (0.125-8) to 1; the mass of the glue is 1-5 wt% of that of the magnetic powder;
(b) and (c) performing compression molding on the precursor of the cross-shaped magnetic core obtained in the step (a) at 20-25 ℃ under 20-480MPa for 8-12s, baking at 200-220 ℃ for 7-10min, and repeating baking for 2-3 times to obtain the cross-shaped magnetic core.
9. A cross-core inductor, characterized in that it is obtained by the manufacturing method according to any one of claims 1 to 8.
10. Use of a cross-core inductor according to claim 9, wherein the cross-core inductor is used in the field of automotive electronics, communication equipment or internet of things.
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| CN108389679A (en) * | 2018-03-20 | 2018-08-10 | 深圳顺络电子股份有限公司 | A kind of inductance element and manufacturing method |
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| CN108389679A (en) * | 2018-03-20 | 2018-08-10 | 深圳顺络电子股份有限公司 | A kind of inductance element and manufacturing method |
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