CN116168942A - Preparation method of power inductor - Google Patents

Preparation method of power inductor Download PDF

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Publication number
CN116168942A
CN116168942A CN202211563016.4A CN202211563016A CN116168942A CN 116168942 A CN116168942 A CN 116168942A CN 202211563016 A CN202211563016 A CN 202211563016A CN 116168942 A CN116168942 A CN 116168942A
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CN
China
Prior art keywords
grooves
planar coil
magnetic core
silver paste
power inductor
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Pending
Application number
CN202211563016.4A
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Chinese (zh)
Inventor
李正龙
林涛
吴长和
王劲
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Jiangsu Lineprinting Materials Co ltd
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Jiangsu Lineprinting Materials Co ltd
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Priority to CN202211563016.4A priority Critical patent/CN116168942A/en
Publication of CN116168942A publication Critical patent/CN116168942A/en
Pending legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
    • H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/34—Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
    • 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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06—Coil winding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06—Coil winding
    • H01F41/076—Forming taps or terminals while winding, e.g. by wrapping or soldering the wire onto pins, or by directly forming terminals from the wire
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/12—Insulating of windings
    • H01F41/122—Insulating between turns or between winding layers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B70/00—Technologies for an efficient end-user side electric power management and consumption
    • Y02B70/10—Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes

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

Abstract

The invention provides a power inductor preparation method, which relates to the technical field of inductor preparation and comprises the following steps: preparing magnetic powder, and pressing the magnetic powder to form a rectangular magnetic core with grooves, wherein the grooves are respectively opened along the side surfaces of the rectangular magnetic core; preparing silver paste, printing the silver paste into the grooves, and then baking to obtain baked magnetic cores; winding a planar coil with the shape matched with that of the groove, wherein the planar coil is provided with two lead-out terminals led outwards, and then pressing the planar coil and the baked magnetic core into a whole, so that the two lead-out terminals are led out from the side opening of the groove respectively to form an inductance semi-finished product; and (3) annealing the inductor semi-finished product, and then performing electrode forming treatment on the lead-out terminal to prepare the power inductor. The low-temperature silver paste and the rectangular magnetic core are baked and annealed together, so that inherent alternating current loss of the inductor is reduced to the minimum; silver paste is printed in the rectangular magnetic core formed by pressing, so that high current can safely pass through the rectangular magnetic core.

Description

Preparation method of power inductor
Technical Field
The invention relates to the technical field of inductor preparation, in particular to a power inductor preparation method.
Background
With the rapid promotion of informatization and intelligent development, the electronic products are increasingly widely applied to high-current low-loss devices. At present, the integrated inductor and the ferrite inductor are widely included in the application, but the integrated inductor cannot anneal at high temperature to achieve the purpose of reducing loss because the temperature resistance level of the insulating layer on the surface of the copper coil is below 220 ℃. The sintering temperature of the ferrite inductor needs to reach above 800 ℃, and the loss after sintering is far higher than that of the metal soft magnetic alloy subjected to annealing treatment at about 350-600 ℃, so that how to prepare the high-current low-loss power inductor is a technical problem to be solved.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides a power inductor preparation method, which comprises the following steps:
step S1, preparing magnetic powder, and pressing the magnetic powder to form a rectangular magnetic core with grooves, wherein the grooves are respectively opened along the side surfaces of the rectangular magnetic core;
s2, preparing silver paste, printing the silver paste into the grooves, and then baking to obtain baked magnetic cores;
step S3, winding a planar coil with the shape matched with that of the groove, wherein the planar coil is provided with two outgoing terminals which are led outwards, and then pressing the planar coil and the baked magnetic core into a whole, so that the two outgoing terminals are led out from the side opening of the groove respectively to form an inductance semi-finished product;
and S4, annealing the inductor semi-finished product, and then performing electrode forming treatment on the lead-out terminal to prepare the power inductor.
Preferably, the magnetic powder comprises a soft magnetic metal material and a resin material, and the ratio of the resin material in the magnetic powder is 1% -5%.
Preferably, the soft magnetic metal material comprises at least one of carbonyl iron powder material, ferrosilicon alloy material, ferronickel molybdenum material and nanocrystalline soft magnetic material;
the resin material includes at least one of an epoxy resin and a phenolic resin.
Preferably, the step S3 includes:
step S31, winding a single-layer multi-strand copper wire coated with an inorganic insulating layer to form the planar coil which is matched with the shape of the groove, wherein the planar coil is provided with two lead-out terminals led out outwards;
step S32, placing the planar coil in the groove of the baked magnetic core, and leading out two leading-out terminals from the side openings of the groove respectively;
and step S33, filling powder into the grooves, and pressing the grooves into a whole, so that the powder fills up the gaps among the strands of copper wires of the planar coil and the grooves, and an inductance semi-finished product is formed.
Preferably, the inorganic insulating layer is made of an inorganic particulate material including at least one of silica, alumina and silicon carbide.
Preferably, in the step S2, the silver paste is printed into the recess, and then baked at a baking temperature of 100 ℃ to 200 ℃.
Preferably, in the step S4, an annealing temperature for annealing the inductor semi-finished product is 400 ℃ to 700 ℃.
Preferably, the sintering temperature of the silver paste is below 700 ℃.
The technical scheme has the following advantages or beneficial effects:
1) Roasting and annealing the low-temperature silver paste and the rectangular magnetic core together to minimize inherent alternating current loss of the inductor;
2) Printing silver paste in the rectangular magnetic core formed by pressing, so that large current can safely pass through the rectangular magnetic core;
3) The copper wire coated with the inorganic insulating layer is wound to form the planar coil, and the inorganic insulating layer can resist high temperature, so that the inductor semi-finished product can be annealed at a higher annealing temperature to further reduce loss.
Drawings
FIG. 1 is a schematic flow chart of a power inductor manufacturing method according to a preferred embodiment of the invention;
fig. 2 is a schematic flow chart of step S3 in the preferred embodiment of the 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, a method for manufacturing a power inductor is now provided, as shown in fig. 1, which includes:
step S1, preparing magnetic powder, and pressing the magnetic powder to form a rectangular magnetic core with grooves, wherein the grooves are respectively opened along the side surfaces of the rectangular magnetic core;
s2, preparing silver paste, printing the silver paste into the grooves, and then baking to obtain baked magnetic cores;
step S3, winding a planar coil with the shape matched with that of the groove, wherein the planar coil is provided with two lead-out terminals led outwards, and then laminating the planar coil and the baked magnetic core into a whole, so that the two lead-out terminals are led out from the side opening of the groove respectively to form an inductance semi-finished product;
and S4, annealing the inductor semi-finished product, and then performing electrode forming treatment on the lead-out terminal to prepare the power inductor.
Specifically, in this embodiment, the shape of the groove and the opening position of the side face are not limited, the shape of the groove may be a shape of a Chinese character 'ji', and the corresponding openings are symmetrically opened on two side faces of the rectangular magnetic core, and it is understood that the two openings may be both disposed on the same side face of the rectangular magnetic core.
The silver paste is preferably low-temperature silver paste with sintering temperature below 700 ℃, and the silver paste is printed in the grooves of the rectangular magnetic cores, so that the low-temperature silver paste and the rectangular magnetic cores are baked together, and inherent alternating current loss of the prepared power inductor can be effectively reduced.
The grooves are preferably rectangular grooves, flatness is required to be ensured in silver paste printing, and the viscosity of the silver paste is preferably 1100-1800dPa.s. In the viscosity range, the silver paste line is smooth and flat during silver paste printing, no permeation, burrs, gaps and other defects exist, and the adhesive force of the silver paste after baking is strong, so that the planar coil can be stably placed in the groove, and the overall stress uniformity of the planar coil is realized when the planar coil and the baked magnetic core are pressed into a whole. And after the lamination is completed, the inductance semi-finished product can be annealed to prepare the electrode. Preferably, the two lead terminals can be bent to one side of the rectangular magnetic core, which is far away from the planar coil, along the direction of the opening, which is far away from the planar coil, and then the inorganic insulating layer and the copper wire which are coated by the two lead terminals are removed in a laser mode, so that the electrode is formed by electroplating.
Further, the low-temperature silver paste and the rectangular magnetic core are baked together and then annealed together, so that inherent alternating current loss of the prepared power inductor is minimized; in addition, silver paste is printed in the rectangular magnetic core formed by pressing, so that high current can safely pass through the rectangular magnetic core, and the requirements of devices with high current and low power consumption are met.
In a preferred embodiment of the present invention, the magnetic powder includes a soft magnetic metal material and a resin material, and the resin material accounts for 1% -5% of the magnetic powder.
In a preferred embodiment of the present invention, the soft magnetic metal material includes at least one of carbonyl iron powder material, iron-silicon alloy material, iron-nickel-molybdenum material, and nanocrystalline soft magnetic material;
the resin material includes at least one of an epoxy resin and a phenolic resin.
In a preferred embodiment of the present invention, as shown in fig. 2, step S3 includes:
step S31, winding a single-layer multi-strand copper wire coated with an inorganic insulating layer to form a planar coil matched with the shape of the groove, wherein the planar coil is provided with two lead-out terminals led out outwards;
step S32, placing the planar coil in a groove of the baked magnetic core, and leading out two leading-out terminals from side openings of the groove respectively;
and step S33, filling powder into the grooves, and pressing the grooves into a whole, so that the powder fills the gaps among the strands of copper wires of the planar coil and the grooves, and an inductance semi-finished product is formed.
Specifically, in the present embodiment, the inorganic insulating layer is made of an inorganic particulate material including at least one of silica, alumina, and silicon carbide. The inorganic insulating layer is used for coating the copper wire, compared with the existing insulating layer, the temperature resistance level is effectively improved, so that in the step S4, the annealing temperature of annealing treatment of the inductor semi-finished product can reach 400-700 ℃, and compared with the existing annealing treatment below 220 ℃, the purpose of reducing loss can be further achieved. Further, the inorganic insulating layer has insulativity and excellent high-voltage resistance, the copper wire inner core can be effectively protected, the problem that the insulating layer of the existing coated copper wire inner core is easy to damage during pressing to cause short circuit of a product is solved, and based on the problem, relatively high pressing pressure can be allowed during pressing, so that forming density is improved, and magnetic conductivity of the product is improved.
In a preferred embodiment of the present invention, in step S2, silver paste is printed into the grooves, and then baked at a baking temperature of 100-200 ℃.
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 (8)

1. A method for manufacturing a power inductor, comprising:
step S1, preparing magnetic powder, and pressing the magnetic powder to form a rectangular magnetic core with grooves, wherein the grooves are respectively opened along the side surfaces of the rectangular magnetic core;
s2, preparing silver paste, printing the silver paste into the grooves, and then baking to obtain baked magnetic cores;
step S3, winding a planar coil with the shape matched with that of the groove, wherein the planar coil is provided with two outgoing terminals which are led outwards, and then pressing the planar coil and the baked magnetic core into a whole, so that the two outgoing terminals are led out from the side opening of the groove respectively to form an inductance semi-finished product;
and S4, annealing the inductor semi-finished product, and then performing electrode forming treatment on the lead-out terminal to prepare the power inductor.
2. The method of manufacturing a power inductor according to claim 1, wherein the magnetic powder comprises a soft magnetic metal material and a resin material, and the resin material accounts for 1% -5% of the magnetic powder.
3. The method of manufacturing a power inductor according to claim 2, wherein the soft magnetic metal material comprises at least one of carbonyl iron powder material, ferrosilicon alloy material, ferronickel molybdenum material, and nanocrystalline soft magnetic material;
the resin material includes at least one of an epoxy resin and a phenolic resin.
4. The method for manufacturing a power inductor according to claim 1, wherein the step S3 includes:
step S31, winding a single-layer multi-strand copper wire coated with an inorganic insulating layer to form the planar coil which is matched with the shape of the groove, wherein the planar coil is provided with two lead-out terminals led out outwards;
step S32, placing the planar coil in the groove of the baked magnetic core, and leading out two leading-out terminals from the side openings of the groove respectively;
and step S33, filling powder into the grooves, and pressing the grooves into a whole, so that the powder fills up the gaps among the strands of copper wires of the planar coil and the grooves, and an inductance semi-finished product is formed.
5. The method of claim 4, wherein the inorganic insulating layer is made of an inorganic particulate material comprising at least one of silica, alumina, and silicon carbide.
6. The method of manufacturing a power inductor according to claim 1, wherein in the step S2, the silver paste is printed into the grooves, and the baking temperature after baking is 100 ℃ to 200 ℃.
7. The method according to claim 1, wherein in the step S4, the annealing temperature for annealing the inductor semi-finished product is 400 ℃ to 700 ℃.
8. The method of claim 1, wherein the sintering temperature of the silver paste is below 700 ℃.
CN202211563016.4A 2022-12-07 2022-12-07 Preparation method of power inductor Pending CN116168942A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CN202211563016.4A CN116168942A (en) 2022-12-07 2022-12-07 Preparation method of power inductor

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CN202211563016.4A CN116168942A (en) 2022-12-07 2022-12-07 Preparation method of power inductor

Publications (1)

Publication Number Publication Date
CN116168942A true CN116168942A (en) 2023-05-26

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ID=86417202

Family Applications (1)

Application Number Title Priority Date Filing Date
CN202211563016.4A Pending CN116168942A (en) 2022-12-07 2022-12-07 Preparation method of power inductor

Country Status (1)

Country Link
CN (1) CN116168942A (en)

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