CN116130231A - Preparation method of miniature mould pressing inductor - Google Patents
Preparation method of miniature mould pressing inductor Download PDFInfo
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- CN116130231A CN116130231A CN202211579657.9A CN202211579657A CN116130231A CN 116130231 A CN116130231 A CN 116130231A CN 202211579657 A CN202211579657 A CN 202211579657A CN 116130231 A CN116130231 A CN 116130231A
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Classifications
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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
- H01F17/00—Fixed inductances of the signal type
- H01F17/04—Fixed inductances of the signal type with magnetic core
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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
- H01F17/00—Fixed inductances of the signal type
- H01F17/04—Fixed inductances of the signal type with magnetic core
- H01F2017/048—Fixed inductances of the signal type with magnetic core with encapsulating core, e.g. made of resin and magnetic powder
Abstract
The invention provides a preparation method of a miniature molded inductor, which comprises the steps of placing at least one prefabricated air coil on the upper part of a prefabricated soft magnetic bottom plate, pressing the air coil into the soft magnetic bottom plate through one-time hot pressing, covering a soft magnetic cover plate on the upper part of the soft magnetic bottom plate, performing secondary hot pressing and molding to obtain an inductor blank, and performing demoulding, baking, curing, cutting and electrode treatment on the inductor blank to obtain a miniature molded inductor finished product. The soft magnetic bottom plate and the coil are adopted to press the molded inductor blank, the cover plate is pre-pressed above the blank, the molding process is simple, the requirement on the die is low, the cost is low, the contact binding force between the surfaces of the blank is strong, and the yield of finished products is high; the preparation process of the miniature mould pressing inductor can form a plurality of inductors at one time, has good consistency of products, realizes batch production by a whole plate cutting method, and greatly improves the production efficiency.
Description
Technical Field
The invention relates to the technical field of molded inductors, in particular to a preparation method of a miniature molded inductor.
Background
As electronic components are being miniaturized, mounted to a low thickness, low electromagnetic interference, and high efficiency, inductors inevitably meet this trend. The molded power inductor is one of important products of electronic components, has the characteristics of small volume, low cost, excellent shielding performance, high reliability, high efficiency, high saturation characteristic, suitability for high-density surface mounting and the like, is widely applied to the fields of mobile communication, computers, automotive electronics, high-resolution televisions, broadcasting satellites and the like, and gradually becomes the main stream of an inductor market.
The molding pressure required by the traditional molded inductor is large, so that the coil inside the inductor is easy to generate large deformation or the insulating paint on the surface of a copper wire is easy to damage, and the phenomenon of open circuit and short circuit is easy to occur in the pressing process.
Chinese patent CN112489972a discloses an inductor and a method for manufacturing the same, in which a conductor coil is placed in a groove of a lower substrate, and an upper substrate and the lower substrate are combined together to obtain a semi-finished product, the upper substrate includes a boss, and the bosses of the upper substrate in the semi-finished product are all inserted into the groove of the lower substrate; performing hot press molding on the semi-finished product, and cutting the semi-finished product into a semi-finished product blank after molding; and carrying out heat treatment on the semi-finished blank and preparing a functional layer to obtain the inductor. Although the method can effectively solve the problem of miniaturization of the inductor and improve the production efficiency, an upper substrate with a center pillar still needs to be prepared in the preparation process, for the miniature inductor, the smaller the size is, the larger the preparation difficulty of the center pillar is, the lower the binding force between the center pillar and the bottom surface of the inductor body is, the yield is low, and the higher the requirement on a die is, and the cost is higher.
Chinese patent CN114400137a discloses a structure and manufacturing method of an integrally formed inductor core, comprising a first magnetic plate provided with a magnetic table and a second magnetic plate provided with a hollowed slot, wherein the first magnetic plate and the second magnetic plate are mutually sleeved, the magnetic table is positioned in the hollowed through slot, the hollow coil is sleeved on the magnetic table, the inner contour surface of the hollow coil is attached to the side surface of the magnetic table, and the outer contour surface is attached to the slot wall of the hollowed through slot; the side of the second magnetic body plate away from the first magnetic body plate is also coated with magnetic material powder coated with insulating resin. The method also has the above-mentioned problems.
The magnetic plate, the substrate or the base prepared in the existing miniature mould pressing inductance preparation process all contain a center pillar, the miniature inductance is small in size, the molding difficulty of the center pillar is large, the requirement on a mould is high, the cost is high, the binding force of the prepared center pillar and the contact surface of the bottom of the inductance body is poor, and the yield of finished products is low.
Disclosure of Invention
Based on the background technology, the invention provides a preparation method of a miniature mould pressing inductor, which aims to solve the problems of high column forming difficulty, high requirement on mould materials and low yield in the preparation of miniature inductor products in the prior art.
A method for preparing miniature mould pressing inductance includes placing at least one prefabricated air coil on top of prefabricated soft magnetic base plate, pressing air coil into soft magnetic base plate by primary hot pressing, covering soft magnetic cover plate on top of soft magnetic base plate, carrying out secondary hot pressing to obtain inductance blank, demoulding, baking to cure, cutting and electrode treatment to obtain miniature mould pressing inductance product.
Further, a plurality of air coils may be disposed on the soft magnetic base plate in an array and simultaneously pressed into the soft magnetic base plate by one hot pressing.
Further, the soft magnetic bottom plate is formed by placing soft magnetic alloy composite powder material in a bottom plate die for pressing, and the soft magnetic cover plate is formed by placing soft magnetic alloy composite powder material in a cover plate die for pressing.
Further, the soft magnetic bottom plate and the soft magnetic cover plate have certain fluidity and deformability in the hot pressing process.
Further, the soft magnetic alloy composite powder is prepared by mixing soft magnetic alloy powder, a binder and a lubricant, granulating, drying and sieving.
Further, the method comprises the steps of, the soft magnetic alloy powder comprises at least one of amorphous soft magnetic alloy powder, nanocrystalline soft magnetic alloy powder, fe-Si-Al alloy powder, fe-Si-Cr alloy powder, fe-Si-Al alloy powder, fe-Si-Ni alloy powder, fe-Ni-Al alloy powder and carbonyl iron powder.
Further, the binder includes at least one of epoxy resin, polyurethane, silicone resin, amino resin, polyimide, phenolic resin, cyanate ester, and acrylic resin.
Further, the lubricant includes at least one of zinc stearate, magnesium stearate, aluminum stearate, calcium stearate, graphite powder, and graphene.
Further, the temperature of the bottom plate mold is 100-200 ℃ when the soft magnetic bottom plate is pressed, and the temperature of the cover plate mold is 100-200 ℃ when the soft magnetic cover plate is pressed.
Wherein the density of the soft magnetic bottom plate is 4.0-5.0g/cm 3 The density of the soft magnetic cover plate is 4.0-5.0g/cm 3 。
A preparation method of a miniature mould pressing inductor comprises the following steps:
a1, prefabricating a soft magnetic bottom plate in a bottom plate die, wherein the soft magnetic bottom plate is not demoulded;
a2, placing the prefabricated hollow coils on a soft magnetic bottom plate, performing first hot pressing, and pressing the hollow coils into the soft magnetic bottom plate;
step A3, placing the prefabricated soft magnetic cover plate on a soft magnetic base plate with a coil inside, performing second hot pressing to integrate the soft magnetic base plate and the soft magnetic cover plate, and forming an inductance blank with an electrode bridge;
step A4, demolding, baking and curing the inductor blank in sequence;
step A5, cutting the inductance blank processed in the step A4 to form a plurality of inductance semi-finished products, wherein pins of coils of each inductance semi-finished product are exposed out of the side surfaces of the inductance semi-finished products;
step A6, spraying the inductance semi-finished product, and then performing laser paint stripping treatment on the exposed side surfaces of the pins of the inductance semi-finished product;
and A7, manufacturing an electrode at a paint stripping position of the inductor semi-finished product to obtain a miniature molded inductor finished product.
Further, in step A2, the method includes:
step A21, winding the hollow coil in advance by using a winding machine, and placing the wound hollow coil on a boss of a fixture;
step A22, sucking out the hollow coil from the boss of the fixture by using an adsorption plate and attaching the hollow coil to the adsorption plate;
and A23, moving the adsorption plate to the upper part of the soft magnetic bottom plate, and placing the air coil on the soft magnetic bottom plate.
Further, the adsorption plate is provided with a suction hole, and the hollow coil is adsorbed in a vacuum adsorption mode.
Further, the pressure of the first hot pressing is 0.1-1t/cm 2 The method comprises the steps of carrying out a first treatment on the surface of the The pressure of the second hot pressing is 3-10t/cm 2
Further, in step A2, the hollow coils are arrayed on the soft magnetic base plate.
Further, adjacent pins between two adjacent air coils are at the same level.
Further, the cutting mode in the step A5 is one or more of laser cutting, blade cutting and diamond wire cutting.
Further, the step A3 is: and performing second hot pressing after performing soft magnetic alloy powder on the soft magnetic bottom plate of the inner coil to form an inductance semi-finished product containing the electrode bridge.
Further, after soft magnetic alloy powder is filled on the soft magnetic bottom plate with the inner coil, the second hot pressing is carried out to form the inductance blank with the electrode bridge.
The beneficial technical effects of the invention are as follows:
(1) The soft magnetic bottom plate and the coil are adopted to press the molded inductor blank, the cover plate is pre-pressed above the blank, the molding process is simple, the requirement on the die is low, the cost is low, the contact binding force between the surfaces of the blank is strong, and the yield of finished products is high;
(2) The preparation process of the miniature mould pressing inductor can form a plurality of inductors at one time, has good consistency of products, realizes batch production by a whole plate cutting method, and greatly improves the production efficiency.
Drawings
FIGS. 1-2 are flow charts of steps of a method for manufacturing a micro molded inductor according to the present invention;
FIG. 3 is a schematic diagram of a soft magnetic back plane in accordance with an embodiment of the present invention;
FIG. 4 is a schematic view of an embodiment of the present invention in which the hollow coil is not pressed into the soft magnetic base plate;
FIG. 5 is a schematic diagram showing a structure of a soft magnetic base plate pressed into an air coil after first hot pressing in the embodiment of the invention;
FIG. 6 is a schematic view of a soft magnetic cover plate disposed on a soft magnetic base plate according to an embodiment of the present invention;
fig. 7 is a schematic diagram of an inductance blank after a second hot pressing according to an embodiment of the present invention
Fig. 8 is a schematic diagram of a semi-finished inductor product after cutting according to an embodiment of the present invention;
FIG. 9 is a schematic diagram of an inductor according to an embodiment of the present invention;
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
It should be noted that, without conflict, the embodiments of the present invention and features of the embodiments may be combined with each other.
The invention is further described below with reference to the drawings and specific examples, which are not intended to be limiting.
Referring to fig. 1-2 and 3-9, the invention provides a method for preparing a miniature molded inductor, which comprises the following steps:
a1, prefabricating a soft magnetic bottom plate in a bottom plate die, wherein the soft magnetic bottom plate is not demoulded;
a2, placing the prefabricated hollow coils on a soft magnetic bottom plate, performing first hot pressing, and pressing the hollow coils into the soft magnetic bottom plate;
step A3, placing the prefabricated soft magnetic cover plate on a soft magnetic base plate with a coil therein, performing second hot pressing to integrate the soft magnetic base plate and the soft magnetic cover plate, and forming an inductance blank with an electrode bridge, as shown in a figure (7);
step A4, demolding, baking and curing the inductor blank in sequence;
step A5, cutting the inductance blank processed in the step A4 to form a plurality of inductance semi-finished products, wherein pins of coils of each inductance semi-finished product are exposed out of the side surfaces of the inductance semi-finished products;
step A6, spraying the semi-finished inductor product, and then performing laser paint stripping treatment on the exposed side surfaces of the pins of the semi-finished inductor product;
and A7, manufacturing an electrode at a paint stripping position of the inductor semi-finished product to obtain a miniature molded inductor finished product.
As another preferred embodiment, further, step A3 is: and filling soft magnetic alloy powder on the soft magnetic bottom plate (1) of the inner coil, and then performing hot pressing for the second time to form an inductance blank containing the electrode bridge.
In the invention, soft magnetic alloy powder is pre-pressed into a soft magnetic base plate (1) firstly, a pre-fabricated air coil (2) is placed at the upper part of the pre-pressed soft magnetic base plate (1) under the condition of no demoulding, the soft magnetic base plate (1) is pressed into the soft magnetic base plate (1) by first hot pressing, a soft magnetic cover plate or soft magnetic alloy powder is filled at the upper part of the magnetic base plate, an inductance blank is obtained by second hot pressing and forming, a whole inductance blank is obtained after baking, an inductance semi-finished product (5) is obtained by cutting the whole inductance blank, and a miniature mould pressing inductance is manufactured by laser, paint stripping and an electroplating electrode (7). The requirement on a die is low without separately manufacturing a middle column, and the similar middle column part in the middle of the hollow coil (2) after being pressed in is integrally formed with the bottom plate, so that the binding force is high, and the product yield is high. Starting the hot press to press for the first time, and placing the hollow coil (2) into the soft magnetic bottom plate (1).
Specifically, the enameled wire is wound into a plurality of air-core coils (2) according to the design size and shape.
Specifically, soft magnetic alloy powder is pre-pressed into a soft magnetic base plate (1) in a base plate die according to the size of the inductor, and the soft magnetic base plate (1) is not demoulded; the soft magnetic bottom plate (1) belongs to a flat plate as shown in fig. 3, and a middle column is not required to be prepared.
Specifically, according to the specification of the magnetic bottom plate, soft magnetic alloy powder is placed in a cover plate die to be pre-pressed into a soft magnetic cover plate (3) and then is demoulded;
specifically, the hot press is started to press the hollow coil (2) into the soft magnetic bottom plate (1).
Specifically, a plurality of air coils (2) can be simultaneously pressed into the soft magnetic base plate (1) at one time, as shown in fig. 5.
Specifically, the whole inductor blank is placed on a workbench of a multi-wire cutting device for cutting, so that a plurality of inductor matrixes are formed, and pins (6) of air coils of each inductor matrix are exposed, as shown in fig. 6.
Further, in step A2, it includes:
step A21, winding the hollow coil (2) in advance by using a winding machine, and placing the wound hollow coil (2) on a boss of a fixture;
step A22, sucking out the hollow coil (2) from the boss by using an adsorption plate and attaching the hollow coil to the adsorption plate;
and A23, moving the adsorption plate to the upper part of the soft magnetic base plate (1), and placing the hollow coil (2) on the soft magnetic base plate (1).
Specifically, in order to prepare miniature mould pressing inductors in batches, a winding machine is used for placing the air coil (2) on a boss of a fixture, and an adsorption plate with an adsorption hole is used for sucking out the air coil (2) under the adsorption of a vacuum device and placing the air coil on a soft magnetic bottom plate (1) in a bottom plate mould; after which a first hot press is performed. The adsorption plate sucks out the hollow coil (2) on the boss of the fixture once, releases vacuum, and simultaneously places the hollow coil (2) on the soft magnetic bottom plate (1), as shown in fig. 4.
Specifically, the specification of the fixture is the same as that of the soft magnetic bottom plate (1). The bosses on the fixture comprise a plurality of bosses which are distributed on the fixture according to the expected inductance quantity and arrangement mode formed on the soft magnetic bottom plate (1) at one time.
Further, the adsorption plate is provided with a suction hole, and the hollow coil (2) is adsorbed in a vacuum adsorption mode.
Further, soft magnetic base plates (1) are formed by placing soft magnetic alloy powder materials in a base plate mold for prepressing, and soft magnetic cover plates are formed by placing soft magnetic alloy powder materials in a cover plate mold for prepressing;
wherein the temperature of the bottom plate mould is 100-200 ℃ when the soft magnetic bottom plate (1) is prepared;
wherein the temperature of the cover plate mold is 100-200 ℃ when the soft magnetic cover plate (4) is prepared;
wherein the density of the soft magnetic bottom plate (1) is 4.0-5.0g/cm 3 The density of the soft magnetic cover plate (4) is 4.0-5.0g/cm 3 。
Further, the pressure of the first hot pressing is 0.1-1t/cm 2 The method comprises the steps of carrying out a first treatment on the surface of the The pressure of the second hot pressing is 3-10t/cm 2 。
Specifically, in the step A4, the baking temperature is 100-200 ℃ and the baking time is 3-6h.
Further, in step A2, the air coils (2) are arrayed on the soft magnetic base plate (1).
Further, adjacent pins (3) between two adjacent air coils (2) are positioned on the same horizontal plane.
Specifically, referring to fig. 4, the coils are arranged in an array, and adjacent pins (6) of the coils are arranged side by side on the same horizontal plane. By adopting the arrangement mode, the coil is mainly prevented from interfering with the pins (6) in the arrangement process, and the arrangement precision of the coil is affected.
Specifically, the hollow coil (2) comprises two pins (6), the pins (6) are distributed on two sides of the coil body, and the pins (6) are respectively close to the bottom end and the upper end of the coil.
Further, the soft magnetic alloy powder is prepared by mixing soft magnetic alloy powder, a binder and a lubricant, granulating, drying and sieving;
the soft magnetic alloy powder comprises at least one of amorphous soft magnetic alloy powder, nanocrystalline soft magnetic alloy powder, fe-Si-Al alloy powder, fe-Si-Cr alloy powder, fe-Si-Al alloy powder, fe-Si-Ni alloy powder, fe-Ni-Al alloy powder and carbonyl iron powder;
the binder comprises at least one of epoxy resin, polyurethane, silicone resin, organic silicon resin, amino resin, polyimide, phenolic resin, cyanate and acrylic resin;
the lubricant comprises at least one of zinc stearate, magnesium stearate, aluminum stearate, calcium stearate, graphite powder and graphene.
Further, the cutting mode in the step A5 is one or more of laser cutting, blade cutting and diamond wire cutting.
Further, the hollow coil (2) is a flat enameled copper wire.
Inventive example 1
In the embodiment, the soft magnetic alloy powder material is selected from composite powder of Fe-Si-B-C amorphous soft magnetic alloy powder and carbonyl iron powder, the adhesive is epoxy resin, the lubricant is graphene, and the composite powder is mixed with the adhesive, the lubricant and acetone and then screened to obtain the soft magnetic alloy powder material.
The manufacturing process is as follows:
prefabricating a hollow coil, a soft magnetic bottom plate and a soft magnetic cover plate:
winding a hollow coil on a flat enameled wire with the specification of 0.065mm x0.33mm according to the design size and shape;
according to the design of the size and the number of the inductors, soft magnetic alloy powder is placed in a bottom plate die to be pre-pressed into a soft magnetic bottom plate, the soft magnetic bottom plate is not demoulded, the temperature in the bottom plate die is 180 ℃, and the pre-pressing pressure is 0.5t/cm 2 The density of the soft magnetic bottom plates is 4.5g/cm 3 。
According to the specification of the soft magnetic bottom plate, placing soft magnetic alloy powder into a cover plate mold to be pre-pressed into a soft magnetic cover plate, and demolding; the temperature in the cover plate mould is 180 ℃, and the pre-pressing pressure is 0.5t/cm 2 The density of the soft magnetic cover plate is 4.5g/cm 3 。
And (3) first pressing:
placing the hollow coil on a boss of a fixture clamp with the same specification as the soft magnetic bottom plate by a winding machine, sucking the hollow coil out of the soft magnetic bottom plate by an adsorption plate with a suction hole under the adsorption of a vacuum device, fixing the hollow coil on the soft magnetic bottom plate in a mold, starting a hot press to perform first pressing, and placing the hollow coil into the soft magnetic bottom plate; wherein, the hollow coil is arranged in an array on the soft magnetic bottom plate, and adjacent pins of the coil are arranged in the same horizontal plane side by side. Specifically, the first hot pressing pressure was 0.5t/cm 2 ；
And (3) secondary pressing:
placing a prefabricated soft magnetic cover plate on the upper part of a soft magnetic bottom plate with an internal coil, starting a hot press to press the soft magnetic cover plate into a whole, and demoulding, baking and curing the soft magnetic cover plate to obtain a whole inductance blank with an electrode bridge; specifically, the second hot pressing pressure is 3t/cm 2 The pressure maintaining time is 120s, and the inductor semi-finished product is placed in a baking device with a temperature rise and fall step curve at 180 ℃ for baking for 4h;
cutting:
placing the whole inductor blank on a workbench of multi-wire cutting equipment, cutting the whole inductor blank into inductor semi-finished products, and exposing pins of the air-core coil; the size of the inductor semi-finished product is 2.0mm multiplied by 1.6mm multiplied by 1.0mm;
laser marking:
marking the exposed positions of pins on the inductor matrix and laser stripping paint;
electrode manufacturing:
and electroplating an electrode at the paint stripping position of the inductor matrix to obtain the miniature mould pressing inductor.
Inductance test:
the prepared miniature mould pressing inductor is tested, the standard inductance value of the inductor is set to be 1 mu H, and an impedance analyzer is used for testing the inductance value L under the conditions of 1V and 1MHz s 0.950 mu H, DC resistance R dc 36.5mΩ; saturation current I sat 4.05A.
Comparative example 1
In this comparative example, the same soft magnetic alloy composite powder material, the same binder, lubricant and external insulating coating material as those in example 1 were used, and parameters such as the type and specification of the enamel wire, the number of turns of winding the coil, the structure and size of the electrode (7), and the size of the inductor finished product were the same as those in example 1, except that the inductor preparation method was different from example 1.
The preparation method of the inductor comprises the following steps:
prefabricating a T-shaped blank: loading the screened soft magnetic alloy powder into a T-shaped die with a preset structure and size, starting a high-precision servo forming press for stamping forming at normal temperature, demolding to obtain a T-shaped blank with columnar bulges, and then placing the T-shaped blank into an oven for baking to obtain a T-shaped blank with certain strength;
the cold pressing pressure adopted when the T-shaped blank is pressed is 3T/cm 2 The dwell time is 1s; when the T-shaped blank is baked to form, the T-shaped blank is placed in baking equipment with a temperature rise and fall step curve at 150 ℃ for baking for 0.5h, and the T-shaped blank with certain strength is obtained;
prefabricating a coil: a flat enamel wire having a specification of 0.065mm x0.33mm was wound into an air-core coil according to a design size and shape as in example 1.
Hot press molding: the air coil is sleeved on a center post of the T-shaped green body, soft magnetic alloy powder is filled, the first inductance green body is obtained through hot press molding, and the first inductance green body is baked, so that a solidified inductance green body is obtained.
Wherein the hot pressing pressure adopted in hot pressing is 3t/cm 2 And (5) maintaining the pressure for 120s, and baking and curing the first inductor blank. Specifically, the baking curing temperature is 180 ℃, baking equipment with a temperature rise and fall step curve can be selected, heat preservation is carried out for 4 hours, and finally, the inductance semi-finished product is obtained, and the dimension of the inductance semi-finished product is 2.0mm multiplied by 1.6mm multiplied by 1.0mm.
Spraying: spraying an insulating resin protective material on the surface of the prepared inductor blank, and baking to solidify the insulating resin protective material on the surface to obtain an inductor semi-finished product;
electrode manufacturing: and stripping the insulating resin protective material and the copper wire enamel at the copper electrode of the prepared power inductor semi-finished product, and electroplating the electrode at the stripping position to obtain the miniature mould pressing inductor.
The prepared miniature mould pressing inductor is tested, the standard inductance value of the inductor is set to be 1 mu H, and an impedance analyzer is used for testing the inductance value L under the conditions of 1V and 1MHz s 0.885 mu H, DC resistance R dc 40.5mΩ; saturation current I sat 3.82A.
Inventive example 2
In this embodiment, the size specification of the micro molded inductor is the same as that of embodiment 1, the soft magnetic alloy powder is a composite powder of Fe-Si-B-Nb-Cu nanocrystalline soft magnetic alloy powder and carbonyl iron powder, and the other inductor structural parameters, raw materials, preparation technology and process parameters are the same as those of embodiment 1, and are described in embodiment 1.
After a miniature mould pressing inductance sample is obtained, the prepared miniature mould pressing inductance is tested, the standard inductance value of the inductance is set to be 1 mu H, and an impedance analyzer is used for testing the inductance value L under the conditions of 1V and 1MHz s 1.010 mu H, DC resistance R dc 35.9mΩ; saturation current I sat 4.15A.
Comparative example 2
In this comparative example, the same soft magnetic alloy composite powder material, the same binder and lubricant, the same type and specification of enamelled wire, the same size of inductance product and other parameters as in example 2 were selected, and the same inductance preparation method as in comparative example 1 was used.
TABLE 1 Performance parameters of the micro-molded inductors prepared in examples 1-2 and comparative examples 1-2
As can be seen from table 1, the inductor prepared by the method has the advantages that the direct current resistance of the inductor prepared by the method is obviously reduced, the saturation current is obviously increased, the inductor performance is excellent, the inductor can be prepared in batches by cutting the whole plate, and the production efficiency is higher.
The foregoing is merely illustrative of the preferred embodiments of the present invention and is not intended to limit the embodiments and scope of the present invention, and it should be appreciated by those skilled in the art that equivalent substitutions and obvious variations may be made using the description and illustrations of the present invention, and are intended to be included in the scope of the present invention.
Claims (17)
1. A method for preparing miniature mould pressing inductance is characterized in that at least one prefabricated air coil is placed on the upper portion of a prefabricated soft magnetic base plate, the air coil is pressed into the soft magnetic base plate through primary hot pressing, a soft magnetic cover plate is covered on the upper portion of the soft magnetic base plate, inductance blanks are obtained through secondary hot pressing and forming, and miniature mould pressing inductance finished products are obtained through demoulding, baking, solidifying, cutting and electrode treatment of the inductance blanks.
2. The method of manufacturing a micro molded inductor according to claim 1, wherein the plurality of air coils are arranged in an array on the soft magnetic base plate and simultaneously pressed into the soft magnetic base plate by a single hot press.
3. The method of manufacturing a micro molded inductor according to claim 1, wherein the soft magnetic base plate is formed by pressing soft magnetic alloy composite powder in a base plate mold, and the soft magnetic cover plate is formed by pressing soft magnetic alloy composite powder in a cover plate mold.
4. The method of claim 1, wherein the soft magnetic base plate and the soft magnetic cover plate have fluidity and deformability during hot pressing.
5. The method for manufacturing a miniature molded inductor as claimed in claim 3, wherein the soft magnetic alloy composite powder is prepared by mixing soft magnetic alloy powder, a binder and a lubricant, granulating, drying and sieving.
6. The method of manufacturing a micro molded inductor according to claim 5, wherein, the soft magnetic alloy powder comprises at least one of amorphous soft magnetic alloy powder, nanocrystalline soft magnetic alloy powder, fe-Si-Al alloy powder, fe-Si-Cr alloy powder, fe-Si-Al alloy powder, fe-Si-Ni alloy powder, fe-Ni-Al alloy powder and carbonyl iron powder.
7. The method of claim 5, wherein the binder comprises at least one of epoxy, polyurethane, silicone, amino, polyimide, phenolic, cyanate, and acrylic.
8. The method of claim 5, wherein the lubricant comprises at least one of zinc stearate, magnesium stearate, aluminum stearate, calcium stearate, graphite powder, and graphene.
9. The method of manufacturing a micro molded inductor according to claim 3, wherein the temperature of the base plate mold is 100-200 ℃ when the soft magnetic base plate is pressed, and the temperature of the cover plate mold is 100-200 ℃ when the soft magnetic cover plate is pressed.
10. The method of manufacturing a miniature molded inductor of claim 1, comprising:
a1, prefabricating a soft magnetic bottom plate in a bottom plate die, wherein the soft magnetic bottom plate is not demoulded;
a2, placing a plurality of prefabricated air coils on the soft magnetic bottom plate, performing first hot pressing, and pressing the air coils into the soft magnetic bottom plate;
a3, placing a prefabricated soft magnetic cover plate on the soft magnetic bottom plate with the coil inside, and performing second hot pressing to integrate the soft magnetic bottom plate and the soft magnetic cover plate and form an inductance blank with an electrode bridge;
step A4, demolding, baking and curing the inductance blank in sequence;
step A5, cutting the inductance blank processed in the step A4 to form a plurality of inductance semi-finished products, wherein pins of the coil of each inductance semi-finished product are exposed out of the side surface of the inductance semi-finished product;
step A6, spraying the inductance semi-finished product, and then performing laser paint stripping treatment on the exposed side surfaces of the pins of the inductance semi-finished product;
and A7, manufacturing an electrode at a paint stripping position of the inductor semi-finished product to obtain a miniature mould pressing inductor finished product.
11. The method of manufacturing a micro molded inductor as claimed in claim 10, wherein in said step A2, comprising:
step A21, winding the hollow coil in advance by using a winding machine, and placing the wound hollow coil on a boss of a fixture;
step A22, sucking the hollow coil out of a boss of the tool clamp by using an adsorption plate and attaching the hollow coil to the adsorption plate;
and step A23, the adsorption plate is moved to the upper part of the soft magnetic bottom plate, and the air coil is placed on the soft magnetic bottom plate.
12. The method of claim 11, wherein the suction holes are formed in the suction plate, and the air-core coil is sucked by vacuum suction.
13. The method of manufacturing a micro molded inductor according to claim 10, wherein the pressure of the first hot pressing is 0.1 to 1t/cm 2 The method comprises the steps of carrying out a first treatment on the surface of the The pressure of the second hot pressing is 3-10t/cm 2 。
14. The method of claim 10, wherein in the step A2, the air-core coils are arranged in an array on the soft magnetic base plate.
15. The method of claim 14, wherein adjacent pins between two adjacent air coils are at the same level.
16. The method of claim 10, wherein the cutting in the step A5 is one or more of laser cutting, blade cutting, and diamond wire cutting.
17. The method for manufacturing a micro molded inductor according to claim 10, wherein the step A3 is: and filling soft magnetic alloy composite powder on the soft magnetic bottom plate with the inner coil, and then performing hot pressing for the second time to form the inductance blank with the electrode bridge.
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| CN202211579657.9A CN116130231A (en) | 2022-12-08 | 2022-12-08 | Preparation method of miniature mould pressing inductor |
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