CN117894582B - Integrally formed inductor and preparation method thereof - Google Patents

Integrally formed inductor and preparation method thereof Download PDF

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Publication number
CN117894582B
CN117894582B CN202410198926.XA CN202410198926A CN117894582B CN 117894582 B CN117894582 B CN 117894582B CN 202410198926 A CN202410198926 A CN 202410198926A CN 117894582 B CN117894582 B CN 117894582B
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powder
integrally formed
glue
epoxy resin
mixed powder
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CN117894582A (en
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谢方平
刘泓铭
陈维林
舒登明
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Shenzhen Dipu Material Technology Co ltd
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Shenzhen Dipu Material Technology Co ltd
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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/24Magnetic cores
    • H01F27/255Magnetic cores made from particles
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206Manufacturing of magnetic cores by mechanical means
    • H01F41/0246Manufacturing of magnetic circuits by moulding or by pressing powder

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

Abstract

The invention relates to an integrally formed inductor and a preparation method thereof. The preparation method comprises the following steps: preparing soft magnetic powder, first glue and second glue, wherein the soft magnetic powder comprises one or more of iron-based alloy powder, reduced iron powder and carbonyl iron powder, the first glue comprises epoxy resin, modified resin, passivating agent, dispersing agent, coupling agent and solvent, and the second glue comprises curing agent, catalyst, dispersing agent, coupling agent and solvent; mixing the soft magnetic powder with the first glue, granulating after the solvent volatilizes, and granulating to obtain mixed powder A; mixing the soft magnetic powder with the second glue, granulating after the solvent volatilizes, and granulating to obtain mixed powder B; mixing the mixed powder A and the mixed powder B to obtain mixed powder C; carrying out die filling; performing pressure forming; and cooling or solidifying the pressure formed product at room temperature to obtain the inductor. The inductor manufactured by the invention can avoid cracking and provide an inductor with better performance.

Description

Integrally formed inductor and preparation method thereof
Technical Field
The invention relates to the technical field of electronic components, in particular to an integrally formed inductor and a preparation method thereof.
Background
As electronic terminal products continue to develop toward miniaturization, integration, multifunction, high power, etc., conventional plug-in inductors cannot meet the requirements of downstream complete machines, and integrated inductors with small volume, low cost, low loss, excellent shielding performance, high reliability, and suitable for high-density surface mounting are widely used in fields of consumer electronics, digital products, mobile communication, computers, high-resolution televisions, set-top boxes, switches, routers, optical fiber communication devices, broadcasting, satellites, automotive electronics, industrial control, etc., and gradually become the main stream direction of the inductor market. The integrated inductor has the advantages of closed magnetic circuit, good magnetic shielding performance, no interference to surrounding components, no interference to adjacent components, good EMI performance, high-density installation of the components, integrated monolithic structure, high density, good mechanical strength, high reliability, heat resistance, good weldability, regular shape and uniformity, and is suitable for a modern automatic surface mounting assembly line production process. The integrated inductor is an integrated structure inductor which is formed by winding an air coil by a numerical control automatic winding machine, implanting a specific die, filling magnetic core powder, performing high-pressure compression molding, and adding an anti-oxidation coating after high-temperature curing.
The current manufacturing method of the integrally formed inductor generally comprises the steps of mixing soft magnetic powder with liquid glue, granulating after volatilizing a solvent, carrying out pressure forming on a coil and the magnetic powder together through a die, heating, baking and curing after the pressure forming, and manufacturing the inductor under the condition that the curing temperature is 100-180 ℃. However, due to the different thermal expansion coefficients of the copper coil and the soft magnetic powder, side cracks are easy to appear in the heating and curing process due to the expansion of the coil, so that the product is bad, and the function and the application of the inductor are affected.
Accordingly, improvements are needed in the art.
Disclosure of Invention
In the prior art, the copper coil and the soft magnetic powder have different thermal expansion coefficients, so that side cracks are easy to appear due to expansion of the coil in the heating and curing process, the product is bad, and the functions and the application of the inductor are affected.
To achieve the above object, in a first aspect, the present invention provides a method for manufacturing an inductor, which specifically includes the following steps:
S1, preparing raw materials: preparing soft magnetic powder, first glue and second glue, wherein the soft magnetic powder comprises one or more of iron-based alloy powder, reduced iron powder and carbonyl iron powder, the first glue comprises epoxy resin, modified resin, passivating agent, dispersing agent, coupling agent and solvent, and the epoxy resin comprises one or more of bisphenol A epoxy resin, bisphenol F epoxy resin, bisphenol A phenolic epoxy resin and o-methyl phenolic epoxy resin; the second glue comprises a curing agent, a catalyst, a dispersing agent, a coupling agent and a solvent.
S2, mixing soft magnetic powder and glue: mixing soft magnetic powder and the first glue, granulating after the solvent volatilizes, and obtaining mixed powder A; mixing the soft magnetic powder with the second glue, granulating after the solvent volatilizes, and obtaining mixed powder B; mixing the mixed powder A and the mixed powder B to obtain mixed powder C;
S3, die filling: welding a coil on a bracket, placing the coil in an inductor mould, filling the mixed powder C in the inductor mould, and performing pressure forming under a compression bar;
s4, pressure forming: forming the mixture in the inductor mold into a desired shape by pressurizing;
S5, curing: and cooling or solidifying the pressure formed product at room temperature to obtain the inductor.
In one implementation, in S1, the modified resin includes one or more of a nitrile modified epoxy resin, an alkyl modified epoxy resin, a silicone modified epoxy resin, a polyurethane modified epoxy resin, and a dimer acid glycidyl ester.
In one implementation, in S1, the passivating agent includes one or more of a phosphate derivative, an N-acyl sarcosine derivative, an imidazoline derivative.
In one implementation, in S1, the coupling agent is a silane coupling agent containing an amino group or an epoxy group.
In one implementation, in S1, the solvent is one or more of acetone, butanone, methyl butanone, toluene, xylene, methylal.
In one implementation, in S1, the curing agent includes one or more of a polyamide resin, a cycloaliphatic amine epoxy adduct, and a modified mannich amine epoxy adduct, and the catalyst is a lewis base compound.
In one implementation, in S1, the dispersant is a polyether modified polysiloxane or polyacrylate dispersant.
In one implementation, in S2, the mixed powder a and the mixed powder B are as follows (5 to 10): 1 to obtain the mixed powder C.
In one implementation, in S5, the low-temperature curing condition is heating at 50-70 ℃ for 1.5-2.5 hours.
In a second aspect, the present invention further provides an integrally formed inductor, which is manufactured by using the method for manufacturing an integrally formed inductor as described in any one of the above.
The beneficial effects are that: according to the preparation method of the integrally formed inductor, the soft magnetic powder and the glue are mixed step by step, and the integrally formed inductor is manufactured in a room temperature or low temperature curing mode after pressure forming, so that the high temperature curing process in the traditional process is avoided, the problem of side cracking in the heating curing process caused by different thermal expansion coefficients of a copper coil and the soft magnetic powder is avoided, the product yield of the preparation process is increased, and the integrally formed inductor with long service life is provided.
Drawings
Fig. 1 is a flow chart of steps of a method for manufacturing an integrally formed inductor according to the present invention.
The achievement of the objects, functional features and advantages of the present invention will be further described with reference to the accompanying drawings, in conjunction with the embodiments.
Detailed Description
The present invention will be described in further detail with reference to the drawings and examples, in order to make the objects, technical solutions and advantages of the present invention more apparent. It should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the invention. Furthermore, the descriptions of the terms "one embodiment," "some embodiments," "examples," "particular examples," or "some examples," etc., described below mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, schematic representations of the above terms are not necessarily for the same embodiment or example. The technical features of the respective embodiments of the present invention may be combined with each other as long as they do not collide with each other.
Referring specifically to fig. 1, fig. 1 is a flowchart illustrating steps of a method for manufacturing an integrally formed inductor according to the present invention. The invention provides a preparation method of an integrally formed inductor, which specifically comprises the following steps:
S1, preparing raw materials: preparing soft magnetic powder, first glue and second glue, wherein the soft magnetic powder comprises one or more of iron-based alloy powder, reduced iron powder and carbonyl iron powder, the first glue comprises epoxy resin, modified resin, passivating agent, dispersing agent, coupling agent and solvent, and the epoxy resin comprises one or more of bisphenol A epoxy resin, bisphenol F epoxy resin, bisphenol A phenolic epoxy resin and o-methyl phenolic epoxy resin; the second glue comprises a curing agent, a catalyst, a dispersing agent, a coupling agent and a solvent.
S2, mixing soft magnetic powder and glue: mixing soft magnetic powder and the first glue, granulating after the solvent volatilizes, and obtaining mixed powder A; mixing the soft magnetic powder with the second glue, granulating after the solvent volatilizes, and obtaining mixed powder B; mixing the mixed powder A and the mixed powder B to obtain mixed powder C;
S3, die filling: welding a coil on a bracket, placing the coil in an inductor mould, filling the mixed powder C in the inductor mould, and performing pressure forming under a compression bar;
s4, pressure forming: forming the mixture in the inductor mold into a desired shape by pressurizing;
s5, curing: and cooling or solidifying the pressure formed product at room temperature to obtain the integrally formed inductor.
Specifically, in S1, the modified resin includes one or more of nitrile modified epoxy resin, alkyl modified epoxy resin, silicone modified epoxy resin, polyurethane modified epoxy resin, and dimer acid glycidyl ester. The passivating agent comprises one or more of phosphate derivatives, N-acyl sarcosine derivatives and imidazoline derivatives. The coupling agent is a silane coupling agent containing amino or epoxy groups. The solvent is one or more of acetone, butanone, methyl butanone, toluene, xylene and methylal.
Wherein the soft magnetic powder is made of iron or other magnetic materials and can enhance magnetism in the heat treatment process, and specifically comprises ferromagnetic powder, ferrite, nickel-zinc soft magnetic ferrite, nanocrystalline soft magnetic powder and the like. The first glue is used for combining the soft magnetic powder, and the epoxy resin and the modified resin enable the manufactured integrated inductor to have good adhesion, bear high temperature and not have obvious influence on the performance of the integrated inductor.
In the second glue, the curing agent comprises one or more of polyamide resin, alicyclic amine epoxy adduct and modified mannich amine (modified MANNICH AMINE) epoxy adduct, and the catalyst is a Lewis base compound. The dispersing agent is polyether modified polysiloxane or polyacrylate dispersing agent. The coupling agent is a silane coupling agent containing amino or epoxy groups. The solvent is one or more of acetone, butanone, methyl butanone, toluene, xylene and methylal.
In S2, further, the weight ratio of the soft magnetic powder to the first glue is: the magnetic powder comprises soft magnetic powder 100, epoxy resin (2-4), modified resin (2-4), passivating agent (0.1-0.3), dispersing agent (0.1-0.3), coupling agent (0.1-0.3) and solvent; the soft magnetic powder and the first glue are mixed according to the following weight ratio: soft magnetic powder 100, a curing agent (0.1-0.3), a catalyst (0.1-0.3), a dispersing agent (0.1-0.3), a coupling agent (0.1-0.3) and a solvent. The mixed powder A and the mixed powder B are prepared from (5-10): 1 to obtain the mixed powder C. The granulating process of the raw materials comprises the steps of drying and adding an adhesive into the ground powder to obtain mixed powder A and mixed powder B which have good fluidity and particle size of about 0.1 mm.
In S4, the pressurizing condition is 1.8-3.5T/cm 2, and the pressure maintaining time is 50-120S. Specifically, when the mixture in the inductor die is heated to 130-150 ℃, the mixture is softened for 30-60 s, so that compressed air is attached to the surface of the inductor die, and after cooling, the compressed air is used for blowing out a pressure molded product through the bottom of the die.
In the step S5, the low-temperature curing condition is that heating is carried out for 1.5-2.5 hours at the temperature of 50-70 ℃. Preferably, the low temperature curing condition is to heat at a low temperature of 60 ℃ for 2 hours for curing.
The invention also provides an integrally formed inductor which is manufactured by adopting the manufacturing method provided by the invention.
In summary, in the method for manufacturing the integrally formed inductor provided by the invention, the soft magnetic powder and the glue are mixed step by selecting the glue, and the integrally formed inductor is manufactured by adopting a mode of room temperature or low temperature curing after pressure forming, so that the high temperature curing process in the traditional process is avoided, the problem of side cracking in the heating curing process caused by different thermal expansion coefficients of the copper coil and the soft magnetic powder is avoided, the product yield of the manufacturing process is increased, and the integrally formed inductor with long service life is provided.
The foregoing description is only of the preferred embodiments of the present invention and is not intended to limit the scope of the invention, and all equivalent structures or equivalent processes using the descriptions and drawings of the present invention or directly or indirectly applied to other related technical fields are included in the scope of the invention.

Claims (10)

1. The preparation method of the integrally formed inductor is characterized by comprising the following steps of:
s1, preparing raw materials: preparing soft magnetic powder, first glue and second glue, wherein the soft magnetic powder comprises one or more of iron-based alloy powder, reduced iron powder and carbonyl iron powder, the first glue comprises epoxy resin, modified resin, passivating agent, dispersing agent, coupling agent and solvent, and the epoxy resin comprises one or more of bisphenol A epoxy resin, bisphenol F epoxy resin, bisphenol A phenolic epoxy resin and o-methyl phenolic epoxy resin; the second glue comprises a curing agent, a catalyst, a dispersing agent, a coupling agent and a solvent;
S2, mixing soft magnetic powder and glue: mixing soft magnetic powder and the first glue, granulating after the solvent volatilizes, and obtaining mixed powder A; mixing the soft magnetic powder with the second glue, granulating after the solvent volatilizes, and obtaining mixed powder B; mixing the mixed powder A and the mixed powder B to obtain mixed powder C;
S3, die filling: welding a coil on a bracket, placing the coil in an inductor mould, filling the mixed powder C in the inductor mould, and performing pressure forming under a compression bar;
s4, pressure forming: forming the mixture in the inductor mold into a desired shape by pressurizing;
s5, curing: and cooling or solidifying the pressure formed product at room temperature to obtain the integrally formed inductor.
2. The method of manufacturing an integrally formed inductor according to claim 1, wherein in S1, the modified resin includes one or more of nitrile modified epoxy resin, alkyl modified epoxy resin, silicone modified epoxy resin, urethane modified epoxy resin, and glycidyl dimer acid.
3. The method of manufacturing an integrally formed inductor according to claim 1, wherein in S1, the passivating agent includes one or more of a phosphate derivative, an N-acyl sarcosine derivative, and an imidazoline derivative.
4. The method of manufacturing an integrally formed inductor according to claim 1, wherein in S1, the coupling agent is a silane coupling agent containing an amino group or an epoxy group.
5. The method of manufacturing an integrally formed inductor according to claim 1, wherein in S1, the solvent is one or more of acetone, methyl ethyl ketone, toluene, xylene, and methylal.
6. The method of manufacturing an integrally formed inductor according to claim 1, wherein in S1, the curing agent includes one or more of a polyamide resin, a cycloaliphatic amine epoxy adduct, and a modified mannich amine epoxy adduct, and the catalyst is a lewis base compound.
7. The method of manufacturing an integrally formed inductor according to claim 1, wherein in S1, the dispersant is a polyether modified polysiloxane-based or polyacrylate-based dispersant.
8. The method of manufacturing an integrally formed inductor according to claim 1, wherein in S2, the mixed powder a and mixed powder B are mixed in the following amounts (5 to 10): 1 to obtain the mixed powder C.
9. The method of manufacturing an integrally formed inductor according to claim 1, wherein in S5, the low temperature curing is performed under a condition of heating at 50 to 70 ℃ for 1.5 to 2.5 hours.
10. An integrally formed inductor, characterized in that it is manufactured by the method for manufacturing an integrally formed inductor according to any one of claims 1-9.
CN202410198926.XA 2024-02-22 2024-02-22 Integrally formed inductor and preparation method thereof Active CN117894582B (en)

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102007549A (en) * 2008-04-15 2011-04-06 东邦亚铅株式会社 Composite magnetic material and method of manufacturing the same
CN103578679A (en) * 2013-10-28 2014-02-12 任静儿 Soft-magnetic inductive iron core material and manufacturing method

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP5232717B2 (en) * 2009-04-27 2013-07-10 株式会社タムラ製作所 Powder magnetic core and manufacturing method thereof
JP6297281B2 (en) * 2013-05-27 2018-03-20 日東電工株式会社 Soft magnetic resin composition, soft magnetic adhesive film, soft magnetic film laminated circuit board, and position detection device
CN114974872A (en) * 2022-06-21 2022-08-30 苏州锦鳞电子科技有限公司 Molded inductor and manufacturing method thereof
CN115966360A (en) * 2022-11-28 2023-04-14 安徽大学绿色产业创新研究院 Impregnation liquid and application thereof, and preparation method and application of magnetic powder core

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102007549A (en) * 2008-04-15 2011-04-06 东邦亚铅株式会社 Composite magnetic material and method of manufacturing the same
CN103578679A (en) * 2013-10-28 2014-02-12 任静儿 Soft-magnetic inductive iron core material and manufacturing method

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