CN116487143A - Manufacturing method of integrated inductor and inductor manufactured by using same - Google Patents
Manufacturing method of integrated inductor and inductor manufactured by using same Download PDFInfo
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- CN116487143A CN116487143A CN202210034759.6A CN202210034759A CN116487143A CN 116487143 A CN116487143 A CN 116487143A CN 202210034759 A CN202210034759 A CN 202210034759A CN 116487143 A CN116487143 A CN 116487143A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 54
- 238000005520 cutting process Methods 0.000 claims abstract description 28
- 238000000034 method Methods 0.000 claims abstract description 19
- 239000006247 magnetic powder Substances 0.000 claims description 126
- 239000000843 powder Substances 0.000 claims description 102
- 238000007731 hot pressing Methods 0.000 claims description 59
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 53
- 239000011159 matrix material Substances 0.000 claims description 47
- 239000000203 mixture Substances 0.000 claims description 43
- 238000011049 filling Methods 0.000 claims description 36
- 238000003825 pressing Methods 0.000 claims description 36
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 claims description 30
- 239000002245 particle Substances 0.000 claims description 28
- 239000000047 product Substances 0.000 claims description 26
- 238000001035 drying Methods 0.000 claims description 15
- 238000010438 heat treatment Methods 0.000 claims description 14
- 229910052742 iron Inorganic materials 0.000 claims description 11
- 239000000314 lubricant Substances 0.000 claims description 10
- 239000000853 adhesive Substances 0.000 claims description 9
- 230000001070 adhesive effect Effects 0.000 claims description 9
- 239000011259 mixed solution Substances 0.000 claims description 9
- 239000011248 coating agent Substances 0.000 claims description 7
- 238000000576 coating method Methods 0.000 claims description 7
- 238000009413 insulation Methods 0.000 claims description 6
- 238000002156 mixing Methods 0.000 claims description 5
- 238000012986 modification Methods 0.000 claims description 4
- 230000004048 modification Effects 0.000 claims description 4
- 239000011265 semifinished product Substances 0.000 claims description 3
- XEVZIAVUCQDJFL-UHFFFAOYSA-N [Cr].[Fe].[Si] Chemical compound [Cr].[Fe].[Si] XEVZIAVUCQDJFL-UHFFFAOYSA-N 0.000 claims description 2
- 239000011810 insulating material Substances 0.000 claims description 2
- UGKDIUIOSMUOAW-UHFFFAOYSA-N iron nickel Chemical compound [Fe].[Ni] UGKDIUIOSMUOAW-UHFFFAOYSA-N 0.000 claims description 2
- -1 iron silicon aluminum Chemical compound 0.000 claims description 2
- 238000007493 shaping process Methods 0.000 abstract description 4
- 238000005516 engineering process Methods 0.000 abstract description 3
- 238000009417 prefabrication Methods 0.000 abstract description 3
- 238000012797 qualification Methods 0.000 abstract description 3
- 230000002950 deficient Effects 0.000 abstract description 2
- 239000003973 paint Substances 0.000 description 27
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 24
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 24
- 238000013461 design Methods 0.000 description 21
- 239000000243 solution Substances 0.000 description 21
- 239000003822 epoxy resin Substances 0.000 description 19
- 229920000647 polyepoxide Polymers 0.000 description 19
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 18
- 229910052802 copper Inorganic materials 0.000 description 18
- 239000010949 copper Substances 0.000 description 18
- 239000002966 varnish Substances 0.000 description 14
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 12
- HGPXWXLYXNVULB-UHFFFAOYSA-M lithium stearate Chemical compound [Li+].CCCCCCCCCCCCCCCCCC([O-])=O HGPXWXLYXNVULB-UHFFFAOYSA-M 0.000 description 12
- 238000003756 stirring Methods 0.000 description 12
- 239000000758 substrate Substances 0.000 description 12
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 9
- 238000010586 diagram Methods 0.000 description 9
- 238000009713 electroplating Methods 0.000 description 9
- 229910052759 nickel Inorganic materials 0.000 description 9
- 238000011056 performance test Methods 0.000 description 9
- 239000011135 tin Substances 0.000 description 9
- 229910052718 tin Inorganic materials 0.000 description 9
- 238000003466 welding Methods 0.000 description 9
- 229910000519 Ferrosilicon Inorganic materials 0.000 description 7
- 238000012545 processing Methods 0.000 description 7
- 238000012216 screening Methods 0.000 description 6
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 4
- 238000013329 compounding Methods 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- XWHPIFXRKKHEKR-UHFFFAOYSA-N iron silicon Chemical compound [Si].[Fe] XWHPIFXRKKHEKR-UHFFFAOYSA-N 0.000 description 3
- 238000003475 lamination Methods 0.000 description 3
- 239000002243 precursor Substances 0.000 description 3
- 239000011863 silicon-based powder Substances 0.000 description 3
- 238000005507 spraying Methods 0.000 description 3
- XOOUIPVCVHRTMJ-UHFFFAOYSA-L zinc stearate Chemical compound [Zn+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O XOOUIPVCVHRTMJ-UHFFFAOYSA-L 0.000 description 3
- 239000003795 chemical substances by application Substances 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- HQKMJHAJHXVSDF-UHFFFAOYSA-L magnesium stearate Chemical compound [Mg+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O HQKMJHAJHXVSDF-UHFFFAOYSA-L 0.000 description 2
- 238000004804 winding Methods 0.000 description 2
- 229910002651 NO3 Inorganic materials 0.000 description 1
- NHNBFGGVMKEFGY-UHFFFAOYSA-N Nitrate Chemical compound [O-][N+]([O-])=O NHNBFGGVMKEFGY-UHFFFAOYSA-N 0.000 description 1
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000004134 energy conservation Methods 0.000 description 1
- 238000005469 granulation Methods 0.000 description 1
- 230000003179 granulation Effects 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 235000019359 magnesium stearate Nutrition 0.000 description 1
- 239000000696 magnetic material Substances 0.000 description 1
- QLOAVXSYZAJECW-UHFFFAOYSA-N methane;molecular fluorine Chemical compound C.FF QLOAVXSYZAJECW-UHFFFAOYSA-N 0.000 description 1
- CWQXQMHSOZUFJS-UHFFFAOYSA-N molybdenum disulfide Chemical compound S=[Mo]=S CWQXQMHSOZUFJS-UHFFFAOYSA-N 0.000 description 1
- 229910052982 molybdenum disulfide Inorganic materials 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 239000010452 phosphate Substances 0.000 description 1
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 229910052814 silicon oxide Inorganic materials 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/02—Fixed inductances of the signal type without magnetic core
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/16—Metallic particles coated with a non-metal
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/02—Compacting only
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/12—Both compacting and sintering
- B22F3/14—Both compacting and sintering simultaneously
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
- B22F7/08—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools with one or more parts not made from powder
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
- H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
- H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
- H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
- H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
- H01F1/147—Alloys characterised by their composition
-
- 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
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
- B22F2003/248—Thermal after-treatment
-
- 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
- H01F2027/348—Preventing eddy currents
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Composite Materials (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Dispersion Chemistry (AREA)
- Coils Or Transformers For Communication (AREA)
- Manufacturing Cores, Coils, And Magnets (AREA)
Abstract
Compared with the prior art, the invention has the following advantages: through whole board shaping, the mode of cutting into the single article again, effectively improves inductor production efficiency, and has cancelled complicated base prefabrication process, has further reduced the technology degree of difficulty and manufacturing cost. Meanwhile, the problem of fit clearance between the coil and the base is solved, on one hand, the overall density of the inductor can be improved, the high performance of the inductor is guaranteed, on the other hand, the positioning precision of the coil is improved, defective products and unqualified products caused by inconsistent cutting positions and actual positions of the coil are avoided, and the process stability and the product qualification rate are improved.
Description
Technical Field
The invention belongs to the technical field of inductors, and particularly relates to a manufacturing method of an integrally formed inductor and an inductor prepared by using the same.
Background
In recent years, due to development and maturity of 5G communication technology, market demand for small-sized and high-performance inductors has been increasing in order to accommodate the trend of miniaturization, thinness and thinness of consumer electronic products. On the premise of maintaining high performance, how to improve the production efficiency of the inductor and reduce the production cost become key problems of research by various manufacturers. The traditional integrally formed inductor adopts a single-die cavity powder filling and pressing forming mode, and the mode has the defects of high limitation in manufacturing small-size inductors, low production efficiency and large equipment and die investment. The patent with publication number CN105355408A describes a method for shaping N whole inductance plates, prefabricated a base with a boss, assembling an air coil on the base, then powder filling, shaping and pressing, finally obtaining a single inductance by cutting, which effectively improves the production efficiency of the inductance, but the method still has the following disadvantages: the base is high in prefabrication difficulty and high in die cost.
Disclosure of Invention
The invention aims to provide a manufacturing method of an integrally formed inductor and the inductor prepared by using the manufacturing method, so that the performance of the inductor is optimized under the conditions of improving the production efficiency of the inductor and reducing the equipment investment.
According to an aspect of the present invention, there is provided a method of manufacturing an integrally formed inductor, comprising the steps of: s1, filling magnetic powder into a mold until the bottom of the mold is fully paved, wherein the filling times are not less than 1 time; s2, pre-pressing the magnetic powder filled in the die to enable the magnetic powder to be preformed into powder blocks, wherein the density of the powder blocks is not higher than 5g/cm 3 The method comprises the steps of carrying out a first treatment on the surface of the S3, transferring the N air coils into a die, and pressing the air coils into preformed powder blocks so as to enable the magnetic powder materials forming the powder blocks to beTightly filled on the inner surface and the outer surface of the hollow coil; s4, filling magnetic powder into the die again until the air coil is buried by the magnetic powder, and pressing the magnetic powder filled in the die to form an inductance parent body primary blank, wherein the filling times are not less than 1 time; s5, hot-pressing the primary blank of the inductor matrix, and then carrying out heat treatment to obtain a blank of the inductor matrix; s6, cutting an inductance parent blank to obtain an inductance matrix containing at least one air-core coil; s, performing surface insulation treatment on the surface of the inductance matrix; s8, removing insulating materials of the conductive terminal part of the hollow wire, exposing the conductive terminal part, and manufacturing an electrode terminal by using the exposed conductive terminal part to obtain an inductor finished product.
The inventor finds that in the method of adopting the magnetic powder prefabricated forming die in long-term production operation, the hollow coil and the base boss are in clearance fit, the coil is positioned inaccurately, the coil is easy to shift during pressing, the qualification rate during cutting is affected, and the powder at the gap of filling powder is difficult to flow in, so that the performance of a pressed product is affected. Compared with the prior art, the invention has the following advantages: through whole board shaping, the mode of cutting into the single article again, effectively improves inductor production efficiency, and has cancelled complicated base prefabrication process, has further reduced the technology degree of difficulty and manufacturing cost. Meanwhile, the problem of fit clearance between the coil and the base is solved, on one hand, the overall density of the inductor can be improved, the high performance of the inductor is guaranteed, on the other hand, the positioning precision of the coil is improved, defective products and unqualified products caused by inconsistent cutting positions and actual positions of the coil are avoided, and the process stability and the product qualification rate are improved.
Alternatively, in S7, the surface insulation treatment may be achieved by uniformly coating a layer of insulating paint on the surface of the inductor base.
Alternatively, the shape of the air coil includes, but is not limited to, circular, elliptical, and racetrack.
The hollow coil is formed by winding a wire. Alternatively, the cross-section of the wire includes, but is not limited to, circular, rectangular.
In S1, the number of times of filling the magnetic powder may be 1 or more, and the types of the magnetic powder to be filled may be the same or different.
Preferably, in S3, after the air-core coil is pressed into the magnetic powder filled in the mold, the upper surface of the air-core coil is not lower than the upper surface of the magnetic powder filled in the mold. Under the state, the pre-pressed magnetic powder plays a limiting role on the air coil, and the air coil is prevented from being displaced in the subsequent secondary pressing and hot pressing processes.
In S3, the number of the hollow coils is not less than 2, and the hollow coils are arranged in the die in an equidistant array. The arrangement mode of the equidistant array is beneficial to orderly cutting the green body.
In S4, the number of times of filling the magnetic powder may be 1 or more, and the types of the magnetic powder to be filled may be the same or different.
Alternatively, the hollow coil is not limited to be placed in the mold, and can be directly placed in the mold after winding is completed, or can be transferred into the mold through the coil transfer jig.
Preferably, in S5, the hot pressing pressure is 100-1000 MPa, the hot pressing temperature is 80-200 ℃, and the dwell time is 10-300 seconds.
Preferably, in S5, the hot pressing pressure is represented by P, the hot pressing temperature is represented by T, the dwell time is represented by T, and P, T, T satisfies the following quantitative relationship: and 2 < P < T >/1000000 < 11 >, wherein the operation unit of P is MPa, the operation unit of T is DEG C, and the operation unit of T is s.
Preferably, in S5, P, T, t satisfies the following quantitative relationship: p T/1000000 < 9
Preferably, in S5, the hot pressing pressure does not exceed 600MPa.
Preferably, in the heat treatment operation of S5, the temperature of the heat treatment is 150 to 200 ℃ and the time of the heat treatment is 1 to 3 hours.
In S5, when the parameters of the hot pressing operation meet the above conditions, the manufactured inductor has good electrical properties (represented by inductance, direct current resistance, saturation current, and temperature rise current or other electrical property parameters).
Preferably, in S1 to S4, the magnetic powder used has a particle size of 50 to 400. Mu.m.
Preferably, in S1-S4, the magnetic powder used has a particle size of 80-260 microns, a flowability of 30-55 seconds/50 g and a bulk density of 1.5-2.5 g/cc.
Preferably, the magnetic powder is prepared from magnetic raw powder, adhesive and lubricant according to the following method: (a) Inorganic coating is carried out on the magnetic raw powder so as to achieve surface insulation modification, and a mixture A is obtained; (b) Adding a mixed solution of an adhesive and acetone into the mixture A, and uniformly mixing the mixture A and the mixture B according to the mass percent, wherein the addition amount of the adhesive is 1-10% of that of the magnetic raw powder; (c) Granulating the mixture B to obtain semi-finished product powder with the particle size of 50-400 microns; (d) And drying the semi-finished powder, adding a lubricant into the semi-finished powder, wherein the adding amount of the lubricant is 0.01-0.5% of the semi-finished powder according to the mass percentage, and thus the magnetic powder is prepared.
Preferably, in the step (a) of preparing the magnetic powder, the magnetic raw powder is subjected to phosphating treatment to achieve surface insulation modification, and the adding amount of the phosphating agent is 0.02% -0.2% by mass percent, so as to obtain a mixture A.
Preferably, in the step (B) of preparing the magnetic powder, a mixed solution of an adhesive and acetone is added into the mixture A, the adhesive is modified epoxy resin and a curing agent thereof, and the addition amount of the adhesive is 1.8-3.2% of that of the magnetic raw powder according to the mass percentage, and the mixture B is obtained by uniformly mixing.
Preferably, in step (c) of preparing the above-mentioned magnetic powder, the mixture B is used for granulation to obtain a semi-finished powder having a particle size of 80 to 260 μm.
Preferably, in the step (d) of preparing the above-mentioned magnetic powder, the semi-finished powder is dried at a drying temperature of 60 to 100 ℃ for 1 to 2 hours, and a lubricant is added to the semi-finished powder, the lubricant being lithium stearate, and the amount of the lubricant added being 0.1 to 0.3% of the semi-finished powder in terms of mass percent, thereby preparing the magnetic powder.
Preferably, the particle size of the magnetic raw powder is 1-30 microns, and the magnetic raw powder comprises at least one of carbonyl iron powder, iron silicon chromium powder, iron silicon aluminum powder, iron nickel powder, iron-based amorphous powder and iron-based nanocrystalline powder. In some embodiments, one or more layers of coating modification may also be performed on the magnetic raw powder employed.
Preferably, the magnetic raw powder is a mixture of carbonyl iron powder and iron-based nanocrystalline powder, and the ratio of the carbonyl iron powder to the iron-based nanocrystalline powder=9:1-3:7 in terms of mass percent.
Optionally, in the step (a), the inorganic coating is performed by forming an inorganic coating film on the surface of the magnetic raw powder, wherein the material forming the inorganic coating film comprises one or more of phosphate, silicate, nitrate, silicon oxide, titanium oxide and aluminum oxide.
Optionally, in the step (d), the lubricant used includes one or more of zinc stearate, lithium stearate, magnesium stearate, graphite fluoride, and molybdenum disulfide.
According to another aspect of the present invention, there is provided an inductor: the inductor is prepared according to the manufacturing method of the integrated inductor.
The inductor manufacturing process provided by the invention adopts repeated pressing to obtain the inductor with the integral bonding and partial lamination structure. The laminated structure of the inductor is composed of a plurality of magnetic layers, soft magnetic materials among the magnetic layers are discontinuously distributed, and the magnetic field mutual interference can be reduced.
Compared with the traditional inductor, the inductor prepared by the process has the characteristics of continuously adjustable inductance value, loss and saturation current. In a specific inductance design, a developer can design the material, thickness and lamination number of the magnetic layer according to different application scenes to meet the optimal requirement of the circuit. Through the optimal design, the prepared high-frequency low-loss power inductor can be suitable for application in multiple occasions, particularly in the application of a high-frequency DC-DC converter, and the eddy current loss of a magnetic layer can be effectively reduced in light load; the direct current overlapping saturated current can be effectively increased during heavy load, so that the efficiency of the DC-DC converter is effectively improved, and the purposes of green and energy conservation are achieved.
Drawings
Fig. 1 is a schematic view of an air coil of the present invention.
Fig. 2 is a schematic diagram of a powder block and coil combination structure of the invention.
Fig. 3 is a schematic diagram of an inductor precursor blank of the present invention.
Fig. 4 is a schematic diagram of an inductance precursor blank of the present invention.
Fig. 5 is a schematic cutting view of the present invention.
Fig. 6 is a schematic diagram of the structure of the inductor base body of the present invention.
Fig. 7 is a schematic diagram of the structure of the insulating varnish coated inductor base body of the present invention.
Fig. 8 is a schematic diagram of the structure of an inductor base body with insulating varnish removed according to the present invention.
Fig. 9 is a schematic diagram of the finished inductor structure of the present invention.
Fig. 10 is a schematic diagram of the powder block and coil assembly structure according to embodiment 5 of the present invention.
Fig. 11 is a schematic diagram of an inductor precursor blank according to example 5 of the present invention.
The reference numerals of fig. 1 to 11 are: air core coil 1, coil pin 1a, powder piece 2, powder piece bottom layer 2a, powder piece center layer 2b, inductance parent body blank 3, inductance parent body blank 4, inductance matrix 5, insulating paint coated inductance matrix 6, insulating paint removed inductance matrix 7, inductor finished product 8, electrode terminal 8a.
Detailed Description
The invention will be further described with reference to the accompanying drawings and examples. It should be noted that the examples described below are intended to facilitate the understanding of the present invention and are not intended to limit the present invention in any way.
Example 1
Treatment group:
s0. copper wires are wound into an air coil 1 shown in figure 1 according to design requirements, pins 1a are arranged at two ends of the coil, the cross section of each copper wire is rectangular, and the shape of each air coil is a racetrack;
s1, filling a layer of magnetic powder into a mold until the bottom of the mold is fully paved;
s2, preforming loose powder blocks 2 by using 50MPa pressure;
s3, transferring the hollow coil 1 into a die, arranging the coils in the die in an equidistant array manner, and pressing the coils into the preformed powder block 2 so that the upper surface of the coil 1 is flush with the upper surface of the powder block 2;
s4, filling magnetic powder into the die until the air coil 1 is completely filled with the magnetic powder, and then pressing the magnetic powder in the filling die to obtain an inductance parent body primary blank 3;
s5, transferring the inductance parent body blank 3 into a hot-pressing die, performing hot pressing, wherein the hot-pressing pressure is 200MPa, the hot-pressing temperature is 160 ℃, the pressure maintaining time is 120 seconds, and performing heat treatment at 180 ℃ for 2 hours to obtain an inductance parent body blank 4;
s6, as shown in FIG. 5, cutting the inductance parent blank 4 according to the design size to obtain a plurality of inductance substrates 5 containing the coils 1, wherein after cutting is completed, coil pins 1a at two ends of the inductance substrates 5 are directly exposed;
s7, as shown in FIG. 7, black insulating paint is rolled on the surface of the inductance matrix 5 to obtain an inductance matrix 6 coated with the insulating paint;
s8, as shown in FIG. 8, removing insulating varnish of the conductive terminal part by laser, and then electroplating the inductance matrix 7 from which the insulating varnish is removed, so as to manufacture an electrode terminal 8a (the electrode terminal is respectively copper, nickel and tin from inside to outside) at the conductive terminal part, thereby obtaining an inductor finished product 8. One side of the electrode terminal 8a is connected to the coil pin 1a, and the other side is led out to the inductor welding surface.
In the embodiment, carbonyl iron powder is used as magnetic raw powder, the magnetic powder is compounded by carbonyl iron powder, epoxy resin and lithium stearate, the particle size of the magnetic powder is 150-200 microns, and the particle size of the carbonyl iron powder is 3-8 microns.
The manufacturing process of the magnetic powder comprises the following steps:
(a) Adding an appropriate amount of acetone solution of phosphoric acid (phosphoric acid mass: carbonyl iron powder mass is 0.1%) into carbonyl iron powder, fully stirring until the solution volatilizes, and drying the powder to obtain a mixture A;
(b) Adding a mixed solution of epoxy resin and acetone (the mass of the epoxy resin is 2% of the mass of carbonyl iron powder) into the mixture A, and fully and uniformly stirring to obtain a mixture B;
(c) Granulating and screening the mixture B by using a swinging granulator to obtain semi-finished magnetic powder with the particle size of 150-200 microns;
(d) Drying the semi-finished magnetic powder at 100 ℃ for 60min;
(e) And adding 0.1% of lithium stearate into the dried semi-finished magnetic powder to obtain a finished magnetic powder product.
The inductor manufactured by the processing group of this embodiment has the characteristics of low dc resistance and large rated current, and takes the inductance specification of the external dimension of 2.0 x 1.6 x 1.0mm and the inductance of 1.0 microhenry as an example, and the performance is shown in table 1.
TABLE 1 Performance test results of inductors prepared by the treatment group of this example
Control group: the inductor is manufactured based on the manufacturing method of the die surface mount inductor disclosed in the prior art CN 105355408A.
(1) Copper wires are wound into an air-core coil 1 shown in figure 1 according to design requirements, and pins 1a are arranged at two ends of the coil;
(2) The base is manufactured by adopting magnetic powder, and comprises a base and N bosses which are arranged on the base and are arranged in an array at intervals, wherein N is more than or equal to 2;
(3) Assembling the air coil 1 and the base: sleeving N air coils 1 on the outer sides of the N bosses in a one-to-one correspondence manner to obtain an assembly of the N air coils 1 and the base, wherein the N air coils 1 in the assembly of the N air coils 1 and the base are also arrayed, and a distance is reserved between every two adjacent air coils 1;
(4) Placing an assembly of N air coils 1 and a base in a die cavity of a cold pressing die, filling magnetic powder into the die cavity, and then performing cold pressing treatment to obtain an inductance parent body primary blank, wherein the pressure of the cold pressing treatment is 100MPa, and the temperature of the cold pressing treatment is not higher than 50 ℃;
(5) Transferring the primary blank of the inductor matrix into a hot-pressing die to sequentially perform hot-pressing treatment and pressure-maintaining treatment, wherein the hot-pressing pressure is 300MPa, the hot-pressing temperature is 160 ℃, the pressure-maintaining time is 120 seconds, and then performing heat treatment at 180 ℃ for 2 hours to obtain a blank of the inductor matrix;
(6) Cutting an inductance matrix blank according to the design size to obtain a plurality of inductance matrixes containing the coils 1, wherein after cutting is finished, coil pins 1a at two ends of the inductance matrixes are directly exposed;
(7) Covering the surface of the inductance matrix 5 with black insulating paint in a spraying mode to obtain an inductance matrix coated with the insulating paint;
(8) And removing the insulating paint of the conductive terminal part by using laser, electroplating the inductance matrix from which the insulating paint is removed, and manufacturing electrode terminals (copper, nickel and tin are respectively arranged on the electrode terminals from inside to outside) at the conductive terminal part to obtain the finished inductor product. One side of the electrode terminal is connected with the coil pin 1a, and the other side is led out to the welding surface of the inductor.
In the above-described process of manufacturing an inductor, the magnetic powder used in the control group of this embodiment is the same as the magnetic powder used in the treatment group of this embodiment.
Taking the inductance specification with the external dimension of 2.0×1.6×1.0mm and the inductance of 1.0 microhenry as an example, the performance of the inductor manufactured by the comparative group in this example is shown in table 2.
TABLE 2 Performance test results of inductors prepared in the control group of this example
In this example, the set treatment group is a specific implementation of the technical solution claimed in the present invention, and the set control group is an implementation of the technical solution reported in the prior art CN 105355408A. Comparing the data presented in tables 1 and 2, the results show that the performance of the inductor manufactured by the treatment group is better, and the inductor manufactured by the treatment group has lower direct current resistance, higher saturation current and higher temperature rise current than the inductor manufactured by the control group on the premise of setting the same inductance.
Example 2
Treatment group:
s0. copper wires are wound into an air coil 1 shown in figure 1 according to design requirements, pins 1a are arranged at two ends of the coil, the cross section of each copper wire is rectangular, and the shape of each air coil is a racetrack;
s1, filling a layer of magnetic powder into a mold until the bottom of the mold is fully paved;
s2, preforming loose powder blocks 2 by using 60MPa pressure;
s3, transferring the hollow coil 1 into a die, arranging the coils in the die in an equidistant array manner, and pressing the coils into the preformed powder block 2 so that the upper surface of the coil 1 is flush with the upper surface of the powder block 2;
s4, filling magnetic powder into the die until the air coil 1 is completely filled with the magnetic powder, and then pressing the magnetic powder in the filling die to obtain an inductance parent body primary blank 3;
s5, transferring the inductance parent body blank 3 into a hot-pressing die, performing hot pressing, wherein the hot-pressing pressure is 400MPa, the hot-pressing temperature is 100 ℃, the pressure maintaining time is 90 seconds, and performing heat treatment at 180 ℃ for 2 hours to obtain an inductance parent body blank 4;
s6, as shown in FIG. 5, cutting the inductance parent blank 4 according to the design size to obtain a plurality of inductance substrates 5 containing the coils 1, wherein after cutting is completed, coil pins 1a at two ends of the inductance substrates 5 are directly exposed;
s7, as shown in FIG. 7, black insulating paint is rolled on the surface of the inductance matrix 5 to obtain an inductance matrix 6 coated with the insulating paint;
s8, as shown in FIG. 8, removing insulating varnish of the conductive terminal part by laser, and then electroplating the inductance matrix 7 from which the insulating varnish is removed, so as to manufacture an electrode terminal 8a (the electrode terminal is respectively copper, nickel and tin from inside to outside) at the conductive terminal part, thereby obtaining an inductor finished product 8. One side of the electrode terminal 8a is connected to the coil pin 1a, and the other side is led out to the inductor welding surface.
In the embodiment, carbonyl iron powder and ferrosilicon chromium powder are used as magnetic raw powder, the magnetic powder is formed by compounding carbonyl iron powder, ferrosilicon chromium powder, epoxy resin and zinc stearate, the particle size of the magnetic powder is 180-250 microns, the particle size of the carbonyl iron powder is 3-8 microns, and the particle size of the ferrosilicon chromium powder is 5-15 microns.
The manufacturing process of the magnetic powder comprises the following steps:
(a) Carbonyl iron powder and ferrosilicon chromium powder are mixed according to the proportion of 1:1, mixing to obtain mixed raw powder, adding an appropriate amount of acetone solution of phosphoric acid (the mass of phosphoric acid is 0.2 percent of that of the mixed raw powder), fully stirring until the solution volatilizes, and drying the powder to obtain a mixture A;
(b) Adding a mixed solution of epoxy resin and acetone (the mass of the epoxy resin is 3 percent of that of the mixed raw powder) into the mixture A, and fully and uniformly stirring to obtain a mixture B;
(c) Granulating and screening the mixture B by using a swinging granulator to obtain semi-finished magnetic powder with the particle size of 180-250 microns;
(d) Drying the semi-finished magnetic powder at 60 ℃ for 60min;
(e) And adding 0.1% zinc stearate into the dried semi-finished magnetic powder to obtain a finished magnetic powder product.
The inductor manufactured by the processing group in this embodiment has the characteristics of low dc resistance and large rated current, and takes the inductance specification of 2.5×2.0×1.2mm and 1.0 microhenry as an example, and the performance is shown in table 3.
TABLE 3 results of Performance test of inductors prepared by the treatment group of this example
Control group: the inductor is manufactured based on the manufacturing method of the die surface mount inductor disclosed in the prior art CN 105355408A.
(1) Copper wires are wound into an air-core coil 1 shown in figure 1 according to design requirements, and pins 1a are arranged at two ends of the coil;
(2) The base is manufactured by adopting magnetic powder, and comprises a base and N bosses which are arranged on the base and are arranged in an array at intervals, wherein N is more than or equal to 2;
(3) Assembling the air coil 1 and the base: sleeving N air coils 1 on the outer sides of the N bosses in a one-to-one correspondence manner to obtain an assembly of the N air coils 1 and the base, wherein the N air coils 1 in the assembly of the N air coils 1 and the base are also arrayed, and a distance is reserved between every two adjacent air coils 1;
(4) Placing an assembly of N air coils 1 and a base in a die cavity of a cold pressing die, filling magnetic powder into the die cavity, and then performing cold pressing treatment to obtain an inductance parent body primary blank, wherein the pressure of the cold pressing treatment is 120MPa, and the temperature of the cold pressing treatment is not higher than 50 ℃;
(5) Transferring the primary blank of the inductor matrix into a hot-pressing die to sequentially perform hot-pressing treatment and pressure-maintaining treatment, wherein the hot-pressing pressure is 400MPa, the hot-pressing temperature is 100 ℃, the pressure-maintaining time is 90 seconds, and then performing heat treatment at 180 ℃ for 2 hours to obtain a blank of the inductor matrix;
(6) Cutting an inductance matrix blank according to the design size to obtain a plurality of inductance matrixes containing the coils 1, wherein after cutting is finished, coil pins 1a at two ends of the inductance matrixes are directly exposed;
(7) Covering the surface of the inductance matrix 5 with black insulating paint in a spraying mode to obtain an inductance matrix coated with the insulating paint;
(8) And removing the insulating paint of the conductive terminal part by using laser, electroplating the inductance matrix from which the insulating paint is removed, and manufacturing electrode terminals (copper, nickel and tin are respectively arranged on the electrode terminals from inside to outside) at the conductive terminal part to obtain the finished inductor product. One side of the electrode terminal is connected with the coil pin 1a, and the other side is led out to the welding surface of the inductor.
In the above-described process of manufacturing an inductor, the magnetic powder used in the control group of this embodiment is the same as the magnetic powder used in the treatment group of this embodiment.
Taking the specification of the inductor with the external dimension of 2.5×2.0×1.2mm and the inductance of 1.0 microhenry as an example, the performance of the inductor manufactured by the comparison group is shown in table 4.
TABLE 4 results of Performance test of inductors prepared in the control group of this example
In this example, the set treatment group is a specific implementation of the technical solution claimed in the present invention, and the set control group is an implementation of the technical solution reported in the prior art CN 105355408A. Comparing the data presented in tables 3 and 4, the results show that the performance of the inductor manufactured by the treatment group is better, and the inductor manufactured by the treatment group has lower direct current resistance, higher saturation current and higher temperature rise current than the inductor manufactured by the control group on the premise of setting the same inductance.
Example 3
Treatment group:
s0. copper wires are wound into an air coil 1 shown in figure 1 according to design requirements, pins 1a are arranged at two ends of the coil, the cross section of each copper wire is rectangular, and the shape of each air coil is a racetrack;
s1, filling a layer of magnetic powder into a mold until the bottom of the mold is fully paved;
s2, preforming loose powder blocks 2 by using 60MPa pressure;
s3, transferring the hollow coil 1 into a die, arranging the coils in the die in an equidistant array manner, and pressing the coils into the preformed powder block 2 so that the upper surface of the coil 1 is flush with the upper surface of the powder block 2;
s4, filling magnetic powder into the die until the air coil 1 is completely filled with the magnetic powder, and then pressing the magnetic powder in the filling die to obtain an inductance parent body primary blank 3;
s5, transferring the inductance parent body blank 3 into a hot-pressing die, performing hot pressing, wherein the hot-pressing pressure is 350MPa, the hot-pressing temperature is 100 ℃, the pressure maintaining time is 120 seconds, and performing heat treatment at 180 ℃ for 2 hours to obtain an inductance parent body blank 4;
s6, as shown in FIG. 5, cutting the inductance parent blank 4 according to the design size to obtain a plurality of inductance substrates 5 containing the coils 1, wherein after cutting is completed, coil pins 1a at two ends of the inductance substrates 5 are directly exposed;
s7, as shown in FIG. 7, black insulating paint is rolled on the surface of the inductance matrix 5 to obtain an inductance matrix 6 coated with the insulating paint;
s8, as shown in FIG. 8, removing insulating varnish of the conductive terminal part by laser, and then electroplating the inductance matrix 7 from which the insulating varnish is removed, so as to manufacture an electrode terminal 8a (the electrode terminal is respectively copper, nickel and tin from inside to outside) at the conductive terminal part, thereby obtaining an inductor finished product 8. One side of the electrode terminal 8a is connected to the coil pin 1a, and the other side is led out to the inductor welding surface.
In the embodiment, the ferrosilicon powder is used as magnetic raw powder, the magnetic powder is formed by compounding ferrosilicon powder, epoxy resin and lithium stearate, the particle size of the composite magnetic powder is 180-250 microns, and the particle size of the ferrosilicon powder is 5-8 microns.
The manufacturing process of the magnetic powder comprises the following steps:
(a) Adding an appropriate amount of acetone solution of phosphoric acid (phosphoric acid mass: 0.2% of the iron silicon powder mass) into the iron silicon powder, fully stirring until the solution volatilizes, and drying the powder to obtain a mixture A;
(b) Adding a mixed solution of epoxy resin and acetone (the mass of the epoxy resin is 3 percent of the mass of the iron silicon powder) into the mixture A, and fully and uniformly stirring to obtain a mixture B;
(c) Granulating and screening the mixture B by using a swinging granulator to obtain semi-finished magnetic powder with the particle size of 180-250 microns;
(d) Drying the semi-finished magnetic powder at 120 ℃ for 30min;
(e) And adding 0.05% of lithium stearate into the dried semi-finished magnetic powder to obtain a finished magnetic powder product.
The inductor manufactured by the present embodiment has the characteristics of low dc resistance and large rated current, and the performance is shown in table 5 below, taking the specification of inductance with an external dimension of 2.5×2.0×1.2mm and an inductance of 2.2 microhenries as an example.
TABLE 5 Performance test results of inductors prepared by the treatment group of this example
Control group: the inductor is manufactured based on the manufacturing method of the die surface mount inductor disclosed in the prior art CN 105355408A.
(1) Copper wires are wound into an air-core coil 1 shown in figure 1 according to design requirements, and pins 1a are arranged at two ends of the coil;
(2) The base is manufactured by adopting magnetic powder, and comprises a base and N bosses which are arranged on the base and are arranged in an array at intervals, wherein N is more than or equal to 2;
(3) Assembling the air coil 1 and the base: sleeving N air coils 1 on the outer sides of the N bosses in a one-to-one correspondence manner to obtain an assembly of the N air coils 1 and the base, wherein the N air coils 1 in the assembly of the N air coils 1 and the base are also arrayed, and a distance is reserved between every two adjacent air coils 1;
(4) Placing an assembly of N air coils 1 and a base in a die cavity of a cold pressing die, filling magnetic powder into the die cavity, and then performing cold pressing treatment to obtain an inductance parent body primary blank, wherein the pressure of the cold pressing treatment is 150MPa, and the temperature of the cold pressing treatment is not higher than 50 ℃;
(5) Transferring the primary blank of the inductor matrix into a hot-pressing die to sequentially perform hot-pressing treatment and pressure-maintaining treatment, wherein the hot-pressing pressure is 350MPa, the hot-pressing temperature is 100 ℃, the pressure-maintaining time is 120 seconds, and then performing heat treatment at 180 ℃ for 2 hours to obtain a blank of the inductor matrix;
(6) Cutting an inductance matrix blank according to the design size to obtain a plurality of inductance matrixes containing the coils 1, wherein after cutting is finished, coil pins 1a at two ends of the inductance matrixes are directly exposed;
(7) Covering the surface of the inductance matrix 5 with black insulating paint in a spraying mode to obtain an inductance matrix coated with the insulating paint;
(8) And removing the insulating paint of the conductive terminal part by using laser, electroplating the inductance matrix from which the insulating paint is removed, and manufacturing electrode terminals (copper, nickel and tin are respectively arranged on the electrode terminals from inside to outside) at the conductive terminal part to obtain the finished inductor product. One side of the electrode terminal is connected with the coil pin 1a, and the other side is led out to the welding surface of the inductor.
In the above-described process of manufacturing an inductor, the magnetic powder used in the control group of this embodiment is the same as the magnetic powder used in the treatment group of this embodiment.
Taking the specification of the inductor with the external dimension of 2.5 x 2.0 x 1.2mm and the inductance of 2.2 microhenry as an example, the performance of the inductor manufactured by the method of the control group is shown in table 6.
TABLE 6 Performance test results of inductors prepared in the control group of this example
In this example, the set treatment group is a specific implementation of the technical solution claimed in the present invention, and the set control group is an implementation of the technical solution reported in the prior art CN 105355408A. Comparing the data presented in tables 5 and 6, the results show that the performance of the inductor manufactured by the treatment group is better, and the inductor manufactured by the treatment group has lower direct current resistance, higher saturation current and higher temperature rise current than the inductor manufactured by the control group on the premise of setting the same inductance.
Example 4
The method for preparing the inductor by each processing group in this embodiment comprises the following steps:
s0. copper wires are wound into an air coil 1 shown in figure 1 according to design requirements, pins 1a are arranged at two ends of the coil, the cross section of each copper wire is rectangular, and the shape of each air coil is a racetrack;
s1, filling a layer of magnetic powder into a mold until the bottom of the mold is fully paved;
s2, preforming loose powder blocks 2 by using 60MPa pressure;
s3, transferring the hollow coil 1 into a die, arranging the coils in the die in an equidistant array manner, and pressing the coils into the preformed powder block 2 so that the upper surface of the coil 1 is flush with the upper surface of the powder block 2;
s4, filling magnetic powder into the die until the air coil 1 is completely filled with the magnetic powder, and then pressing the magnetic powder in the filling die to obtain an inductance parent body primary blank 3;
s5, transferring the primary blank 3 of the inductor matrix into a hot-pressing die, performing hot pressing, wherein P is used for representing hot-pressing pressure, T is used for representing hot-pressing temperature, T is used for representing dwell time, and then performing heat treatment at 180 ℃ for 2 hours to obtain a blank 4 of the inductor matrix;
s6, as shown in FIG. 5, cutting the inductance parent blank 4 according to the design size to obtain a plurality of inductance substrates 5 containing the coils 1, wherein after cutting is completed, coil pins 1a at two ends of the inductance substrates 5 are directly exposed;
s7, as shown in FIG. 7, black insulating paint is rolled on the surface of the inductance matrix 5 to obtain an inductance matrix 6 coated with the insulating paint;
s8, as shown in FIG. 8, removing insulating varnish of the conductive terminal part by laser, and then electroplating the inductance matrix 7 from which the insulating varnish is removed, so as to manufacture an electrode terminal 8a (the electrode terminal is respectively copper, nickel and tin from inside to outside) at the conductive terminal part, thereby obtaining an inductor finished product 8. One side of the electrode terminal 8a is connected to the coil pin 1a, and the other side is led out to the inductor welding surface.
In this embodiment, different processing sets are set with different combinations of three parameters including a hot pressing pressure P, a hot pressing temperature T, and a dwell time T of hot pressing operations involved in the preparation process of the inductor as variables, so as to explore the influence of the hot pressing operation parameter combinations on the performance of the prepared inductor. The numbers of each treatment group and the corresponding hot pressing parameter combinations are shown in table 7.
TABLE 7 combinations of hot pressing parameters for each treatment group of this example
In the above-described process for producing an inductor, the magnetic powder used in this example was the same as that used in the treatment group of example 1.
Taking the specification of the inductance with an overall dimension of 2.0×1.6×1.0mm (specification 201610-1R 0) as an example, the performance of the inductor manufactured by each processing group in this example is shown in table 8. Test results show that in the hot pressing step of manufacturing the inductor, when three parameters of hot pressing pressure P, hot pressing temperature T and dwell time T meet 2 < P < T/1000000 < 11, a molded inductor finished product can be manufactured, and the manufactured inductor has smaller direct current resistance and good electrical performance, wherein when 9 < P < T/1000000 < 11, a molded inductor can still be manufactured, but the corresponding inductor finished product has slight cracking in the range, and when |P < T/1000000 < 9, the lamination effect of the corresponding inductor is better. When |P.t/1000000| < 2, the DC resistance of the inductor is significantly larger, and when |P.t/1000000| > 11, no shaped inductor product is obtained.
TABLE 8 results of Performance test for each treatment group of this example
Example 5
Treatment group:
s0. copper wires are wound into an air coil 1 shown in figure 1 according to design requirements, pins 1a are arranged at two ends of the coil, the cross section of each copper wire is rectangular, and the shape of each air coil is a racetrack;
s1, uniformly filling a layer of magnetic powder A into a die, and filling a layer of magnetic powder B above the magnetic powder A until the bottom of the die is fully paved;
s2, preforming a loose powder block 2 by using 50MPa pressure, wherein the loose powder block 2 consists of two parts, namely a bottom layer 2a formed by magnetic powder A and a central layer 2B formed by magnetic powder B, as shown in FIG. 10;
s3, transferring the hollow coil 1 into a die, arranging the coils in the die in an equidistant array manner, and pressing the coils into the preformed powder block 2, so that the upper surface of the coil 1 is flush with the upper surface of the powder block 2, and the coil is positioned in a central layer 2B formed by the magnetic powder B, as shown in FIG. 11;
s4, filling magnetic powder A into the die until the air coil 1 is completely filled with the magnetic powder, and then pressing the magnetic powder in the filling die to obtain an inductance parent body primary blank 3;
s5, transferring the inductance parent body blank 3 into a hot-pressing die, performing hot pressing, wherein the hot-pressing pressure is 200MPa, the hot-pressing temperature is 160 ℃, the pressure maintaining time is 120 seconds, and performing heat treatment at 180 ℃ for 2 hours to obtain an inductance parent body blank 4;
s6, as shown in FIG. 5, cutting the inductance parent blank 4 according to the design size to obtain a plurality of inductance substrates 5 containing the coils 1, wherein after cutting is completed, coil pins 1a at two ends of the inductance substrates 5 are directly exposed;
s7, as shown in FIG. 7, black insulating paint is rolled on the surface of the inductance matrix 5 to obtain an inductance matrix 6 coated with the insulating paint;
s8, as shown in FIG. 8, removing insulating varnish of the conductive terminal part by laser, and then electroplating the inductance matrix 7 from which the insulating varnish is removed, so as to manufacture an electrode terminal 8a (the electrode terminal is respectively copper, nickel and tin from inside to outside) at the conductive terminal part, thereby obtaining an inductor finished product 8. One side of the electrode terminal 8a is connected to the coil pin 1a, and the other side is led out to the inductor welding surface.
In the embodiment, the magnetic powder A takes carbonyl iron powder as magnetic raw powder, the magnetic powder A is formed by compounding carbonyl iron powder, epoxy resin and lithium stearate, the particle size of the magnetic powder A is 150-200 microns, and the particle size of the carbonyl iron powder is 3-8 microns.
The manufacturing flow of the magnetic powder A is as follows:
(a) Adding an appropriate amount of acetone solution of phosphoric acid (phosphoric acid mass: carbonyl iron powder mass is 0.1%) into carbonyl iron powder, fully stirring until the solution volatilizes, and drying the powder to obtain a mixture A;
(b) Adding a mixed solution of epoxy resin and acetone (the mass of the epoxy resin is 2% of the mass of carbonyl iron powder) into the mixture A, and fully and uniformly stirring to obtain a mixture B;
(c) Granulating and screening the mixture B by using a swinging granulator to obtain semi-finished magnetic powder with the particle size of 150-200 microns;
(d) Drying the semi-finished magnetic powder at 100 ℃ for 60min;
(e) And adding 0.1% of lithium stearate into the dried semi-finished product magnetic powder to obtain a finished product of the magnetic powder A.
In the embodiment, the magnetic powder B is prepared by compounding carbonyl iron powder, iron-based nanocrystalline powder, epoxy resin and lithium stearate, wherein the particle size of the magnetic powder B is 150-200 microns, the particle size of the carbonyl iron powder is 3-8 microns, and the particle size of the iron-based nanocrystalline powder is 3-6 microns.
The manufacturing flow of the magnetic powder B is as follows:
(a) Uniformly mixing carbonyl iron powder and iron-based nanocrystalline powder to obtain a raw powder mixture, wherein the mass ratio of the carbonyl iron powder to the iron-based nanocrystalline powder is 8:2, adding an appropriate amount of acetone solution of phosphoric acid (the mass of phosphoric acid is 0.1 percent of that of the raw powder mixture) into the raw powder mixture, fully stirring until the solution volatilizes, and drying the powder to obtain a mixture A;
(b) Adding a mixed solution of epoxy resin and acetone (the mass of the epoxy resin is 2% of that of the raw powder mixture) into the mixture A, and fully and uniformly stirring to obtain a mixture B;
(c) Granulating and screening the mixture B by using a swinging granulator to obtain semi-finished magnetic powder with the particle size of 150-200 microns;
(d) Drying the semi-finished magnetic powder at 100 ℃ for 60min;
(e) And adding 0.1% of lithium stearate into the dried semi-finished magnetic powder to obtain a finished product of the magnetic powder B.
The inductor manufactured by the processing set of this embodiment has the characteristics of low dc resistance, large rated current and high quality factor, and takes the inductance specification of 2.0×1.6×1.0mm and 1.0 microhenry of the external dimension as an example, and the performance is shown in table 9.
TABLE 9 results of Performance test of inductors prepared by the treatment group of this example
Control group:
an inductor was fabricated in the manner described in the processing set of example 1 of the present invention.
S0. copper wires are wound into an air coil 1 shown in figure 1 according to design requirements, pins 1a are arranged at two ends of the coil, the cross section of each copper wire is rectangular, and the shape of each air coil is a racetrack;
s1, filling a layer of magnetic powder into a mold until the bottom of the mold is fully paved;
s2, preforming loose powder blocks 2 by using 50MPa pressure;
s3, transferring the hollow coil 1 into a die, arranging the coils in the die in an equidistant array manner, and pressing the coils into the preformed powder block 2 so that the upper surface of the coil 1 is flush with the upper surface of the powder block 2;
s4, filling magnetic powder into the die until the air coil 1 is completely filled with the magnetic powder, and then pressing the magnetic powder in the filling die to obtain an inductance parent body primary blank 3;
s5, transferring the inductance parent body blank 3 into a hot-pressing die, performing hot pressing, wherein the hot-pressing pressure is 200MPa, the hot-pressing temperature is 160 ℃, the pressure maintaining time is 120 seconds, and performing heat treatment at 180 ℃ for 2 hours to obtain an inductance parent body blank 4;
s6, as shown in FIG. 5, cutting the inductance parent blank 4 according to the design size to obtain a plurality of inductance substrates 5 containing the coils 1, wherein after cutting is completed, coil pins 1a at two ends of the inductance substrates 5 are directly exposed;
s7, as shown in FIG. 7, black insulating paint is rolled on the surface of the inductance matrix 5 to obtain an inductance matrix 6 coated with the insulating paint;
s8, as shown in FIG. 8, removing insulating varnish of the conductive terminal part by laser, and then electroplating the inductance matrix 7 from which the insulating varnish is removed, so as to manufacture an electrode terminal 8a (the electrode terminal is respectively copper, nickel and tin from inside to outside) at the conductive terminal part, thereby obtaining an inductor finished product 8. One side of the electrode terminal 8a is connected to the coil pin 1a, and the other side is led out to the inductor welding surface.
In the embodiment, carbonyl iron powder is used as magnetic raw powder, the magnetic powder is compounded by carbonyl iron powder, epoxy resin and lithium stearate, the particle size of the magnetic powder is 150-200 microns, and the particle size of the carbonyl iron powder is 3-8 microns.
The manufacturing process of the magnetic powder comprises the following steps:
(a) Adding an appropriate amount of acetone solution of phosphoric acid (phosphoric acid mass: carbonyl iron powder mass is 0.1%) into carbonyl iron powder, fully stirring until the solution volatilizes, and drying the powder to obtain a mixture A;
(b) Adding a mixed solution of epoxy resin and acetone (the mass of the epoxy resin is 2% of the mass of carbonyl iron powder) into the mixture A, and fully and uniformly stirring to obtain a mixture B;
(c) Granulating and screening the mixture B by using a swinging granulator to obtain semi-finished magnetic powder with the particle size of 150-200 microns;
(d) Drying the semi-finished magnetic powder at 100 ℃ for 60min;
(e) And adding 0.1% of lithium stearate into the dried semi-finished magnetic powder to obtain a finished magnetic powder product.
Table 10 results of performance test of inductors prepared in the comparative group of this example
In this embodiment, the set treatment group and the control group are specific embodiments of the technical scheme claimed in the present invention, and the difference is that the set treatment group adopts a mode of filling and pressing multiple layers of different types of powder, and the main material of the central layer is replaced by the composite magnetic powder of carbonyl iron powder and iron-based amorphous powder. Comparing the data presented in tables 9 and 10, the results show that the performance of the inductor manufactured by the treatment group is better, and the inductor manufactured by the treatment group has higher saturation current and quality factor than the inductor manufactured by the control group under the premise of setting the same inductance.
The above embodiments are only for illustrating the technical solution of the present invention and not for limiting the scope of the present invention, and although the present invention has been described in detail with reference to the preferred embodiments, it should be understood by those skilled in the art that the technical solution of the present invention may be modified or substituted without departing from the spirit and scope of the technical solution of the present invention.
Claims (12)
1. A method of manufacturing an integrally formed inductor, comprising the steps of:
s1, filling magnetic powder into a mold until the bottom of the mold is fully paved;
s2, pre-pressing the magnetic powder filled in the die to form a powder block by pre-forming the magnetic powder, wherein the density of the powder block is not higher than 5g/cm 3 ；
S3, transferring the N air coils into a die, and pressing the air coils into preformed powder blocks so that magnetic powder forming the powder blocks is tightly filled on the inner surface and the outer surface of the air coils;
s4, filling magnetic powder into the die again until the air coil is buried by the magnetic powder, and pressing the magnetic powder filled in the die to form an inductance parent body primary blank;
s5, hot-pressing the inductance parent body primary blank, and then carrying out heat treatment to obtain an inductance parent body blank;
s6, cutting the inductance parent blank to obtain an inductance matrix containing at least one air core coil;
s7, carrying out surface insulation treatment on the surface of the inductance matrix;
s8, removing insulating materials of the conductive terminal part of the hollow wire, exposing the conductive terminal part, and manufacturing an electrode terminal by using the exposed conductive terminal part to obtain an inductor finished product.
2. The method of manufacturing an integrally formed inductor as claimed in claim 1, wherein: in the step S1, the number of times of filling the magnetic powder may be 1 or more, and the types of the magnetic powder to be filled may be the same or different.
3. The method of manufacturing an integrally formed inductor as claimed in claim 1, wherein: in S3, after the air-core coil is pressed into the magnetic powder filled in the mold, the upper surface of the air-core coil is not lower than the upper surface of the magnetic powder filled in the mold.
4. The method of manufacturing an integrally formed inductor as claimed in claim 1, wherein: in the step S3, the number of the hollow coils is not less than 2, and the hollow coils are arranged in the die in an equidistant array.
5. The method of manufacturing an integrally formed inductor as claimed in claim 1, wherein: in the step S4, the number of times of filling the magnetic powder may be 1 or more, and the types of the magnetic powder to be filled may be the same or different.
6. The method of manufacturing an integrally formed inductor as claimed in claim 1, wherein: in the step S5, the hot pressing pressure is 100-1000 MPa, the hot pressing temperature is 80-200 ℃, and the pressure maintaining time is 10-300 seconds.
7. The method of manufacturing an integrally formed inductor as claimed in claim 1, wherein: in S5, the hot pressing pressure is represented by P, the hot pressing temperature is represented by T, the dwell time is represented by T, and P, T, T satisfies the following quantitative relationship: and 2 < P < T >/1000000 < 11 >, wherein the operation unit of P is MPa, the operation unit of T is DEG C, and the operation unit of T is s.
8. The method of manufacturing an integrally formed inductor as claimed in claim 7, wherein: in the step S5, the hot pressing pressure is not more than 600MPa.
9. The method of manufacturing an integrally formed inductor as claimed in claim 1, wherein: in the step S1 to the step S4, the particle size of the magnetic powder used is 50 to 400 μm.
10. The method for manufacturing an integrated inductor according to claim 9, wherein said magnetic powder is prepared from magnetic raw powder, an adhesive and a lubricant according to the following method:
(a) Inorganic coating is carried out on the magnetic raw powder so as to achieve surface insulation modification, and a mixture A is obtained;
(b) Adding a mixed solution of the adhesive and acetone into the mixture A, and uniformly mixing the mixture A and the mixture B according to the mass percent, wherein the addition amount of the adhesive is 1-10% of that of the magnetic raw powder;
(c) Granulating by using the mixture B to obtain semi-finished product powder with the particle size of 50-400 microns;
(d) And drying the semi-finished powder, adding the lubricant into the semi-finished powder, wherein the adding amount of the lubricant is 0.01-1.0% of the semi-finished powder according to the mass percentage, and thus the magnetic powder is prepared.
11. The method of manufacturing an integrally formed inductor as claimed in claim 10, wherein: the particle size of the magnetic raw powder is 1-30 microns, and the magnetic raw powder comprises at least one of carbonyl iron powder, iron silicon chromium powder, iron silicon aluminum powder, iron nickel powder, iron-based amorphous powder and iron-based nanocrystalline powder.
12. An inductor, characterized in that: the inductor manufactured according to any one of claims 1 to 11.
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| CN202210034759.6A CN116487143A (en) | 2022-01-13 | 2022-01-13 | Manufacturing method of integrated inductor and inductor manufactured by using same |
| PCT/CN2022/079895 WO2023133994A1 (en) | 2022-01-13 | 2022-03-09 | Method for manufacturing integrally formed inductor, and inductor prepared by applying same |
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| CN202210034759.6A CN116487143A (en) | 2022-01-13 | 2022-01-13 | Manufacturing method of integrated inductor and inductor manufactured by using same |
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| CN117038298A (en) * | 2023-08-23 | 2023-11-10 | 东莞市三体微电子技术有限公司 | Isolation type inductance row and manufacturing method thereof |
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| DE10155898A1 (en) * | 2001-11-14 | 2003-05-28 | Vacuumschmelze Gmbh & Co Kg | Inductive component and method for its production |
| TW201337984A (en) * | 2012-03-09 | 2013-09-16 | Mag Layers Scient Technics Co | Manufacture process of surface-mount type chip coil |
| CN103280298A (en) * | 2013-05-29 | 2013-09-04 | 深圳顺络电子股份有限公司 | Inductance coil and laser-cutting manufacturing method of inductance coil |
| CN105355408B (en) * | 2015-11-18 | 2018-02-13 | 宁波韵升电子元器件技术有限公司 | A kind of manufacture method of embossing surface attachment inductance |
| CN112435844A (en) * | 2020-12-04 | 2021-03-02 | 横店集团东磁股份有限公司 | Integrated co-fired inductor and preparation method thereof |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN117038298A (en) * | 2023-08-23 | 2023-11-10 | 东莞市三体微电子技术有限公司 | Isolation type inductance row and manufacturing method thereof |
| CN117038298B (en) * | 2023-08-23 | 2024-02-20 | 东莞市三体微电子技术有限公司 | Isolation type inductance row and manufacturing method thereof |
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