CN116013671A - Preparation method of inductor - Google Patents
Preparation method of inductor Download PDFInfo
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- CN116013671A CN116013671A CN202211563041.2A CN202211563041A CN116013671A CN 116013671 A CN116013671 A CN 116013671A CN 202211563041 A CN202211563041 A CN 202211563041A CN 116013671 A CN116013671 A CN 116013671A
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Abstract
The invention provides a preparation method of an inductor, which relates to the technical field of inductor preparation and comprises the following steps: respectively pressing to form a columnar magnetic core and a tubular shell which is hollow and is provided with two ends; winding a hollow coil on the columnar magnetic core, wherein two ends of the hollow coil extend outwards from two ends of the columnar magnetic core to form an extension part; placing a columnar magnetic core wound with an air-core coil in a tubular shell, filling powder into the tubular shell, and performing secondary pressing to obtain an inductance semi-finished product; and correspondingly assembling two copper caps at two ends of the inductor semi-finished product, so that each copper cap is respectively welded and connected with the corresponding extension part and the end part of the inductor semi-finished product to prepare the inductor finished product. The method has the advantages that the columnar magnetic core and the tubular shell are formed by pre-pressing, so that when the inductance semi-finished product is prepared by secondary pressing, the fluidity of the powder is reduced, the large-particle powder is prevented from being extruded into copper wires to cause short circuit, and the columnar magnetic core and the tubular shell form retaining walls during secondary pressing, so that the deformation of the air core coil is prevented.
Description
Technical Field
The invention relates to the technical field of inductor preparation, in particular to a preparation method of an inductor.
Background
Inductors, also known as induction coils, are capable of converting electrical energy into magnetic energy for storage, and are one of the basic elements that make up electronic circuits, and are widely used in electronic circuits. The inductor is similar to a transformer in structure, but only has one winding, has certain inductance and only blocks current change, so that the inductor plays roles of current blocking, voltage reduction, cross-linked coupling, load and the like in an alternating current circuit.
Along with the smaller and smaller size of electronic components, the inductor is continuously miniaturized, and the integrated inductor is generated. However, as the use of integrally formed inductors has become more and more widespread, the problems that are exposed have increased. The existing integrated inductor is mainly formed by filling magnetic powder in an air core copper coil and pressing. In the pressing process, under the action of high pressure, the magnetic powder can puncture the insulating layer on the surface of the copper coil to form powder and a short circuit phenomenon between the powder and the adjacent coil, and particularly, the adverse phenomenon is more obvious when the coil is applied at high frequency.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides a preparation method of an inductor, which comprises the following steps:
step S1, respectively pressing to form a columnar magnetic core and a hollow tubular shell with two open ends by adopting soft magnetic materials;
s2, winding an air coil on the columnar magnetic core, wherein two ends of the air coil extend outwards from two ends of the columnar magnetic core to form an extension part;
s3, placing the columnar magnetic core wound with the air-core coil in the tubular shell, filling powder into the tubular shell, and performing secondary pressing to obtain an inductance semi-finished product;
and S4, correspondingly assembling two copper caps at two ends of the inductor semi-finished product, so that each copper cap is respectively welded and connected with the corresponding extension part and the end part of the inductor semi-finished product, and thus the inductor finished product is prepared.
Preferably, in the step S1, the process of forming the columnar magnetic core by pressing the soft magnetic material includes:
step S11, pressing and forming the soft magnetic material to obtain a formed magnetic core;
and step S12, baking the formed magnetic core for 30-240S at 180-420 ℃ to prepare the columnar magnetic core.
Preferably, the step S2 includes:
s21, cutting the outer wall of the columnar magnetic core by a thread cutting machine to form a thread groove matched with the shape of the hollow coil, and cutting the end part of the columnar magnetic core to form a containing groove matched with a copper wire for winding the hollow coil;
step S22, the hollow coil is wound on the outer wall of the columnar magnetic core in a rotating way along one end of the columnar magnetic core, so that the hollow coil is completely embedded into the thread groove, and the extension parts formed at the two ends of the hollow coil extend outwards from the two ends of the columnar magnetic core along the corresponding accommodating grooves;
and S23, coating magnetic powder glue for filling gaps among the thread grooves on the outer side of the hollow coil, and then baking in a drying oven to solidify the magnetic powder glue.
Preferably, the length of the extension part protruding out of the end part of the columnar magnetic core is 0.015mm-0.03mm.
Preferably, the step S3 includes:
step S31, placing the columnar magnetic core wound with the hollow coil in the tubular shell, filling powder into the tubular shell, and then placing the tubular shell in a pressing die for pressing and forming to obtain a formed semi-finished product;
and S32, baking the molded semi-finished product to thoroughly cure the powder material, thereby obtaining the inductance semi-finished product.
Preferably, in the step S31, the pressing temperature of the press molding is 150-220 ℃, the pressing time is 60-180S, and the pressing pressure is 4T/cm 2 -10T/cm 2 。
Preferably, in the step S32, the baking temperature for baking the molded semi-finished product is 180-420 ℃, and the baking time is 60-240 min.
Preferably, a groove is formed in one side of the copper cap, which faces the inductor semi-finished product; the step S4 includes:
step S41, uniformly filling the solder into the inner wall of the groove;
and S42, covering the side, facing the end part of the inductance semi-finished product, of the groove of the copper cap on the end part of the inductance semi-finished product, pressing for 3S-10S at 280-320 ℃, and melting the solder to enable each copper cap to be welded and connected with the corresponding extension part and the end part of the inductance semi-finished product.
Preferably, the surface of the copper cap is plated with a nickel layer and a tin layer in sequence.
Preferably, the thickness of the nickel layer is 3-12 μm, the thickness of the tin layer is 6-12 μm, and the thickness of the copper cap is 0.1-0.2 mm.
The technical scheme has the following advantages or beneficial effects:
1) The columnar magnetic core and the tubular shell are formed by pre-pressing, so that the fluidity of the powder material is reduced when the inductance semi-finished product is prepared by secondary pressing, the short circuit caused by the extrusion of large-particle powder material into copper wires is prevented, and the columnar magnetic core and the tubular shell form retaining walls during secondary pressing, so that the deformation of the air core coil is prevented;
2) The columnar magnetic core and the tubular shell are formed by pre-pressing, so that the density of the material can be increased, and the performance of the prepared inductor cost can be effectively improved;
3) The outer wall of the columnar magnetic core is cut to form a thread groove matched with the hollow coil, so that the hollow coil can be embedded into the thread groove, and meanwhile, the short circuit caused by extruding large-particle powder into copper wires is further prevented by coating the thread groove on the outer side of the hollow coil;
4) The electrode of the inductor finished product is formed by adopting a copper cap welding mode, so that the manufacturing process is reduced, and the preparation cost of the device is effectively reduced.
Drawings
FIG. 1 is a schematic flow chart of a method for manufacturing an inductor according to a preferred embodiment of the invention;
FIG. 2 is a flow chart of a process of forming a columnar magnetic core by pressing a soft magnetic material according to a preferred embodiment of the present invention;
FIG. 3 is a flow chart of step S2 in the preferred embodiment of the present invention;
FIG. 4 is a schematic view showing a cylindrical magnetic core wound with an air coil according to a preferred embodiment of the present invention;
FIG. 5 is a flow chart of step S3 in the preferred embodiment of the present invention;
FIG. 6 is a bottom view of a copper cap in accordance with a preferred embodiment of the present invention;
FIG. 7 is a flow chart of step S5 in the preferred embodiment of the present invention;
fig. 8 is a cross-sectional view of a finished inductor product in accordance with a preferred embodiment of the present invention.
Detailed Description
The invention will now be described in detail with reference to the drawings and specific examples. The present invention is not limited to the embodiment, and other embodiments may fall within the scope of the present invention as long as they conform to the gist of the present invention.
In a preferred embodiment of the present invention, based on the above-mentioned problems existing in the prior art, there is now provided a method for manufacturing an inductor, as shown in fig. 1, comprising:
step S1, respectively pressing to form a columnar magnetic core and a hollow tubular shell with two open ends by adopting soft magnetic materials;
s2, winding a hollow coil on the columnar magnetic core, wherein two ends of the hollow coil extend outwards from two ends of the columnar magnetic core to form an extension part;
s3, placing the columnar magnetic core wound with the air-core coil in a tubular shell, filling powder into the tubular shell, and performing secondary pressing to obtain an inductance semi-finished product;
and S4, correspondingly assembling two copper caps at two ends of the inductor semi-finished product, so that each copper cap is respectively welded and connected with the corresponding extension part and the end part of the inductor semi-finished product to prepare the inductor finished product.
Specifically, in this embodiment, the soft magnetic material is preferably formed by mixing a polymer resin material with a soft magnetic material such as an alloy material, an amorphous material, or a nanocrystalline material. The air-core coil is preferably formed by winding a round copper wire or a flat copper wire which is single-stranded and includes an insulating layer.
Further specifically, the preparation process of the finished inductor product comprises a twice pressing process, wherein the twice pressing process is to press the columnar magnetic core and the tubular shell respectively, and the twice pressing process is to fill powder material into the tubular shell loaded with the columnar magnetic core wound with the air-core coil and press the powder material to form the semi-finished inductor product. Through first suppression formation column magnetic core and tubular shell, can increase the density of material itself, when making product self performance promote for column magnetic core and tubular shell can regard as the barricade on the one hand when secondary suppression, prevent that hollow coil from being out of shape under the suppression pressure effect, on the other hand can reduce the mobility of powder, prevent that large granule powder from extruding into between the copper line and causing the short circuit, promote the yields.
Furthermore, after the inductor semi-finished product is obtained, a corresponding inductor electrode needs to be prepared, in this embodiment, a copper cap is used as the inductor electrode, and a welding mode is adopted to connect with the extension part of the air core coil and the end part of the inductor semi-finished product to form a closed loop, so that a finished inductor product with complete magnetic shielding and good welding performance is obtained. Compared with the existing electrode preparation mode, the technical scheme reduces the manufacturing process and effectively reduces the device preparation cost.
In a preferred embodiment of the present invention, in step S1, as shown in fig. 2, the process of forming the columnar magnetic core by pressing the soft magnetic material includes:
step S11, pressing and forming the soft magnetic material to obtain a formed magnetic core;
and step S12, baking the formed magnetic core for 30-240S at 180-420 ℃ to prepare the columnar magnetic core.
In a preferred embodiment of the present invention, as shown in fig. 3, step S2 includes:
s21, cutting the outer wall of the columnar magnetic core by a thread cutting machine to form a thread groove matched with the shape of the hollow coil, and cutting the end part of the columnar magnetic core to form a containing groove matched with a copper wire for winding the hollow coil;
step S22, the hollow coil is wound on the outer wall of the columnar magnetic core in a rotating way along one end of the columnar magnetic core so that the hollow coil is completely embedded into the thread groove, and extension parts formed at two ends of the hollow coil extend outwards from two ends of the columnar magnetic core along the corresponding accommodating groove;
and S23, coating magnetic powder glue for filling up gaps among the thread grooves on the outer side of the air coil, and then baking in a drying oven to solidify the magnetic powder glue.
Specifically, in the present embodiment, as shown in fig. 4, the columnar core 2 around which the air-core coil 1 is wound, it can be seen that after the air-core coil 1 is wound, the extension portions 11 at both ends thereof extend out of both ends of the columnar core 2 so as to be welded with the copper cap later. Preferably, the extension 11 extends from the end of the columnar core 2 by a length of 0.015mm to 0.03mm.
Further specifically, through the screw thread groove of the adaptation hollow coil of cutting formation at the outer wall of column magnetic core for the hollow coil can imbed in the screw thread groove, passes through the coating screw thread groove in the outside of hollow coil simultaneously, further prevents that large granule powder material from extruding into between the copper line and causing the short circuit.
In a preferred embodiment of the present invention, as shown in fig. 5, step S3 includes:
step S31, placing a columnar magnetic core wound with an air-core coil in a tubular shell, filling powder into the tubular shell, and then placing the tubular shell in a pressing die for pressing and forming to obtain a formed semi-finished product;
and S32, baking the molded semi-finished product to thoroughly solidify the powder material, thereby obtaining the inductance semi-finished product.
In the preferred embodiment of the present invention, in step S31, the pressing temperature of the press molding is 150-220 ℃, the pressing time is 60-180S, and the pressing pressure is 4T/cm 2 -10T/cm 2 。
In the preferred embodiment of the present invention, in step S32, the baking temperature for baking the molded semi-finished product is 180 ℃ to 420 ℃ and the baking time is 60min to 240min.
In the preferred embodiment of the invention, as shown in fig. 6, a groove 31 is formed on the side of the copper cap 3 facing the inductor semi-finished product 4; as shown in fig. 7, step S4 includes:
step S41, uniformly filling solder into the inner wall of the groove;
and S42, covering the side, facing the end part of the inductance semi-finished product, of the groove of the copper cap, then pressing for 3S-10S at 280-320 ℃, and melting the solder to enable each copper cap to be respectively welded and connected with the corresponding extension part and the end part of the inductance semi-finished product.
In particular, in the present embodiment, as shown in fig. 8, it can be seen that the inner diameter of the groove 31 of the copper cap 3 is adapted to the outer diameter of the inductor semi-finished product 4. After the solder is uniformly filled into the inner wall of the groove 31, the copper cap 3 is covered at the end part of the inductor semi-finished product 4 to realize preliminary fixation, and then the copper cap 3 is heated while a certain pressing pressure is applied to the copper cap 3, so that the solder is melted at a high temperature, the electrode preparation process is simplified while the welding firmness among the copper cap 3, the extension part 11 and the end part of the inductor semi-finished product 4 is realized, and the device preparation cost is effectively reduced.
In a preferred embodiment of the invention, the surface of the copper cap is electroplated with a nickel layer and a tin layer in sequence.
In a preferred embodiment of the invention, the nickel layer has a thickness of 3 μm to 12 μm, the tin layer has a thickness of 6 μm to 12 μm, and the copper cap has a thickness of 0.1mm to 0.2mm.
The foregoing description is only illustrative of the preferred embodiments of the present invention and is not to be construed as limiting the scope of the invention, and it will be appreciated by those skilled in the art that equivalent substitutions and obvious variations may be made using the description and drawings, and are intended to be included within the scope of the present invention.
Claims (10)
1. A method of manufacturing an inductor, comprising:
step S1, respectively pressing to form a columnar magnetic core and a hollow tubular shell with two open ends by adopting soft magnetic materials;
s2, winding an air coil on the columnar magnetic core, wherein two ends of the air coil extend outwards from two ends of the columnar magnetic core to form an extension part;
s3, placing the columnar magnetic core wound with the air-core coil in the tubular shell, filling powder into the tubular shell, and performing secondary pressing to obtain an inductance semi-finished product;
and S4, correspondingly assembling two copper caps at two ends of the inductor semi-finished product, so that each copper cap is respectively welded and connected with the corresponding extension part and the end part of the inductor semi-finished product, and thus the inductor finished product is prepared.
2. The method of manufacturing an inductor according to claim 1, wherein in the step S1, the process of forming the columnar magnetic core by pressing the soft magnetic material includes:
step S11, pressing and forming the soft magnetic material to obtain a formed magnetic core;
and step S12, baking the formed magnetic core for 30-240S at 180-420 ℃ to prepare the columnar magnetic core.
3. The method of manufacturing an inductor according to claim 1, wherein the step S2 comprises:
s21, cutting the outer wall of the columnar magnetic core by a thread cutting machine to form a thread groove matched with the shape of the hollow coil, and cutting the end part of the columnar magnetic core to form a containing groove matched with a copper wire for winding the hollow coil;
step S22, the hollow coil is wound on the outer wall of the columnar magnetic core in a rotating way along one end of the columnar magnetic core, so that the hollow coil is completely embedded into the thread groove, and the extension parts formed at the two ends of the hollow coil extend outwards from the two ends of the columnar magnetic core along the corresponding accommodating grooves;
and S23, coating magnetic powder glue for filling gaps among the thread grooves on the outer side of the hollow coil, and then baking in a drying oven to solidify the magnetic powder glue.
4. A method of manufacturing an inductor according to claim 1 or 3, wherein the extension extends beyond the end of the columnar core by a length of 0.015mm to 0.03mm.
5. The method of manufacturing an inductor according to claim 1, wherein the step S3 comprises:
step S31, placing the columnar magnetic core wound with the hollow coil in the tubular shell, filling powder into the tubular shell, and then placing the tubular shell in a pressing die for pressing and forming to obtain a formed semi-finished product;
and S32, baking the molded semi-finished product to thoroughly cure the powder material, thereby obtaining the inductance semi-finished product.
6. The method of manufacturing an inductor according to claim 5, wherein in the step S31, the press temperature of the press forming is 150 ℃ to 220 ℃, the press time is 60S to 180S, and the press pressure is 4T/cm 2 -10T/cm 2 。
7. The method of manufacturing an inductor according to claim 6, wherein in the step S32, the baking temperature for baking the molded semi-finished product is 180 ℃ to 420 ℃ and the baking time is 60min to 240min.
8. The method of manufacturing an inductor according to claim 1, wherein a groove is provided in a side of the copper cap facing the inductor semi-finished product; the step S4 includes:
step S41, uniformly filling the solder into the inner wall of the groove;
and S42, covering the side, facing the end part of the inductance semi-finished product, of the groove of the copper cap on the end part of the inductance semi-finished product, pressing for 3S-10S at 280-320 ℃, and melting the solder to enable each copper cap to be welded and connected with the corresponding extension part and the end part of the inductance semi-finished product.
9. The method of manufacturing an inductor according to claim 8, wherein the surface of the copper cap is plated with a nickel layer and a tin layer in this order.
10. The method of manufacturing an inductor according to claim 9, wherein the nickel layer has a thickness of 3 μm to 12 μm, the tin layer has a thickness of 6 μm to 12 μm, and the copper cap has a thickness of 0.1mm to 0.2mm.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202211563041.2A CN116013671A (en) | 2022-12-07 | 2022-12-07 | Preparation method of inductor |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202211563041.2A CN116013671A (en) | 2022-12-07 | 2022-12-07 | Preparation method of inductor |
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| CN116013671A true CN116013671A (en) | 2023-04-25 |
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| CN202211563041.2A Pending CN116013671A (en) | 2022-12-07 | 2022-12-07 | Preparation method of inductor |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117153539A (en) * | 2023-06-07 | 2023-12-01 | 淮安顺络文盛电子有限公司 | Inductance element and preparation method thereof |
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- 2022-12-07 CN CN202211563041.2A patent/CN116013671A/en active Pending
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117153539A (en) * | 2023-06-07 | 2023-12-01 | 淮安顺络文盛电子有限公司 | Inductance element and preparation method thereof |
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