CN114974872A - Molded inductor and manufacturing method thereof - Google Patents

Molded inductor and manufacturing method thereof Download PDF

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CN114974872A
CN114974872A CN202210702661.3A CN202210702661A CN114974872A CN 114974872 A CN114974872 A CN 114974872A CN 202210702661 A CN202210702661 A CN 202210702661A CN 114974872 A CN114974872 A CN 114974872A
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powder
soft magnetic
composite powder
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thermosetting resin
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苗弘
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Suzhou Jinlin Electronic Technology Co ltd
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
    • H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/20—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder
    • H01F1/22—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together
    • H01F1/24—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
    • H01F1/26—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated by macromolecular organic substances
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

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  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
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  • Spectroscopy & Molecular Physics (AREA)
  • Chemical & Material Sciences (AREA)
  • Dispersion Chemistry (AREA)
  • Soft Magnetic Materials (AREA)

Abstract

The invention relates to a die-pressed inductor and a manufacturing method thereof. A manufacturing method of a molded inductor comprises the following steps: providing first composite powder, wherein the first composite powder comprises first metal soft magnetic powder and first thermosetting resin, and the curing rate of the first thermosetting resin is more than or equal to 90%; uniformly mixing the first composite powder, the second metal soft magnetic powder and an insulating coating material, and then granulating, wherein the insulating coating material comprises second thermosetting resin to obtain second composite powder; and placing the second composite powder and the winding in a mold together, and then sequentially carrying out normal-temperature compression molding and curing treatment to obtain the compression molding inductor. The manufacturing method of the molded inductor is simple in process, the first thermosetting resin is good in chemical and physical stability, and can be dispersed in the whole material system, stress generated in the manufacturing process can be locally homogenized, cracks can be reduced, and therefore the performance of the molded inductor is improved.

Description

Molded inductor and manufacturing method thereof
Technical Field
The invention relates to the technical field of inductors, in particular to a die pressing inductor and a manufacturing method thereof.
Background
With the gradual development and mutual fusion of network technology, computer technology, communication technology and artificial intelligence technology, people begin to enter the fourth industrial revolution era; the era is mainly characterized in that close connection and information interaction are established between people and people, between objects and between people and objects, so that new life styles such as smart phones, smart homes, smart cities and the like appear, and along with the gradual breakthrough of related bottleneck technologies, intelligent transportation (including internet automobiles, intelligent parking and the like), AI robots, even the early and late AI robots, the society, agriculture and industry, and related internet of things can appear. The complex connections depend on the information transmission, communication and processing of a hardware system, can be an information transmitting end, an information receiving end and a cloud end, and the key of the intelligent hardware is a chip and related components.
The inductor device is widely used in various intelligent hardware systems, such as smart phones, smart televisions, smart home appliances, tablet computers, notebook computers, various communication terminals and servers, as one of the main passive components around the chip, and the main functions of the inductor device include conversion, storage and filtering of electromagnetic signals and energy. The molded inductor is one of the inductor devices and is widely applied. However, cracks are easily generated in the process of molding the inductor by normal-temperature pressing (commonly called cold pressing), and the use of the molded inductor is influenced.
Disclosure of Invention
In view of the above, it is necessary to provide a molded inductor and a method for manufacturing the same, which can reduce cracks, in order to solve the problem of how to reduce cracks in the molded inductor.
A manufacturing method of a molded inductor comprises the following steps:
providing first composite powder, wherein the first composite powder comprises first metal soft magnetic powder and first thermosetting resin, and the curing rate of the first thermosetting resin is more than or equal to 90%;
uniformly mixing the first composite powder, the second metal soft magnetic powder and an insulating coating material, and then granulating, wherein the insulating coating material comprises second thermosetting resin to obtain second composite powder; and
and placing the second composite powder and the winding into a mold together, and then sequentially carrying out normal-temperature compression molding and curing treatment to obtain the compression molding inductor.
The manufacturing method of the molded inductor is simple in process, the first thermosetting resin is good in chemical and physical stability, and can be dispersed in the whole material system, stress generated in the manufacturing process can be locally homogenized, cracks can be reduced, and therefore the performance of the molded inductor is improved.
In one possible implementation, the first composite powder is obtained by the following steps:
uniformly mixing a plurality of wastes comprising first metal soft magnetic powder and first thermosetting resin, and then curing until the curing rate of the first thermosetting resin is more than or equal to 90% to obtain a cured mixture; and
and crushing the solidified mixture to obtain first composite powder.
In a possible implementation, after the solidified mixture is crushed, the following steps may be further included:
and (3) carrying out surface treatment on the crushed mixture by using a coupling agent, wherein the weight ratio of the coupling agent to the crushed mixture is (0.05-0.5): 100.
In one possible implementation manner, the mass ratio of the second metal soft magnetic powder to the first composite powder is 95:5 to 50: 50.
In one possible implementation, a ratio of the average particle size D50 of the first composite powder to the average particle size D50 of the second metallic soft magnetic powder is 1.05:1 to 1.50: 1.
In a feasible implementation manner, in the operation of uniformly mixing the first composite powder, the second metal soft magnetic powder and the insulating coating material and then performing granulation treatment, the glue content is 0.5% -4.0%.
In one possible implementation manner, the operation of placing the second composite powder and the winding together in a mold for normal-temperature compression molding is as follows: and placing the second composite powder and the winding in a mold together, adjusting to a set pressure, and maintaining the pressure for 0.1-5 s.
In one possible implementation, the first metal soft magnetic powder is the same kind as the second metal soft magnetic powder.
In one possible implementation, the first metallic soft magnetic powder and the second metallic soft magnetic powder are independently selected from carbonyl iron powder, andraw iron powder, atomized Fe (100-x-y) Si x Cr y At least one of powder, atomized iron-based amorphous soft magnetic powder, atomized iron-based amorphous nanocrystalline powder, atomized iron-silicon-aluminum alloy powder and atomized iron-nickel alloy powder; wherein x is 3.5 to 6.5, and y is 0.0 to 6.5.
In one possible implementation, the first thermosetting resin and the second thermosetting resin are independently selected from at least one of epoxy resin, phenolic resin, cyanate ester, bismaleimide and silicone resin.
The molded inductor according to an embodiment is manufactured by any one of the above manufacturing methods of a molded inductor.
The molded inductor is manufactured by any one of the manufacturing methods of the molded inductor, the first thermosetting resin has good chemical and physical stability in the manufacturing process, is dispersed in the whole material system, and can locally homogenize stress generated in the manufacturing process, so that cracks can be reduced, and the performance of the molded inductor is improved.
Drawings
Fig. 1 is a flowchart of a method for manufacturing a molded inductor according to an embodiment of the invention.
Detailed Description
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in detail below. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.
Referring to fig. 1, a method for manufacturing a molded inductor according to an embodiment of the present invention includes the following steps:
s10, providing first composite powder, wherein the first composite powder comprises first metal soft magnetic powder and first thermosetting resin, and the curing rate of the first thermosetting resin is larger than or equal to 90%.
In one possible implementation, the first composite powder is obtained by the following steps:
uniformly mixing a plurality of wastes comprising first metal soft magnetic powder and first thermosetting resin, and then curing until the curing rate of the first thermosetting resin is more than or equal to 90% to obtain a cured mixture; and
and crushing the solidified mixture to obtain first composite powder.
The purpose of the solidification treatment is to make the granulated powder brittle, which is beneficial to subsequent crushing. The solidified mixture may be crushed by a crusher such as a jet mill, a universal crusher, a ball mill, etc. to obtain fine powder, i.e., the first composite powder.
In the above implementation, the scrap including the first metallic soft magnetic powder and the first thermosetting resin is, for example, a tailing generated from a production process or a defective product generated due to a production quality problem. The invention utilizes the waste material as one of the raw materials to manufacture the molded inductor, can realize the full recycling of the waste material, protects the environment and reduces the cost.
In one possible implementation, after the solidified mixture is crushed, the following steps may be further included:
and (3) carrying out surface treatment on the crushed mixture by using a coupling agent, wherein the weight ratio of the coupling agent to the crushed mixture is (0.05-0.5): 100.
In the above implementation, the coupling agent may be, for example, a KH550 silane coupling agent or other feasible coupling agents. After the surface treatment of the coupling agent, the surface bonding force between the crushed mixture surface and the subsequently used resin (i.e., the second thermosetting resin) can be improved.
In the first composite powder of step S10, the curing rate of the first thermosetting resin is high, and in the subsequent processing, the part of the first thermosetting resin is not changed to a large extent, for example, expansion with heat and contraction with cold or shrinkage caused by resin curing does not occur, so that the chemical and physical stability is good.
And S20, uniformly mixing the first composite powder, the second metal soft magnetic powder and the insulating coating material obtained in the step S10, and then granulating, wherein the insulating coating material comprises second thermosetting resin, so that second composite powder is obtained.
The insulating coating material can include other auxiliary agents such as a curing agent, a coupling agent, a toughening agent and a leveling agent besides the second thermosetting resin, and the types and the contents of the other auxiliary agents can be set according to actual requirements.
In one feasible implementation manner, in the operation of uniformly mixing the first composite powder, the second metal soft magnetic powder and the insulating coating material and then performing granulation treatment, the glue content is 0.5% -4.0%. Wherein the glue content refers to a mass ratio of the resin to other powder materials including the first composite powder and the second metallic soft magnetic powder.
In one possible implementation manner, the mass ratio of the second metal soft magnetic powder to the first composite powder is 95:5 to 50: 50. Tests prove that the mass ratio can obviously improve the crack phenomenon of the molded inductor.
In one possible implementation, the ratio of the average particle size D50 of the first composite powder to the average particle size D50 of the second metallic soft magnetic powder is 1.05:1 to 1.50: 1. By adopting the ratio, the cracks of the die pressing inductor can be reduced, the production efficiency can be ensured, and the surface insulating layer (comprising the resin layer) of the first metal soft magnetic powder can be prevented from being damaged.
In one of the possible implementations, the first metallic soft magnetic powder is the same kind as the second metallic soft magnetic powder. This makes the magnetic properties of the first metal soft magnetic powder and the second metal soft magnetic powder uniform.
In one possible implementation manner, the first metal soft magnetic powder and the second metal soft magnetic powder are independently selected from carbonyl iron powder, reduced iron powder, atomized iron powder and atomized Fe (100-x-y) Si x Cr y At least one of powder, atomized iron-based amorphous soft magnetic powder, atomized iron-based amorphous nanocrystalline powder, atomized iron-silicon-aluminum alloy powder and atomized iron-nickel alloy powder; wherein x is 3.5 to 6.5, and y is 0.0 to 6.5. The first metal soft magnetic powder and the second metal soft magnetic powder of the present invention can be obtained by further modifying the surface of the metal soft magnetic powder of the above kind.
In one possible implementation, the first thermosetting resin and the second thermosetting resin are independently selected from at least one of epoxy resin, phenolic resin, cyanate ester, bismaleimide and silicone resin.
In the method for manufacturing a molded inductor according to the present invention, the first thermosetting resin and the second thermosetting resin may be the same or different.
And S30, placing the second composite powder obtained in the step S20 and the winding into a mold together, and then sequentially carrying out normal-temperature compression molding and curing treatment to obtain the compression molded inductor.
In one possible implementation manner, the operation of placing the second composite powder and the winding together in a mold for normal-temperature compression molding is as follows: and placing the second composite powder and the winding in a mold together, adjusting to a set pressure, and maintaining the pressure for 0.1-5 s. And (4) demolding after the pressure maintaining treatment is finished.
Wherein the compression molding temperature is normal temperature.
Among them, the curing treatment may be performed by a curing treatment method commonly used in the art.
The manufacturing method of the molded inductor is simple in process, the first thermosetting resin is good in chemical and physical stability, and can be dispersed in the whole material system, stress generated in the manufacturing process can be locally homogenized, cracks can be reduced, and therefore the performance of the molded inductor is improved.
By adopting the manufacturing method, the waste materials can be fully utilized, and the performance of the obtained product is consistent with the characteristics of the product manufactured by adopting the new materials.
The molded inductor according to an embodiment is manufactured by any one of the manufacturing methods of the molded inductor.
The molded inductor is manufactured by any one of the manufacturing methods of the molded inductor, the first thermosetting resin has good chemical and physical stability in the manufacturing process, is dispersed in the whole material system, and can locally homogenize stress generated in the manufacturing process, so that cracks can be reduced, and the performance of the molded inductor is improved.
While the technical solutions of the present application are illustrated in order to make the technical solutions of the present application more specific, clear and easy to understand by referring to the above implementation contents, it should be noted that the contents to be protected by the present application are not limited to the following embodiments 1 to 13.
Examples 1 to 6
The manufacturing methods of the molded inductors of examples 1 to 6 are different only in the particle size of the first composite powder, and the specific steps are as follows:
FeCr with D50 of 10 μm 4.5 Si 3.5 The airflow crushing granulation powder of the scrap carbonyl iron and an epoxy resin-based thermosetting resin system (hereinafter referred to as a resin system) in a certain proportion are taken as raw materials to form a composite material of the die pressing inductor, and the FeCr 4.5 Si 3.5 The weight ratio of the metal soft magnetic powder, the airflow crushing powder and the resin system is 100: 3.0;
examples 1 to 6, the scrap powder used was carbonyl iron powder granulated powder (the grain size of the granulated powder was-60 to +300 mesh, the average grain size D50 was 150 μm, and the average grain size D50 of carbonyl iron powder raw powder was 5 μm), which was completely solidified by a baking system at 160 ℃ for 11 hours, and after the solidification, the powder was crushed by air flow; then, performing surface treatment on the crushed mixture by using a KH550 silane coupling agent, wherein the weight ratio of the KH550 silane coupling agent to the crushed mixture is 0.1:100, and obtaining first composite powder;
FeCr 4.5 Si 3.5 the raw powder is phosphatized by using 0.2 weight percent of phosphoric acid, and acetone with 5 weight percent of metal powder is added as a diluent during the phosphatization;
the first composite powder and the passivated FeCr 4.5 Si 3.5 Mixing the powder with a resin system solution for granulation treatment, wherein the resin system solution is a mixture of resin accounting for 3% of the weight of all metal powder and acetone accounting for 10% of the weight of the metal powder; naturally drying the granulated powder, and then drying at the temperature of 80 ℃ for 60 minutes to completely volatilize the acetone; the resin system comprises bisphenol A epoxy resin E44 and alicyclic amine curing agent, wherein the epoxy equivalent of the bisphenol A epoxy resin E44 is 220-240, and the weight ratio of the bisphenol A epoxy resin E44 to the alicyclic amine curing agent is 4: 1.
Examples 1 to 6 in which the first composite powder was added in a FeCr ratio 4.5 Si 3.5 The particle sizes of the first composite powders of examples 1 to 6 were 7.0. mu.m, 8.0. mu.m, 10.5. mu.m, 12.2. mu.m, 15.0. mu.m, and 20.2. mu.m, in this order, based on 15% by weight of the powder.
Finally, preparing the die pressing inductor by normal temperature pressing, wherein the pressure is 600MPa, the pressure is maintained for 2 seconds, the external dimension of the inductor is 10mm110mm14.0mm, and the standard inductance value is 100 uH; and baking the inductor after mould pressing to completely cure the resin, wherein the curing temperature is 120 ℃ for 130 minutes +170 ℃ for 130 minutes, the curing rate of the resin is 90%, the number of the inductors tested in each time is 100, and whether cracks exist in the appearance of the inductors is observed by using a microscope, and the results are shown in table 1.
Table 1 experimental results of the molded inductors of examples 1 to 6
Examples Example 1 Example 2 Example 3 Example 4 Example 5 Example 6
Breaking force (mum) 7.0 8.0 10.5 12.2 15.0 20.2
Appearance crack (%) 2 1 0 0 0 5
As can be seen from the results of Table 1, the improvement in appearance is not remarkable when the crushed particle size is too small, because it is difficult to uniformly disperse the powder having a small particle size in FeCr 4.5 Si 3.5 The improvement effect is also general due to insufficient number of dispersed points among the raw powders when the particle size is large and limited improvement of stress concentration caused by the large particle size, and the optimum crushing particle size is 10.5 μm to 15.0 μm.
Example 7 to example 13
The manufacturing methods of the molded inductors of examples 7 to 13 are different only in the addition ratio of the first composite powder, and specifically include the following steps:
examples 7 to 13 use FeCr with D50 of 10 μm 4.5 Si 3.5 Certain proportion of scrapped FeCr 4.5 Si 3.5 The granulated powder in the airflow crushing state and an epoxy resin-based thermosetting resin system (hereinafter referred to as a resin system) are used as raw materials to form the composite material of the molding inductor, and the added FeCr 4.5 Si 3.5 Metallic soft magnetic powder plus FeCr 4.5 Si 3.5 The weight ratio of the airflow crushed powder to the resin system is 100: 3.0;
examples 7 to 13 in which the scrap powder used is FeCr 4.5 Si 3.5 Granulating powder (the granularity of the granulating powder is-60 to +300 meshes, the average granularity D50 is 160 mu m, the average granularity D50 of carbonyl iron powder raw powder is 10 mu m), completely solidifying the granulating powder by adopting a baking system of 160 ℃ for 11 hours, carrying out airflow crushing after solidification, and the average granularity D50 of the granulating powder after airflow crushing is 12 mu m; then, performing surface treatment on the crushed mixture by using a KH550 silane coupling agent, wherein the weight ratio of the KH550 silane coupling agent to the crushed mixture is 0.1:100, and obtaining first composite powder;
FeCr 4.5 Si 3.5 the raw powder is phosphatized by using 0.2 weight percent of phosphoric acid, and acetone with 5 weight percent of metal powder is added as a diluent during the phosphatization;
the first composite powder and the passivated FeCr 4.5 Si 3.5 Mixing the powder with a resin system solution for granulation, wherein the resin system solution is a mixture of 3% of resin and 10% of acetone in weight of all metal powder; naturally drying the granulated powder, and then drying at the temperature of 80 ℃ for 60 minutes to completely volatilize the acetone; the resin system comprises bisphenol A epoxy resin E44 and an alicyclic amine curing agent, wherein the epoxy equivalent of the bisphenol A epoxy resin E44 is 220-240, and the weight ratio of the bisphenol A epoxy resin E44 to the alicyclic amine curing agent is 4: 1.
Examples 7 to 13 were carried out in the order of the first composite powder addition ratio of FeCr 4.5 Si 3.5 2%, 5%, 10%, 20%, 3% of the powder weight0％、40％、50％。
Finally, preparing the die pressing inductor by normal temperature pressing, wherein the pressure is 600MPa, the pressure is maintained for 2 seconds, the external dimension of the inductor is 10mm110mm14.0mm, and the standard inductance value is 100 uH; after the mold pressing, the inductor was baked to completely cure the resin, the curing system was 120 ℃ for 130 minutes +170 ℃ for 160 minutes, the curing rate of the resin was 98%, the number of inductor tests was 100, and the appearance was observed by a microscope to see whether or not there was a crack, the results of which are shown in table 2.
Table 2 experimental results of the molded inductors of examples 7 to 13
Figure BDA0003704936310000101
As can be seen from the results of Table 2, when the addition amount is less than 5%, the improvement in the appearance of the molded inductor is not significant; when the addition amount is more than 5%, the appearance of the molded inductor is improved obviously.
Comparative example 1
This comparative example is a comparative example to example 7, providing a molded inductor and method of making the same, differing from the method of making example 7 only in that: and crushing the granular powder in a gas flow state without adding the scrapped carbonyl iron.
In comparative example 1, the same inductance test method as in example 7 was used, and the molded inductor obtained in example 7 was observed with a microscope to see whether or not cracks were present in the appearance, and the appearance crack ratio was 8%.
Comparing examples 1 to 13 with comparative example 1, it can be seen that the mold-pressed inductors of examples 1 to 13 according to the present invention have a good crack-improving effect, indicating that the mold-pressed inductor manufacturing method according to the present invention can reduce cracks in the mold-pressed inductor.
And (3) performance testing:
1. the inductance values of the molded inductors of examples 1 to 13 and comparative example 1 were measured by the following methods: the device model is Agilent 4284A, the test parameters are 100kHz @1V, the test parameters are set in the test process (1), (2) two probes of an instrument are respectively contacted with two electrodes of an inductor, and (3) the test result of the instrument is read on a display screen, and the result is shown in table 3.
2. The crush strengths of the molded inductors of examples 1 to 13 and comparative example 1 were measured by the following methods: the device model sw-200 (representing that the maximum test pressure is 200kg) has no test parameters, in the test process, a plane with the minimum inductance is contacted with an instrument platform and is ensured to be positioned under a pressure head, (2) the pressure head starts to descend with the descending speed of 3 mm/s, (3) the pressure head is contacted with a product plane and is pressurized until a product collapses, and the pressure value at the moment is recorded, (4) data processing is carried out, the pressure value is obtained by dividing the area of the contact surface of the inductance and the instrument by the pressure value, the unit is MPa, and the result is shown in a table 3.
Table 3 test data for the properties of the molded inductors of examples 1 to 13
Figure BDA0003704936310000111
Figure BDA0003704936310000121
Remarking: in Table 3 "/" indicates that the item is none.
As can be seen from table 3, the inductance and the crush strength of the molded inductors of examples 1 to 13 of the present invention were not much changed from those of comparative example 1, indicating that the performance of the product obtained by the method of manufacturing the molded inductor of the present invention was consistent with that of the product manufactured using the new material (i.e., comparative example 1).
The technical features of the embodiments described above may be arbitrarily combined, and for the sake of brevity, all possible combinations of the technical features in the embodiments described above are not described, but should be considered as being within the scope of the present specification as long as there is no contradiction between the combinations of the technical features.
The above-mentioned embodiments only express several embodiments of the present invention, and the description thereof is more specific and detailed, but not construed as limiting the scope of the invention. It should be noted that, for a person skilled in the art, several variations and modifications can be made without departing from the inventive concept, which falls within the scope of the present invention. Therefore, the protection scope of the present patent shall be subject to the appended claims.

Claims (11)

1. A manufacturing method of a molded inductor is characterized by comprising the following steps:
providing first composite powder, wherein the first composite powder comprises first metal soft magnetic powder and first thermosetting resin, and the curing rate of the first thermosetting resin is more than or equal to 90%;
uniformly mixing the first composite powder, the second metal soft magnetic powder and an insulating coating material, and then granulating, wherein the insulating coating material comprises second thermosetting resin to obtain second composite powder; and
and placing the second composite powder and the winding into a mold together, and then sequentially carrying out normal-temperature compression molding and curing treatment to obtain the compression molding inductor.
2. The method of making a molded inductor according to claim 1 wherein said first composite powder is obtained by the steps of:
uniformly mixing a plurality of wastes comprising first metal soft magnetic powder and first thermosetting resin, and then curing until the curing rate of the first thermosetting resin is more than or equal to 90% to obtain a cured mixture; and
and crushing the solidified mixture to obtain first composite powder.
3. The method of claim 2, further comprising the following steps after the step of crushing the solidified mixture:
and (3) carrying out surface treatment on the crushed mixture by using a coupling agent, wherein the weight ratio of the coupling agent to the crushed mixture is (0.05-0.5): 100.
4. The method for manufacturing the molded inductor according to claim 1, wherein the mass ratio of the second metal soft magnetic powder to the first composite powder is 95:5 to 50: 50.
5. The method of manufacturing a molded inductor according to claim 1, wherein a ratio of an average particle size D50 of the first composite powder to an average particle size D50 of the second metal soft magnetic powder is 1.05:1 to 1.50: 1.
6. The method for manufacturing a molded inductor according to claim 1, wherein the granulation is performed after the first composite powder, the second metal soft magnetic powder and the insulating coating material are uniformly mixed, and the glue content is 0.5-4.0%.
7. The method for manufacturing a molded inductor according to claim 1, wherein the operations of placing the second composite powder and the winding together in a mold for molding at room temperature are as follows: and placing the second composite powder and the winding in a mold together, adjusting to a set pressure, and maintaining the pressure for 0.1-5 s.
8. The method of manufacturing a molded inductor according to claim 1, wherein said first metal soft magnetic powder is the same kind as said second metal soft magnetic powder.
9. The method for manufacturing a molded inductor according to claim 1 or 8, wherein the first metal soft magnetic powder and the second metal soft magnetic powder are independently selected from carbonyl iron powder, reduced iron powder, atomized iron powder, and atomized Fe (100-x-y) Si x Cr y At least one of powder, atomized iron-based amorphous soft magnetic powder, atomized iron-based amorphous nanocrystalline powder, atomized iron-silicon-aluminum alloy powder and atomized iron-nickel alloy powder; wherein x is 3.5 to 6.5, and y is 0.0 to 6.5.
10. The method of claim 1, wherein the first thermosetting resin and the second thermosetting resin are independently selected from at least one of epoxy resin, phenolic resin, cyanate ester, bismaleimide and silicone resin.
11. A molded inductor, characterized in that it is manufactured by the method of any one of claims 1 to 10.
CN202210702661.3A 2022-06-21 2022-06-21 Molded inductor and manufacturing method thereof Pending CN114974872A (en)

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