CN115565767A - Self-heating curing integrated inductor and production process thereof - Google Patents

Self-heating curing integrated inductor and production process thereof Download PDF

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CN115565767A
CN115565767A CN202211184794.2A CN202211184794A CN115565767A CN 115565767 A CN115565767 A CN 115565767A CN 202211184794 A CN202211184794 A CN 202211184794A CN 115565767 A CN115565767 A CN 115565767A
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inductor
self
inductance
electrode pins
heating
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侯江涛
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Suzhou Bangding New Material Co ltd
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Suzhou Bangding New Material Co ltd
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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/30Fastening or clamping coils, windings, or parts thereof together; Fastening or mounting coils or windings on core, casing, or other support
    • H01F27/306Fastening or mounting coils or windings on core, casing or other support
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/24Magnetic cores
    • H01F27/255Magnetic cores made from particles
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/29Terminals; Tapping arrangements for signal inductances
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/34Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/34Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
    • H01F27/346Preventing or reducing leakage fields
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus 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
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus 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
    • H01F41/02Apparatus 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
    • H01F41/0206Manufacturing of magnetic cores by mechanical means
    • H01F41/0246Manufacturing of magnetic circuits by moulding or by pressing powder
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus 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
    • H01F41/02Apparatus 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
    • H01F41/04Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/10Connecting leads to windings

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  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Coils Or Transformers For Communication (AREA)

Abstract

The invention discloses a self-heating curing integrated inductor and a production process thereof, wherein the inductor comprises an inductor body, an inductor coil is arranged in the inductor body and is positioned in the middle of the inductor body, the inductor coil is formed by winding a copper wire, and two ends of the copper wire in the inductor coil are connected with electrode pins; the production process comprises the steps of after a semi-finished product is formed by cold pressing, electrifying, heating an internal electrified coil, and realizing heating, curing and forming from inside to outside; by adopting the process to prepare the inductor, the inductance is greatly improved, the phenomenon of internal and external cracking is prevented, and the phenomena of magnetic flux leakage and magnetic flux distortion loss caused by internal cracks of the traditional integrated inductor are effectively solved.

Description

Self-heating curing integrated inductor and production process thereof
Technical Field
The invention relates to the technical field of inductors, in particular to a self-heating curing integrated inductor and a production process thereof.
Background
The original model of the inductance element is that a lead is wound into a cylindrical coil, when a current i is conducted into the coil, magnetic flux phi can be generated in the coil and energy is stored, the electromagnetic induction of the inductance element is divided into self-induction and mutual induction, and the electromagnetic induction phenomenon caused by the change of the magnetic flux generated by the magnetic field of the inductance element in the coil is called self-induction phenomenon; the phenomenon of electromagnetic induction, which is caused by the change of the magnetic flux of the external magnetic field in the coil, is called "mutual induction".
However, in the conventional inductance element, the inductance element manufactured by the common cold pressing or hot pressing process cannot solve the problems of increased magnetic loss, decreased inductance, short circuit and the like caused by cracks in the inner and peripheral gaps of the inductance due to the influence of thermal expansion during temperature rise curing due to an outside-in heating mode.
Disclosure of Invention
In order to overcome the technical problems, the invention aims to provide a self-heating curing integrated inductor and a production process thereof.
The purpose of the invention can be realized by the following technical scheme:
the self-heating and curing integrated inductor comprises an inductor body, wherein an inductor coil is arranged inside the inductor body and is located in the middle of the inductor body, the inductor coil is formed by winding a copper wire, and two ends of the copper wire in the inductor coil are connected with electrode pins.
As a further scheme of the invention: the inductor body is formed through cold pressing, the two electrode pins penetrate through the side wall of the inductor body, built-in grooves are symmetrically formed in the two sides of the top end of the inductor body, and the two electrode pins are arranged in the built-in grooves in a bending mode.
As a further scheme of the invention: the inductor body comprises a cover body and a shell, wherein an assembly groove is formed in the middle of one side of the cover body, a positioning boss is arranged in the middle of the assembly groove and is oval, and placing openings are formed in two ends of the side face of the cover body and are used for placing electrode pins.
As a further scheme of the invention: the two electrode pins are positioned on one side and arranged in parallel.
As a further scheme of the invention: and the two electrode pins are bent to be flush with the upper surface of the cover body, and the end surfaces of the two electrode pins do not exceed the side wall of the shell.
As a further scheme of the invention: a production process of a semi-integrated self-heating curing integrated inductor is characterized by comprising the following steps:
a1, connecting an inductance coil with two electrode pins; then placing the inductance coil connected with the electrode pin into a cavity of a cold pressing die;
a2, filling soft magnetic composite powder in a cavity of the cold pressing die, and performing cold pressing to form a semi-finished inductor product;
a3, placing the inductor semi-finished product into an extrusion die for fixing and pressurizing;
and A4, connecting an external lead with the two electrode pins, electrifying, increasing pressure of the upper pressing column in the electrifying self-heating curing process, and bending the electrode pins into the built-in groove after electrifying self-heating curing to obtain a self-heating curing integrated inductor finished product.
As a further scheme of the invention: the production process of the self-heating curing integrated inductor with the cover body and the shell body is characterized by comprising the following steps of:
b1: filling soft magnetic composite powder in a cavity of the cold pressing die, and performing cold pressing to form a cover body;
b2: connecting the inductance coil with two electrode pins; then assembling the inductance coil connected with the electrode pin with the cover body;
b3: placing the assembled cover body into an extrusion die, wherein the extrusion die in the embodiment comprises a bottom plate, a limiting plate and an upper compression column, the bottom plate is fixedly connected with the limiting plate, the limiting plate is provided with a through molding port, the molding port faces upwards, soft magnetic composite powder is filled in the molding port, the assembled cover body is covered on the molding port, and the upper compression column presses the top surface of the cover body;
b4: connecting an external lead with the two electrode pins, electrifying, increasing pressure of the upper pressing column in the electrifying self-heating curing process, cutting off redundant electrode pins after electrifying self-heating curing, and obtaining a self-heating curing integrated inductor finished product with the cover body and the shell after gluing, stripping paint and electroplating.
As a further scheme of the invention: the production process of the integrally formed self-heating curing integrated inductor is characterized by comprising the following steps of:
c1: connecting the inductance coil with two electrode pins; then, placing the inductance coil connected with the electrode pins into a cavity of an extrusion die, wherein the extrusion die comprises an upper pressing column, a lower supporting column and a forming table, the forming table and the lower supporting column are installed in a matched mode, the cavity is formed by the lower supporting column and the forming table, through holes and placing grooves are symmetrically formed in the two sides of the cavity of the forming table, the placing grooves are used for placing the electrode pins, and the through holes are used for leading in wires;
c2: filling soft magnetic composite powder in the cavity, applying pressure by the upper compression column, leading in a lead from the via hole, connecting an external lead with the two electrode pins, electrifying, increasing pressure by the upper compression column in the electrifying self-heating curing process, bending the electrode pins into the built-in groove after electrifying self-heating curing, and obtaining the integrally formed self-heating cured integrated inductor finished product.
The invention has the beneficial effects that:
1. according to the self-heating curing integrated inductor, the internal inductance coil is electrified to generate heat, the inductance value change rate of the self-heating curing integrated inductor formed by heating from inside to outside can be increased by 14.93% on the original basis, and the inductance value change rate of the inductor element formed by heating and curing from outside to inside is a reduced negative value because the final curing of the inductor element formed by cold pressing or hot pressing is in a heating mode from outside to inside, so that the inductance value of the self-heating curing integrated inductor is greatly improved and the power loss is lower than that of the traditional integrated inductor.
2. The inductor of the invention prevents the internal and external cracking phenomenon through self-heating curing molding from inside to outside, and the center post of the self-heating curing integrated inductor is compact and has no crack gap, thereby effectively solving the magnetic flux leakage and magnetic flux distortion loss phenomena caused by the internal cracks of the traditional integrated inductor, and being greatly superior to the traditional integrated inductor in the aspects of improving the inductance quality reliability and reducing the loss.
Drawings
The invention will be further described with reference to the accompanying drawings.
FIG. 1 is a flow chart of the production process of the present invention;
FIG. 2 is a schematic overall structure diagram of a first embodiment of the present invention;
FIG. 3 is a schematic diagram of an electrode pin position structure according to a first embodiment of the present invention;
FIG. 4 is a schematic cross-sectional view of the first embodiment of the present invention;
FIG. 5 is a schematic diagram of a power-on structure of the first embodiment of the present invention;
FIG. 6 is a schematic view of a cover structure according to a second embodiment of the present invention;
fig. 7 is a schematic view of an assembly structure of a cover and an inductor according to a second embodiment of the present invention;
FIG. 8 is a schematic diagram of the electrode pin position structure according to the second embodiment of the present invention;
FIG. 9 is a schematic diagram of the power-on structure of the second embodiment of the present invention;
FIG. 10 is a schematic diagram of the electrode pin position structure according to the third embodiment of the present invention;
FIG. 11 is a schematic diagram of the power-on structure of the third embodiment of the present invention;
FIG. 12 is a schematic diagram of the power-on structure of the fourth embodiment of the present invention;
FIG. 13 is a schematic diagram of a conventional integral inductor internal cracking structure;
FIG. 14 is a schematic view of the internal structure of the self-heating curing integral inductor of the present invention;
FIG. 15 is a schematic diagram of a conventional internal hole air gap flux twist diagram for an integral inductor;
FIG. 16 is a schematic diagram of a conventional integrated inductor internal magnetic field interaction stack;
fig. 17 is a structural schematic diagram of a flux twist diagram of a Step lap stack and a B-joint air gap in a conventional integrated inductor.
In the figure: 1. an inductor body; 11. a built-in groove; 2. an electrode pin; 3. an inductor coil; 4. a cover body; 41. positioning the boss; 5. a housing; 6. and (4) conducting wires.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The first embodiment is as follows:
as shown in fig. 1-4, the inductor includes an inductor body 1, and the inductor body 1 in this embodiment is formed by cold press molding with a cold press mold, and an inductor coil 3 is disposed inside the inductor body 1, and the inductor coil 3 is located in the middle of the inductor body 1, the inductor body 1 completely wraps the inductor coil 3, the inductor coil 3 is formed by winding a copper wire, two ends of the copper wire in the inductor coil 3 are both connected with electrode pins 2, the two electrode pins 2 both penetrate through the sidewall of the inductor body 1, further, the built-in grooves 11 are symmetrically disposed on both sides of the top end of the inductor body 1, the two electrode pins 2 are bent and disposed in the built-in grooves 11, wherein the bent end surfaces of the two electrode pins 2 keep a certain distance from the end surfaces of the built-in grooves 11, and damage to the electrode pins 2 is avoided.
Furthermore, the production process of the inductor comprises the following steps:
a1: connecting an inductance coil 3 with two electrode pins 2; then, placing the inductance coil 3 connected with the electrode pin 2 into a cavity of a cold pressing die:
a2: filling soft magnetic composite powder in a cavity of the cold pressing die, and performing cold pressing to form a semi-finished inductor product;
a3: placing the inductor semi-finished product into an extrusion die for fixing and pressurizing, wherein the extrusion die comprises an upper pressure column and a lower support column, and the inductor semi-finished product is placed between the upper pressure column and the lower support column and is kept stable;
a4: connecting an external lead 6 with the two electrode pins 2, electrifying, increasing pressure of the upper compression column in the electrifying self-heating curing process, bending the electrode pins 2 into the built-in groove 11 after electrifying self-heating curing, and obtaining a semi-integrally formed self-heating curing integrated inductor finished product.
Example two:
as shown in fig. 5-8, the difference between the first embodiment and the second embodiment is that the inductor body 1 in the present embodiment includes a cover 4 and a housing 5, the housing 5 is formed by heating and heating in subsequent energization, an assembly groove is formed in the middle of one side of the cover 4, a positioning boss 41 is disposed in the middle of the assembly groove, the positioning boss 41 is oval, placement openings are formed at two ends of the side surface of the cover 4 to communicate the assembly groove with the outside for placing the electrode pins 2, the placement direction of the electrode pins 2 is different from that in the first embodiment, and the two electrode pins 2 are disposed on one side and are arranged in parallel;
further, the inductor production process of the embodiment includes the following steps:
b1: filling soft magnetic composite powder (FesiCr, fesi, fesiB and the like) into a cavity of the cold pressing die, and performing cold pressing to form a cover body 4;
b2: connecting an inductance coil 3 with two electrode pins 2; then assembling the inductance coil 3 connected with the electrode pin 2 with the cover body 4;
b3: placing the assembled cover body 4 into an extrusion die, wherein the extrusion die in the embodiment comprises a bottom plate, a limiting plate and an upper compression column, the bottom plate is fixedly connected with the limiting plate, the limiting plate is provided with a through molding opening, the molding opening faces upwards, soft magnetic composite powder is filled in the molding opening, the assembled cover body 4 is covered on the molding opening, and the upper compression column presses the top surface of the cover body 4;
b4: connecting an external lead 6 with the two electrode pins 2, electrifying, increasing pressure of the upper pressure column in the electrifying and self-heating curing process, cutting off redundant electrode pins 2 after electrifying and self-heating curing, and obtaining a self-heating curing integrated inductor finished product with the cover body 4 and the shell body 5 after gluing, stripping paint and electroplating.
Example three:
as shown in fig. 9 and fig. 10, the present embodiment is different from the second embodiment in that the two electrode pins 2 are bent to be flush with the upper surface of the cover 4, and the two electrode pins 2 are shortened compared with the second embodiment, and the end surfaces of the two electrode pins 2 do not exceed the side wall of the housing 5;
furthermore, the inductor production process of the present embodiment is different from the second embodiment in that: through holes are symmetrically formed in two ends of an upper compression leg of the extrusion die, and two external leads 6 penetrate through the through holes to electrify the two electrode pins 2.
Example four:
as shown in fig. 11, the inductor structure in this embodiment is identical to that in the first embodiment, except that the manufacturing process of the inductor:
the inductor production process comprises the following steps:
c1: connecting an inductance coil 3 with two electrode pins 2; then, placing the inductance coil 3 connected with the electrode pins 2 into a cavity of an extrusion die, wherein the extrusion die comprises an upper compression leg, a lower support column and a forming table, the forming table and the lower support column are installed in a matched mode, the lower support column and the forming table form the cavity, through holes and placing grooves are symmetrically formed in the two sides of the cavity of the forming table, the placing grooves are used for placing the electrode pins 2, and the through holes are used for leading in wires 6;
c2: filling soft magnetic composite powder in the cavity, applying pressure to the upper pressing column, introducing a lead 6 from the via hole, connecting the external lead 6 with the two electrode pins 2, electrifying, increasing pressure to the upper pressing column in the electrifying and self-heating curing process, and bending the electrode pins 2 into the built-in groove 11 after electrifying and self-heating curing to obtain an integrally-formed self-heating curing integrated inductor finished product.
Further, the inductor production process is characterized in that the external lead 6 is used for electrifying the internal inductance coil 3, and the internal inductance coil 3 is electrified to generate heat so as to realize the heating, curing and molding from inside to outside.
The rate of change of inductance values of the self-heating curing integral inductor of the present invention compared with the conventional integral inductor is shown in the following table:
Figure BDA0003867034640000071
Figure BDA0003867034640000081
it can be seen from the comparison of the above table that the inductance of the self-heating curing integral inductor of the present invention is greatly improved compared with the conventional integral inductor by adopting the way that the internal inductor coil 3 is electrified to generate heat, and the inductance change rate of the self-heating curing integral inductor formed by heating from inside to outside is maximally improved to 14.93%, and the inductance change rate of the inductor element formed by heating from outside to inside by using the conventional cold pressing or hot pressing process is reduced to a negative value.
As further shown in fig. 12-17, the inductor of the present invention is formed by thermal curing from inside to outside, so as to prevent internal and external cracking, and the center pillar of the self-thermal curing integrated inductor is dense and has no crack gap, so as to effectively solve the problems of magnetic flux leakage and magnetic flux distortion loss caused by internal cracks of the conventional integrated inductor, and is greatly superior to the conventional integrated inductor in terms of improving the quality reliability of the inductor and reducing the magnetic loss.
In the description of the present invention, it should be understood that the terms "upper", "lower", "left", "right", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings only for convenience in describing the present invention and simplifying the description, but do not indicate or imply that the device or element referred to must have a specific orientation and a specific orientation configuration and operation, and thus, should not be construed as limiting the present invention. Furthermore, "first" and "second" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the present invention, the meaning of "a plurality" is two or more unless otherwise specified.
In the description of the present invention, it should be noted that, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and the like are to be construed broadly and may be, for example, fixedly connected, detachably connected, or integrally connected; can be mechanically or electrically connected; they may be directly connected or indirectly connected through an intermediate member, or they may be connected through two or more elements. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art.
While one embodiment of the present invention has been described in detail, the description is only a preferred embodiment of the present invention and should not be taken as limiting the scope of the invention. All equivalent changes and modifications made within the scope of the present invention shall fall within the scope of the present invention.

Claims (6)

1. The utility model provides an integrative inductance of self-heating solidification, its characterized in that, includes inductance body (1), inductance body (1) inside is provided with inductance coil (3), inductance coil (3) are located inductance body (1) middle part, inductance coil (3) are formed by the copper conductor coiling, copper conductor both ends in inductance coil (3) all are connected with electrode pin (2).
2. The inductance assembly of claim 1, wherein the inductance body (1) is formed by cold press molding, and the two electrode pins (2) are disposed through the sidewall of the inductance body (1), the top end of the inductance body (1) has two symmetrical built-in slots (11), and the two electrode pins (2) are bent and disposed in the built-in slots (11).
3. The inductor with self-heating curing integration according to claim 1, wherein the inductor body (1) comprises a cover body (4) and a shell (5), an assembly groove is formed in the middle of one side of the cover body (4), a positioning boss (41) is arranged in the middle of the assembly groove, the positioning boss (41) is oval, and placing openings are formed in two ends of the side surface of the cover body (4) and used for placing the electrode pins (2).
4. The self-heating curing integral inductor according to claim 3, wherein the two electrode pins (2) are located at one side and are arranged in parallel.
5. The self-heating curing integrated inductor according to claim 3, wherein the two electrode pins (2) are bent to be flush with the upper surface of the cover (4), and the end surfaces of the two electrode pins (2) do not extend beyond the side wall of the housing (5).
6. A production process of an auto-thermal curing integrated inductor is characterized by comprising the following steps:
a1, connecting an inductance coil (3) with two electrode pins (2); then placing the inductance coil (3) connected with the electrode pin (2) into a cavity of a cold pressing die;
a2, filling soft magnetic composite powder in a cavity of the cold pressing die, and performing cold pressing to form a semi-finished inductor product;
a3, placing the inductor semi-finished product into an extrusion die for fixing and pressurizing;
and A4, connecting an external lead (6) with the two electrode pins (2), electrifying, increasing pressure of the upper pressure column in the electrifying and self-heating curing process, and bending the electrode pins (2) into the built-in groove (11) after electrifying and self-heating curing to obtain a self-heating curing integrated inductor finished product.
CN202211184794.2A 2022-09-27 2022-09-27 Self-heating curing integrated inductor and production process thereof Pending CN115565767A (en)

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Application Number Priority Date Filing Date Title
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