EP3772070B1 - Inductive component and method for manufacturing an inductive component - Google Patents
Inductive component and method for manufacturing an inductive component Download PDFInfo
- Publication number
- EP3772070B1 EP3772070B1 EP20184972.6A EP20184972A EP3772070B1 EP 3772070 B1 EP3772070 B1 EP 3772070B1 EP 20184972 A EP20184972 A EP 20184972A EP 3772070 B1 EP3772070 B1 EP 3772070B1
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- EP
- European Patent Office
- Prior art keywords
- sintered particles
- binder
- coil
- magnetic core
- mixture
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- 230000001939 inductive effect Effects 0.000 title claims description 60
- 238000000034 method Methods 0.000 title claims description 28
- 238000004519 manufacturing process Methods 0.000 title claims description 22
- 239000002245 particle Substances 0.000 claims description 155
- 239000000203 mixture Substances 0.000 claims description 51
- 239000011230 binding agent Substances 0.000 claims description 50
- 239000000696 magnetic material Substances 0.000 claims description 21
- 239000000463 material Substances 0.000 claims description 21
- 229910000859 α-Fe Inorganic materials 0.000 claims description 19
- 238000005245 sintering Methods 0.000 claims description 12
- 230000001965 increasing effect Effects 0.000 claims description 7
- 230000003213 activating effect Effects 0.000 claims description 3
- 238000003825 pressing Methods 0.000 claims description 3
- 238000010586 diagram Methods 0.000 description 14
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 11
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 10
- 239000000919 ceramic Substances 0.000 description 9
- 238000005259 measurement Methods 0.000 description 8
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 7
- 239000007858 starting material Substances 0.000 description 6
- 239000002699 waste material Substances 0.000 description 6
- 239000011572 manganese Substances 0.000 description 5
- 229910052759 nickel Inorganic materials 0.000 description 5
- 239000002994 raw material Substances 0.000 description 5
- 239000011701 zinc Substances 0.000 description 5
- 229910052725 zinc Inorganic materials 0.000 description 5
- 230000004907 flux Effects 0.000 description 4
- AMWRITDGCCNYAT-UHFFFAOYSA-L hydroxy(oxo)manganese;manganese Chemical compound [Mn].O[Mn]=O.O[Mn]=O AMWRITDGCCNYAT-UHFFFAOYSA-L 0.000 description 4
- 229910052748 manganese Inorganic materials 0.000 description 4
- 239000000843 powder Substances 0.000 description 4
- 238000012545 processing Methods 0.000 description 4
- 239000000725 suspension Substances 0.000 description 4
- 238000012360 testing method Methods 0.000 description 4
- 229910000640 Fe alloy Inorganic materials 0.000 description 3
- 238000009826 distribution Methods 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 239000000758 substrate Substances 0.000 description 3
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 2
- 229910003962 NiZn Inorganic materials 0.000 description 2
- 238000013459 approach Methods 0.000 description 2
- 239000008187 granular material Substances 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000001354 calcination Methods 0.000 description 1
- VTYYLEPIZMXCLO-UHFFFAOYSA-L calcium carbonate Substances [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 1
- 229910000019 calcium carbonate Inorganic materials 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 238000007731 hot pressing Methods 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000012212 insulator Substances 0.000 description 1
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 description 1
- 239000001095 magnesium carbonate Substances 0.000 description 1
- 229910000021 magnesium carbonate Inorganic materials 0.000 description 1
- 239000006247 magnetic powder Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 239000002861 polymer material Substances 0.000 description 1
- 238000004064 recycling Methods 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- JBQYATWDVHIOAR-UHFFFAOYSA-N tellanylidenegermanium Chemical compound [Te]=[Ge] JBQYATWDVHIOAR-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
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- 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
- H01F1/34—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 non-metallic substances, e.g. ferrites
- H01F1/342—Oxides
- H01F1/344—Ferrites, e.g. having a cubic spinel structure (X2+O)(Y23+O3), e.g. magnetite Fe3O4
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- 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
- H01F1/032—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 hard-magnetic materials
- H01F1/04—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 hard-magnetic materials metals or alloys
- H01F1/06—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 hard-magnetic materials metals or alloys in the form of particles, e.g. powder
- H01F1/08—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 hard-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together
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- 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
- H01F1/20—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 in the form of particles, e.g. powder
- H01F1/22—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 in the form of particles, e.g. powder pressed, sintered, or bound together
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- 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
- H01F1/34—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 non-metallic substances, e.g. ferrites
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- 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
- H01F1/34—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 non-metallic substances, e.g. ferrites
- H01F1/36—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 non-metallic substances, e.g. ferrites in the form of particles
- H01F1/37—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 non-metallic substances, e.g. ferrites in the form of particles in a bonding agent
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/04—Fixed inductances of the signal type with magnetic core
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/24—Magnetic cores
- H01F27/255—Magnetic cores made from particles
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- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
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- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/32—Insulating of coils, windings, or parts thereof
- H01F27/327—Encapsulating or impregnating
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- 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
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- 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
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/0206—Manufacturing of magnetic cores by mechanical means
- H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/12—Insulating of windings
- H01F41/127—Encapsulating or impregnating
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- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/04—Fixed inductances of the signal type with magnetic core
- H01F2017/048—Fixed inductances of the signal type with magnetic core with encapsulating core, e.g. made of resin and magnetic powder
Definitions
- the invention relates to a method for producing an inductive component and an inductive component.
- a method for producing an inductive component is known.
- a solid body is successively formed from a coil and several magnetic powders.
- the body is then placed in a furnace and sintered at around 900°C to form the inductive component.
- a method for producing an inductive component is known.
- a coil is placed in a first ceramic suspension with a first ceramic powder, and the first ceramic suspension is cured to form a first ceramic molded body.
- the first ceramic shaped body with the coil is then placed in a second ceramic suspension with a second ceramic powder and the second ceramic suspension is cured to form a second ceramic shaped body.
- the inductive component is formed by firing the shaped bodies.
- a coil device comprising a substrate, a coil, an insulator, a magnetic flux control device and electrodes.
- the substrate, the coil, the insulation and the control component are arranged within a base body made of a magnetic material.
- the invention is based on the object of creating a method that enables simple and inexpensive production of an inductive component with improved electromagnetic properties.
- a base body which includes a magnetic material.
- the magnetic material can be produced, for example, by recycling waste magnetic material or by processing raw material. For example, waste magnetic material may be crushed, filtered, and/or blended and activated into the magnetic material.
- the base body is formed from the magnetic material.
- the base body can be sintered in a simple and cost-effective manner at a comparatively high temperature, since the sintering takes place without the at least one coil and the melting temperature of the material of the at least one coil does not have to be taken into account. After sintering, the sintered base body is crushed, resulting in sintered particles.
- the electromagnetic properties of the inductive component can be influenced by crushing and/or selecting the sintered particles for producing the at least one mixture. At least one mixture is then produced from the sintered particles and a binder. The at least one mixture is arranged in a mold together with the at least one coil and the binder is then activated so that the binder binds the sintered particles together to form at least one magnetic core.
- the formed magnetic core surrounds the at least one coil in the desired manner.
- the at least one magnetic core preferably surrounds the at least one coil with the exception of connection contacts complete. Due to the fact that the sintering takes place without the at least one coil and the sintered particles are connected to the at least one magnetic core by means of the binding agent, the production of the inductive component is simple and inexpensive.
- the sintered particles are preferably separated into first sintered particles and second sintered particles according to their particle shape and/or their particle size.
- the sintered particles are separated according to their particle size, in particular their minimum dimension and/or their maximum dimension, into a first coarse fraction with the first sintered particles and a second fine fraction with second sintered particles that are smaller than the first sintered particles.
- a first mixture is produced from the first sintered particles and a binder.
- a second mixture is correspondingly produced from the second sintered particles and a binder.
- the at least one coil and the first mixture are arranged in a first mold and then the binder in the first mixture is activated so that the first sintered particles with the binder form the first magnetic core.
- the first magnetic core at least partially surrounds the at least one coil.
- the resulting component with the at least one coil and the first magnetic core and the second mixture are arranged in a second mold and then the binder in the second mixture is activated so that the second sintered particles with the binder form the second magnetic core.
- the first magnetic core preferably completely surrounds the at least one coil, with the exception of connection contacts. With the exception of connection contacts, the second magnetic core completely surrounds the first magnetic core and the at least one coil.
- the electromagnetic and/or mechanical properties of the component can be influenced in a desired manner by producing a plurality of magnetic cores with different sintered particles.
- a method according to claim 2 ensures simple and inexpensive production of the inductive component with improved electromagnetic properties.
- the at least one ferrite material is easily and inexpensively available.
- the at least one ferrite material enables high inductance and/or soft saturation.
- the at least one ferrite material enables comparatively lower AC voltage losses (AC losses) and/or comparatively higher voltages in high-voltage tests (AC HiPot test).
- the at least one ferrite material includes in particular manganese (Mn), zinc (Zn) and/or nickel (Ni), for example NiZn and/or MnZn.
- a method according to claim 3 ensures simple and inexpensive production of the inductive component with improved electromagnetic properties. Because the sintering takes place without the at least one coil, sintering is possible at a comparatively high temperature T S . The duration of the sintering process is shorter, the higher the temperature T S is. The sintering time can be shortened accordingly. Sintering affects the electromagnetic properties of the sintered particles. Due to the fact that the temperature T S and the duration of the sintering can be easily and flexibly selected or adjusted are, the electromagnetic properties can be influenced in the desired way.
- a method according to claim 4 ensures simple and inexpensive production of the inductive component with improved electromagnetic properties.
- the sintered particles are processed in such a way that their shape approaches a spherical shape and/or a cube shape.
- the aspect ratios of the sintered particles are at least partially reduced by processing. Due to the fact that the sintered particles approximate the shape of a sphere or cube, the at least one magnetic core has an essentially uniform density and thus essentially uniform electromagnetic properties. In addition, the at least one magnetic core has high mechanical stability since the sintered particles are evenly wetted by the binder.
- a method according to claim 5 ensures simple and inexpensive production of the inductive component with improved electromagnetic properties. Because the sintered particles are processed by means of a ball mill, their shape approaches a spherical shape and/or a cube shape. The aspect ratios of the sintered particles are preferably at least partially reduced as a result of the processing.
- the ball mill comprises a rotating drum in which balls, for example metal balls, are located. The sintered particles are fed to the ball mill as ground material and processed by the balls in the drum in the manner described.
- a method according to claim 6 ensures simple and inexpensive production of the inductive component with improved electromagnetic properties. Because the sintered particles are separated on the basis of particle shape and/or particle size, the sintered particles used for the at least one mixture can be selected in a desired manner. The separation or selection based on the particle shape takes place, for example, such that sintered particles with an aspect ratio A of at least 0.5, in particular at least 0.6, in particular at least 0.7, in particular at least 0.8, and in particular at least 0.9 are separated and used for creating the at least one mixture. Furthermore, the sintered particles are separated based on the particle size, for example, in such a way that a first coarse fraction and a second fine fraction of sintered particles are produced.
- the sintered particles are separated based on the particle size, for example, in such a way that the particle size is in a desired range.
- the electromagnetic properties of the at least one core can be specifically influenced.
- a method according to claim 7 ensures simple and inexpensive production of the inductive component with improved electromagnetic properties.
- at least 80%, in particular at least 90%, and in particular at least 95% of the sintered particles used to produce the at least one mixture have the respective aspect ratio A.
- Aspect ratio A ensures that the sintered particles come as close as possible in shape to a spherical or cube shape.
- the aspect ratio A characterizes the ratio of a minimum dimension A min to a maximum dimension A max of the respective sintered particle.
- the following applies to the aspect ratio A: A A min /A max .
- the aspect ratio A is preferably: 0.5 ⁇ A ⁇ 1, in particular 0.6 ⁇ A ⁇ 0.9, and in particular 0.7 ⁇ A ⁇ 0.8.
- the aspect ratio A can be chosen depending on the desired distribution of the magnetic flux.
- Advantageous properties result from an aspect ratio A ⁇ 0.75.
- a method according to claim 8 ensures simple and inexpensive production of the inductive component with improved electromagnetic properties.
- at least 80%, in particular at least 90%, and in particular at least 95% of the sintered particles used have the respective minimum dimension A min .
- the sintered particles used are preferably separated according to their particle size into a first fraction containing first sintered particles and a second fraction containing second sintered particles.
- For a minimum dimension A 1min of the first sintered particles the following preferably applies: 500 ⁇ m ⁇ A 1min ⁇ 1000 ⁇ m, in particular 600 ⁇ m ⁇ A 1min ⁇ 900 ⁇ m, and in particular 700 ⁇ m ⁇ A 1min ⁇ 800 ⁇ m.
- a minimum dimension A 2min of the second sintered particles the following preferably applies: 10 ⁇ m ⁇ A 2min ⁇ 500 ⁇ m, in particular 100 ⁇ m ⁇ A 1min ⁇ 400 ⁇ m, and in particular 200 ⁇ m ⁇ A 1min ⁇ 300 ⁇ m.
- Preferably at least 70%, in particular at least 80%, in particular at least 90%, and in particular at least 95% of the sintered particles used have the minimum dimension A 1min or A 2min .
- a method according to claim 9 ensures simple and inexpensive production of the inductive component with improved electromagnetic properties.
- the first sintered particles and the second sintered particles preferably differ in their particle shape and/or in their particle size.
- the sintered particles are preferably separated according to their aspect ratio and/or their particle size, in particular their minimum dimension and/or their maximum dimension.
- the electromagnetic properties of the inductive component can be influenced in the desired manner through the targeted selection of the sintered particles used.
- the sintered particles are separated into a first coarse fraction containing first sintered particles and into a second fine fraction containing second sintered particles which are smaller than the first sintered particles.
- a first mixture for forming a first magnetic core and a second mixture for forming a second magnetic core can be produced.
- the first sintered particles are mixed with a binder.
- the second sintered particles are mixed with a binder. The at least one coil and the first mixture are arranged in a mold and then the binder of the first mixture is activated so that the first sintered particles with the binder form the first magnetic core.
- the component obtained with the at least one coil and the first magnetic core is arranged in a second mold together with the second mixture. Then the binder is activated in the second mixture, so that the second sintered particles with the binder have a second form a magnetic core.
- the second magnetic core at least partially surrounds the first magnetic core and the at least one coil.
- a minimum dimension A 1min of the first sintered particles the following preferably applies: 500 ⁇ m ⁇ A 1min ⁇ 1000 ⁇ m, in particular 600 ⁇ m ⁇ A 1min ⁇ 900 ⁇ m, and in particular 700 ⁇ m ⁇ A 1min ⁇ 800 ⁇ m.
- a minimum dimension A 2min of the second sintered particles the following preferably applies: 10 ⁇ m ⁇ A 1min ⁇ 500 ⁇ m, in particular 100 ⁇ m ⁇ A 2min ⁇ 400 ⁇ m, and in particular 200 ⁇ m ⁇ A 1min ⁇ 300 ⁇ m.
- Preferably at least 70%, in particular at least 80%, in particular at least 90%, and in particular at least 95% of the sintered particles used have the minimum dimension A 1min or A 2min .
- the two-stage manufacturing process optimizes the electromagnetic and mechanical properties of the inductive component.
- the electromagnetic properties can be influenced in a desired manner.
- the first magnetic core preferably completely surrounds the at least one coil, with the exception of connection contacts.
- the second magnetic core preferably completely surrounds the first magnetic core and the at least one coil, with the exception of connection contacts.
- the electromagnetic and/or mechanical properties of the component can be influenced in a desired manner by producing a plurality of magnetic cores with different sintered particles. Due to the fact that the comparatively smaller second sintered particles form the second magnetic core lying on the outside, the component has in particular a smooth surface.
- a method according to claim 10 ensures simple and inexpensive production of the inductive component with improved electromagnetic properties.
- the binder is activated in a simple manner by increasing the temperature of the at least one mixture and/or by increasing the pressure on the at least one mixture. By activating the binder, the sintered particles are connected to one another to form the at least one core.
- a polymer material and/or a resin, for example, is used as the binder.
- a method according to claim 11 ensures simple and inexpensive production of the inductive component with improved electromagnetic properties.
- the mass ratio m adjusts the density and/or the air gap of the inductive component in the desired manner.
- a method according to claim 12 ensures simple and inexpensive production of the inductive component with improved electromagnetic properties.
- the base body is easily produced by pressing the magnetic material.
- the magnetic material is preferably in the form of granules and/or powder.
- the magnetic material includes at least one ferrite material.
- the magnetic material is provided such that at least one raw material and/or at least one waste material is processed and/or activated.
- multiple raw materials and/or multiple waste materials are mixed and/or processed.
- waste magnetic materials are recycled.
- the invention is also based on the object of creating an inductive component that can be produced simply, inexpensively and with improved electromagnetic properties.
- the advantages of the inductive component correspond to the advantages of the method already described.
- the inductive component can in particular also be developed with the features of at least one of claims 1 to 12.
- the sintered particles are connected to the activated binder to form the at least one core.
- the sintered particles comprise a magnetic material, in particular at least one ferrite material.
- the sintered particles have a particular particle shape, in particular a particular aspect ratio, and/or a particular particle size, as has already been described in relation to claims 1 to 12 . Reference is made to the relevant features.
- the electromagnetic properties can be influenced in a desired manner by the formation of a plurality of magnetic cores and the selection of the sintered particles used for this purpose.
- An inductive component 1 comprises a coil 2, a first magnetic core 3 and a second magnetic core 4.
- the coil 2 is designed as a cylindrical coil, for example.
- the coil 2 consists of an electrically conductive material.
- the coil 2 has connection contacts 5, 6.
- the first magnetic core 3 surrounds the coil 2.
- the first magnetic core 3 comprises first sintered particles P 1 which are bonded to one another by means of a first binder B 1 .
- the second magnetic core 4 surrounds the first magnetic core 3 and the coil 2.
- the second magnetic core 4 comprises second sintered particles P 2 bonded together by a second binder B 2 .
- the connection contacts 5, 6 are led through the first magnetic core 3 and the second magnetic core 4 to the outside.
- the first sintered particles P 1 each have a minimum dimension A 1min and a maximum dimension A 1max .
- At least 70%, in particular at least 80%, in particular at least 90%, and in particular at least 95% of the first sintered particles P 1 each have a minimum dimension A 1min . where: 500 ⁇ m ⁇ A 1min ⁇ 1000 ⁇ m, in particular 600 ⁇ m ⁇ A 1min ⁇ 900 ⁇ m, and in particular 700 ⁇ m ⁇ A 1min ⁇ 800 ⁇ m.
- At least 70%, in particular at least 80%, in particular at least 90%, and in particular at least 95% of the first sintered particles P 1 have a respective aspect ratio A 1 , where the following applies: 0.5 ⁇ A 1 ⁇ 1, in particular 0.6 ⁇ A 1 ⁇ 1, in particular 0.7 ⁇ A 1 ⁇ 1, in particular 0.8 ⁇ A 1 ⁇ 1, and in particular 0.9 ⁇ A 1 ⁇ 1.
- the aspect ratio A 1 is preferably 0.5 ⁇ A 1 ⁇ 1, in particular 0.6 ⁇ A 1 ⁇ 0.9, and in particular 0.7 ⁇ A 1 ⁇ 0.8.
- the aspect ratio A 1 can be chosen depending on the desired distribution of the magnetic flux. Advantageous properties result from an aspect ratio A 1 ⁇ 0.75.
- the second sintered particles P 2 each have a minimum dimension A 2min and a maximum dimension A 2max .
- At least 70%, in particular at least 80%, in particular at least 90%, and in particular at least 95% of the second sintered particles P 2 have a respective minimum dimension A 2min , where the following applies: 10 ⁇ m ⁇ A 2min ⁇ 500 ⁇ m, in particular 100 ⁇ m ⁇ A 2min ⁇ 400 ⁇ m, and in particular 200 ⁇ m ⁇ A 2min ⁇ 300 ⁇ m.
- At least 70%, in particular at least 80%, in particular at least 90%, and in particular at least 95% of the second sintered particles P 2 have a respective aspect ratio A 2 , where: 0.5 ⁇ A 2 ⁇ 1, in particular 0.6 ⁇ A 2 ⁇ 1, in particular 0.7 ⁇ A 2 ⁇ 1, in particular 0.8 ⁇ A 2 ⁇ 1, and in particular 0.9 ⁇ A 2 ⁇ 1.
- the aspect ratio A 2 is preferably 0.5 ⁇ A 2 ⁇ 1, in particular 0.6 ⁇ A 2 ⁇ 0.9, and in particular 0.7 ⁇ A 2 ⁇ 0.8.
- the aspect ratio A 2 can be chosen depending on the desired distribution of the magnetic flux. Advantageous properties result from an aspect ratio A 2 ⁇ 0.75.
- the first sintered particles P 1 and the second sintered particles P 2 differ in their particle shape or in their aspect ratio A 1 or A 2 and/or in their particle size or in their minimum dimension A 1min or A 2min .
- starting materials R 1 to R n are first mixed together to form a starting material mixture R M .
- the starting materials R 1 to R n are, for example, raw materials and/or waste materials that are to be recycled or reprocessed.
- the Starting materials R 1 to R n include, for example, zinc oxide (ZnO), manganese oxide (MnO) and/or iron oxide.
- the starting material mixture R M is activated and/or calcined in a step S 2 .
- a starting material mixture R M containing calcium and magnesium carbonate is heated for dewatering and/or for decomposition.
- the activated raw material mixture R M forms a magnetic material M from.
- the magnetic material M is, for example, in the form of a powder and/or granules.
- the magnetic material M comprises at least one ferrite material, for example MnZn ferrite material and/or NiZn ferrite material.
- the magnetic material M is pressed into a base body G in a step S 3 .
- the base body G is also referred to as a green body.
- a subsequent step S 4 the base body G is sintered.
- the sintering takes place at a temperature T S , where: T S ⁇ 1000° C., in particular T S ⁇ 1100° C., in particular T S ⁇ 1200° C.
- the sintered body is denoted by G S .
- a step S 5 the sintered base body G S is crushed.
- the crushing takes place, for example, by means of a crushing machine or crushing machine (crusher).
- the comminution produces sintered particles, which are generally denoted by P.
- the sintered particles P each have a minimum dimension A min and a maximum dimension A max that define a respective aspect ratio A .
- A A min /A max .
- the aspect ratios A of the sintered particles P are widely scattered.
- sintered particles P with an elongated shape, which each have a small aspect ratio A also arise during comminution.
- a shape that essentially corresponds to a spherical shape and/or a cube shape is desired.
- a step S 6 the aspect ratios A of the sintered particles P are reduced.
- the maximum dimension A max of each sintered particle P is adjusted to the minimum dimension A min .
- the sintered particles P are processed, for example, using a ball mill.
- the ball mill comprises a drum and metal balls arranged therein.
- the sintered particles P are placed in the drum and processed by further comminution and/or friction due to rotation of the drum by means of the metal balls, so that the aspect ratios A of the sintered particles P are at least partially reduced.
- the sintered particles P are separated based on their particle shape and/or based on their particle size.
- the sintered particles P are separated into a first fraction with first sintered particles P 1 and a second fraction with second sintered particles P 2 .
- the first sintered particles P 1 have the minimum dimension A 1min and the maximum dimension A 1max and the aspect ratio A 1
- the second sintered particles P 2 have the minimum dimension A 2min , the maximum dimension A 2max and the aspect ratio A 2
- the first fraction comprises coarser particles compared to the second fraction. Accordingly, the following applies to at least 70% of the sintered particles P 1 , P 2 : A 1min >A 2min and/or A 1max >A 2min and/or A 1min >A 2max .
- Sintered particles P sorted out in step S 7 which belong neither to the first fraction nor to the second fraction, can be returned and further comminuted in step S 5 and/or further processed in step S 6 . This is in 2 illustrated by the dashed lines.
- a first mixture X 1 is produced from the first sintered particles P 1 and the first binder B 1 .
- a second mixture X 2 is produced from the second sintered particles P 2 and the second binder B 2 .
- the binders B 1 and B 2 can be the same or different.
- the binders B 1 , B 2 are, for example, a polymer plastic and/or a resin.
- the first mixture X 1 has a mass ratio m 1 of the mass m P1 of the first sintered particles P 1 to the mass m B1 of the first binder B 1 .
- the following preferably applies to the mass ratio m 1 : 75/25 ⁇ m 1 ⁇ 99/1, in particular 80/20 ⁇ m 1 ⁇ 98/2, and 85/15 ⁇ m 1 ⁇ 95/5.
- the second mixture X 2 has a mass ratio m 2 of the mass m P2 of the second sintered particles P 2 to the mass m B2 of the second binder B 2 .
- m 2 m P2 /m B2 applies to the mass ratio m 2 .
- the mass ratio m 2 is preferably: 75/25 ⁇ m 2 ⁇ 99/1, in particular 80/20 ⁇ m 2 ⁇ 98/2, and 85/15 ⁇ m 2 ⁇ 95/5.
- the mass ratio is generally denoted by m.
- a step S 9 the first mixture X 1 and the coil 2 are arranged in a first mold Fi.
- the first binder B 1 is activated so that the first binder B 1 binds the first sintered particles P 1 to form the first magnetic core 3 .
- a pressure p 1 on the first mixture X 1 and/or a temperature T 1 of the first mixture X 1 is increased.
- the first magnetic core 3 with the coil 2 is removed from the mold.
- a subsequent step S 10 the first magnetic core 3 with the coil 2 and the second mixture X 2 is arranged in a second mold F 2 .
- the second binder B 2 is activated so that the second binder B 2 binds the second sintered particles P 2 into the second magnetic core 4 .
- the second binder B 2 is activated by increasing a pressure p 2 on the second mixture X 2 and/or by increasing a temperature T 2 of the second mixture X 2 .
- the second core 4 is demoulded with the first magnetic core 3 and the coil 2 .
- the inductive component 1 is provided by demoulding.
- 3 illustrates measurement curves for the quality factor Q (Q value) at frequencies f of 100 kHz, 500 kHz and 1 MHz over time t.
- the quality factor Q of the inductive components 1 according to the invention (cf. middle and lower diagram) is more constant over time t than the inductive component according to the prior art (cf. upper diagram).
- 3 smoothed measurement curves which should enable a simpler comparison with regard to the constancy of the quality factors Q.
- the components 1 according to the invention hardly age thermally and thus ensure that the behavior of an electrical circuit with the inductive components 1 according to the invention does not change as a result of parameters changing over time t, such as the quality factor Q or the AC power loss P AC and their function does not is impaired.
- a comparison of the measurement curves in figure 5 with the measurement curves in 6 makes it clear that the quality factor Q of the inductive component 1 according to the invention hardly changes over time t and the components 1 according to the invention hardly age thermally.
- the inductive component 1 has at least one coil 2 .
- the inductive component 1 preferably has exactly one coil or exactly two coils.
- the sintered particles P produced by crushing the sintered base body Gs can be processed, separated and/or selected in any way.
- the order of the steps mentioned is arbitrary.
- Known filters and/or sieves and/or separators can be used for separating and/or selecting.
- the electromagnetic properties of the inductive component 1 can be set in the desired manner. In particular, the inductance, the saturation behavior and/or the air gap can be adjusted.
- the binder B can be activated by cold pressing or hot pressing.
- the magnetic material M and thus the at least one magnetic core 3, 4 preferably includes at least one ferrite material.
- Ferrite material is inexpensive and readily available. Comparatively good electromagnetic properties of the inductive component 1 are achieved through the use of ferrite material.
- the inductive component 1 has a high inductance, a desired saturation behavior, low losses and/or can be operated with a high voltage.
- Such inductive components 1 pass, for example, a high-voltage test (AC HiPot test) at a voltage of 3 kV AC (3 mA, 3 seconds).
- the sintered particles are generally denoted by P.
- the aspect ratio is generally denoted by A.
- the minimum dimension is generally denoted A min .
- the maximum dimension is generally denoted by A max .
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Description
Die Erfindung betrifft ein Verfahren zur Herstellung eines induktiven Bauteils sowie ein induktives Bauteil.The invention relates to a method for producing an inductive component and an inductive component.
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Der Erfindung liegt die Aufgabe zugrunde, ein Verfahren zu schaffen, das eine einfache und kostengünstige Herstellung eines induktiven Bauteils mit verbesserten elektromagnetischen Eigenschaften ermöglicht.The invention is based on the object of creating a method that enables simple and inexpensive production of an inductive component with improved electromagnetic properties.
Diese Aufgabe wird durch ein Verfahren mit den Merkmalen des Anspruchs 1 gelöst. Zunächst wird ein Grundkörper bereitgestellt, der ein magnetisches Material umfasst. Das magnetische Material kann beispielsweise durch das Wiederaufbereiten von magnetischem Abfallmaterial oder durch das Aufbereiten von Rohmaterial erzeugt werden. Beispielsweise kann magnetisches Abfallmaterial zerkleinert, gefiltert und/oder gemischt werden und zu dem magnetischen Material aktiviert werden. Der Grundkörper wird insbesondere aus dem magnetischen Material geformt. Das Sintern des Grundkörpers kann in einfacher und kostengünstiger Weise bei einer vergleichsweise hohen Temperatur erfolgen, da das Sintern ohne die mindestens eine Spule erfolgt und die Schmelztemperatur des Materials der mindestens einen Spule nicht beachtet werden muss. Nach dem Sintern wird der gesinterte Grundkörper zerkleinert, so dass gesinterte Partikel entstehen. Durch das Zerkleinern und/oder das Auswählen der gesinterten Partikel für das Erzeugen der mindestens einen Mischung können die elektromagnetischen Eigenschaften des induktiven Bauteils beeinflusst werden. Anschließend wird aus den gesinterten Partikeln und einem Bindemittel mindestens eine Mischung erzeugt. Die mindestens eine Mischung wird zusammen mit der mindestens einer Spule in einer Form angeordnet und anschließend das Bindemittel aktiviert, so dass das Bindemittel die gesinterten Partikel zu mindestens einem magnetischen Kern verbindet. Der ausgebildete magnetische Kern umgibt die mindestens eine Spule in der gewünschten Weise. Vorzugsweise umgibt der mindestens eine magnetische Kern die mindestens eine Spule mit Ausnahme von Anschlusskontakten vollständig. Dadurch, dass das Sintern ohne die mindestens eine Spule erfolgt und die gesinterten Partikel mittels des Bindemittels zu dem mindestens einen magnetischen Kern verbunden werden, ist die Herstellung des induktiven Bauteils einfach und kostengünstig. Durch das Zerkleinern des gesinterten Grundkörpers und die Auswahl der zum Erzeugen der mindestens einen Mischung verwendeten gesinterten Partikel können die elektromagnetischen Eigenschaften des induktiven Bauteils gezielt beeinflusst werden.This object is achieved by a method having the features of
Die gesinterten Partikel werden vorzugsweise nach ihrer Partikelform und/oder ihrer Partikelgröße in erste gesinterte Partikel und zweite gesinterte Partikel separiert. Die gesinterten Partikel werden nach ihrer Partikelgröße, insbesondere ihrer minimalen Abmessung und/oder ihrer maximalen Abmessung, in eine erste grobe Fraktion mit den ersten gesinterten Partikeln und eine zweite feine Fraktion mit im Vergleich zu den ersten gesinterten Partikeln kleineren zweiten gesinterten Partikeln separiert. Aus den ersten gesinterten Partikeln und einem Bindemittel wird eine erste Mischung erzeugt. Entsprechend wird aus den zweiten gesinterten Partikeln und einem Bindemittel eine zweite Mischung erzeugt. Die mindestens eine Spule und die erste Mischung werden in einer ersten Form angeordnet und anschließend das Bindemittel in der ersten Mischung aktiviert, so dass die ersten gesinterten Partikel mit dem Bindemittel den ersten magnetischen Kern ausbilden. Der erste magnetische Kern umgibt die mindestens eine Spule zumindest teilweise. Das entstandene Bauteil mit der mindestens einen Spule und dem ersten magnetischen Kern und die zweite Mischung werden in einer zweiten Form angeordnet und anschließend das Bindemittel in der zweiten Mischung aktiviert, so dass die zweiten gesinterten Partikel mit dem Bindemittel den zweiten magnetischen Kern ausbilden. Vorzugsweise umgibt der erste magnetische Kern die mindestens eine Spule mit Ausnahme von Anschlusskontakten vollständig. Der zweite magnetische Kern umgibt mit Ausnahme von Anschlusskontakten den ersten magnetischen Kern und die mindestens eine Spule vollständig. Durch das Erzeugen mehrerer magnetischer Kerne mit sich unterscheidenden gesinterten Partikeln können die elektromagnetischen und/oder mechanischen Eigenschaften des Bauteils in gewünschter Weise beeinflusst werden.The sintered particles are preferably separated into first sintered particles and second sintered particles according to their particle shape and/or their particle size. The sintered particles are separated according to their particle size, in particular their minimum dimension and/or their maximum dimension, into a first coarse fraction with the first sintered particles and a second fine fraction with second sintered particles that are smaller than the first sintered particles. A first mixture is produced from the first sintered particles and a binder. A second mixture is correspondingly produced from the second sintered particles and a binder. The at least one coil and the first mixture are arranged in a first mold and then the binder in the first mixture is activated so that the first sintered particles with the binder form the first magnetic core. The first magnetic core at least partially surrounds the at least one coil. The resulting component with the at least one coil and the first magnetic core and the second mixture are arranged in a second mold and then the binder in the second mixture is activated so that the second sintered particles with the binder form the second magnetic core. The first magnetic core preferably completely surrounds the at least one coil, with the exception of connection contacts. With the exception of connection contacts, the second magnetic core completely surrounds the first magnetic core and the at least one coil. The electromagnetic and/or mechanical properties of the component can be influenced in a desired manner by producing a plurality of magnetic cores with different sintered particles.
Ein Verfahren nach Anspruch 2 gewährleistet eine einfache und kostengünstige Herstellung des induktiven Bauteils mit verbesserten elektromagnetischen Eigenschaften. Das mindestens eine Ferritmaterial ist einfach und kostengünstig verfügbar. Das mindestens eine Ferritmaterial ermöglicht eine hohe Induktivität und/oder eine weiche Sättigung. Das mindestens eine Ferritmaterial ermöglicht vergleichsweise geringere Wechselspannungsverluste (AC Losses) und/oder vergleichsweise höhere Spannungen bei Hochspannungstests (AC HiPot test). Das mindestens eine Ferritmaterial umfasst insbesondere Mangan (Mn), Zink (Zn) und/oder Nickel (Ni), beispielsweise NiZn und/oder MnZn.A method according to
Ein Verfahren nach Anspruch 3 gewährleistet eine einfache und kostengünstige Herstellung des induktiven Bauteils mit verbesserten elektromagnetischen Eigenschaften. Dadurch, dass das Sintern ohne die mindestens eine Spule erfolgt, ist das Sintern mit einer vergleichsweise hohen Temperatur TS möglich. Die Zeitdauer des Sintervorgangs ist umso kürzer, je höher die Temperatur TS ist. Die Zeitdauer des Sintervorgangs kann dementsprechend verkürzt werden. Das Sintern beeinflusst die elektromagnetischen Eigenschaften der gesinterten Partikel. Dadurch, dass die Temperatur TS und die Zeitdauer des Sinterns einfach und flexibel wählbar bzw. einstellbar sind, können die elektromagnetischen Eigenschaften in gewünschter Weise beeinflusst werden.A method according to
Ein Verfahren nach Anspruch 4 gewährleistet eine einfache und kostengünstige Herstellung des induktiven Bauteils mit verbesserten elektromagnetischen Eigenschaften. Das Aspektverhältnis charakterisiert das Verhältnis einer minimalen Abmessung Amin zu einer maximalen Abmessung Amax des jeweiligen gesinterten Partikels. Für das Aspektverhältnis A gilt somit: A = Amin/Amax. Vor dem Erzeugen der mindestens einen Mischung werden die gesinterten Partikel derart bearbeitet, dass sich ihre Form einer Kugelform und/oder Würfelform annähert. Die Aspektverhältnisse der gesinterten Partikel werden durch eine Bearbeitung zumindest teilweise verkleinert. Dadurch, dass die gesinterten Partikel ihre Form einer Kugelform bzw. Würfelform annähern, weist der mindestens eine magnetische Kern eine im Wesentlichen gleichmäßige Dichte und somit im Wesentlichen gleichmäßige elektromagnetische Eigenschaften auf. Darüber hinaus weist der mindestens eine magnetische Kern eine hohe mechanische Stabilität auf, da die gesinterten Partikel von dem Bindemittel gleichmäßig benetzt werden.A method according to
Ein Verfahren nach Anspruch 5 gewährleistet eine einfache und kostengünstige Herstellung des induktiven Bauteils mit verbesserten elektromagnetischen Eigenschaften. Dadurch, dass die gesinterten Partikel mittels einer Kugelmühle bearbeitet werden, nähert sich ihre Form einer Kugelform und/oder Würfelform an. Durch das Bearbeiten werden vorzugsweise die Aspektverhältnisse der gesinterten Partikel zumindest teilweise verkleinert. Die Kugelmühle umfasst eine rotierende Trommel, in der sich Kugeln, beispielsweise Metallkugeln, befinden. Die gesinterten Partikel werden als Mahlgut der Kugelmühle zugeführt und von den Kugeln in der Trommel in der beschriebenen Weise bearbeitet.A method according to
Ein Verfahren nach Anspruch 6 gewährleistet eine einfache und kostengünstige Herstellung des induktiven Bauteils mit verbesserten elektromagnetischen Eigenschaften. Dadurch, dass die gesinterten Partikel anhand der Partikelform und/oder der Partikelgröße separiert werden, können die für die mindestens eine Mischung verwendeten gesinterten Partikel in gewünschter Weise ausgewählt werden. Das Separieren bzw. Auswählen anhand der Partikelform erfolgt beispielsweise derart, dass gesinterte Partikel mit einem Aspektverhältnis A von mindestens 0,5, insbesondere mindestens 0,6, insbesondere mindestens 0,7, insbesondere mindestens 0,8, und insbesondere mindestens 0,9 separiert und für das Erzeugen der mindestens einen Mischung verwendet werden. Weiterhin werden die gesinterten Partikel anhand der Partikelgröße beispielsweise derart separat, dass eine erste grobe Fraktion und eine zweite feine Fraktion von gesinterten Partikeln erzeugt werden. Weiterhin werden die gesinterten Partikel anhand der Partikelgröße beispielsweise derart separiert, dass die Partikelgröße in einem gewünschten Bereich liegt. Durch die Auswahl der gesinterten Partikel nach ihrer Partikelform und/oder Partikelgröße können die elektromagnetischen Eigenschaften des mindestens einen Kerns gezielt beeinflusst werden.A method according to
Ein Verfahren nach Anspruch 7 gewährleistet eine einfache und kostengünstige Herstellung des induktiven Bauteils mit verbesserten elektromagnetischen Eigenschaften. Vorzugsweise haben mindestens 80 %, insbesondere mindestens 90 %, und insbesondere mindestens 95 % der zum Erzeugen der mindestens einen Mischung verwendeten gesinterten Partikel das jeweilige Aspektverhältnis A. Das Aspektverhältnis A gewährleistet, dass die gesinterten Partikel in ihrer Form einer Kugelform bzw. Würfelform möglichst nahekommen. Das Aspektverhältnis A charakterisiert das Verhältnis einer minimalen Abmessung Amin zu einer maximalen Abmessung Amax des jeweiligen gesinterten Partikels. Für das Aspektverhältnis A gilt: A = Amin/Amax. Vorzugsweise gilt für das Aspektverhältnis A: 0,5 ≤ A ≤ 1, insbesondere 0,6 ≤ A ≤ 0,9, und insbesondere 0,7 ≤ A ≤ 0,8. Das Aspektverhältnis A kann in Abhängigkeit der gewünschten Verteilung des magnetischen Flusses gewählt werden. Vorteilhafte Eigenschaften ergeben sich bei einem Aspektverhältnis A ≈ 0,75.A method according to claim 7 ensures simple and inexpensive production of the inductive component with improved electromagnetic properties. Preferably at least 80%, in particular at least 90%, and in particular at least 95% of the sintered particles used to produce the at least one mixture have the respective aspect ratio A. Aspect ratio A ensures that the sintered particles come as close as possible in shape to a spherical or cube shape. The aspect ratio A characterizes the ratio of a minimum dimension A min to a maximum dimension A max of the respective sintered particle. The following applies to the aspect ratio A: A=A min /A max . The aspect ratio A is preferably: 0.5≦A≦1, in particular 0.6≦A≦0.9, and in particular 0.7≦A≦0.8. The aspect ratio A can be chosen depending on the desired distribution of the magnetic flux. Advantageous properties result from an aspect ratio A≈0.75.
Ein Verfahren nach Anspruch 8 gewährleistet eine einfache und kostengünstige Herstellung des induktiven Bauteils mit verbesserten elektromagnetischen Eigenschaften. Vorzugsweise haben mindestens 80 %, insbesondere mindestens 90 %, und insbesondere mindestens 95 % der verwendeten gesinterten Partikel die jeweilige minimale Abmessung Amin. Vorzugsweise werden die verwendeten gesinterten Partikel nach ihrer Partikelgröße in eine erste Fraktion mit ersten gesinterten Partikeln und in eine zweite Fraktion mit zweiten gesinterten Partikeln separiert. Für eine minimale Abmessung A1min der ersten gesinterten Partikel gilt vorzugsweise: 500 µm ≤ A1min ≤ 1000 µm, insbesondere 600 µm ≤ A1min ≤ 900 µm, und insbesondere 700 µm ≤ A1min ≤ 800 µm. Für eine minimale Abmessung A2min der zweiten gesinterten Partikel gilt vorzugsweise: 10 µm ≤ A2min ≤ 500 µm, insbesondere 100 µm ≤ A1min ≤ 400 µm, und insbesondere 200 µm ≤ A1min ≤ 300 µm. Vorzugsweise haben mindestens 70 %, insbesondere mindestens 80 %, insbesondere mindestens 90 %, und insbesondere mindestens 95 % der verwendeten gesinterten Partikel die minimale Abmessung A1min bzw. A2min.A method according to claim 8 ensures simple and inexpensive production of the inductive component with improved electromagnetic properties. Preferably at least 80%, in particular at least 90%, and in particular at least 95% of the sintered particles used have the respective minimum dimension A min . The sintered particles used are preferably separated according to their particle size into a first fraction containing first sintered particles and a second fraction containing second sintered particles. For a minimum dimension A 1min of the first sintered particles, the following preferably applies: 500 μm≦A 1min ≦1000 μm, in particular 600 μm≦A 1min ≦900 μm, and in particular 700 μm≦A 1min ≦800 μm. For a minimum dimension A 2min of the second sintered particles, the following preferably applies: 10 μm≦A 2min ≦500 μm, in particular 100 μm≦A 1min ≦400 μm, and in particular 200 μm≦A 1min ≦300 μm. Preferably at least 70%, in particular at least 80%, in particular at least 90%, and in particular at least 95% of the sintered particles used have the minimum dimension A 1min or A 2min .
Ein Verfahren nach Anspruch 9 gewährleistet eine einfache und kostengünstige Herstellung des induktiven Bauteils mit verbesserten elektromagnetischen Eigenschaften. Vorzugsweise unterscheiden sich die ersten gesinterten Partikel und die zweiten gesinterten Partikel in ihrer Partikelform und/oder in ihrer Partikelgröße. Vorzugsweise werden die gesinterten Partikel nach ihrem Aspektverhältnis und/oder ihrer Partikelgröße, insbesondere ihrer minimalen Abmessung und/oder ihrer maximalen Abmessung separiert. Durch die gezielte Auswahl der verwendeten gesinterten Partikel können die elektromagnetischen Eigenschaften des induktiven Bauteils in gewünschter Weise beeinflusst werden.A method according to claim 9 ensures simple and inexpensive production of the inductive component with improved electromagnetic properties. The first sintered particles and the second sintered particles preferably differ in their particle shape and/or in their particle size. The sintered particles are preferably separated according to their aspect ratio and/or their particle size, in particular their minimum dimension and/or their maximum dimension. The electromagnetic properties of the inductive component can be influenced in the desired manner through the targeted selection of the sintered particles used.
Vorzugsweise werden die gesinterten Partikel in eine erste grobe Fraktion mit ersten gesinterten Partikeln und in eine zweite feine Fraktion mit im Vergleich zu den ersten gesinterten Partikeln kleineren zweiten gesinterten Partikeln separiert. Dadurch, dass die gesinterten Partikel in eine erste grobe Fraktion und eine zweite feine Fraktion separiert werden, können eine erste Mischung zur Ausbildung eines ersten magnetischen Kerns und eine zweite Mischung zur Ausbildung eines zweiten magnetischen Kerns erzeugt werden. Zum Erzeugen der ersten Mischung werden die ersten gesinterten Partikel mit einem Bindemittel gemischt. Entsprechend werden zum Erzeugen der zweiten Mischung die zweiten gesinterten Partikel mit einem Bindemittel gemischt. Die mindestens eine Spule und die erste Mischung werden in einer Form angeordnet und anschließend das Bindemittel der ersten Mischung aktiviert, so dass die ersten gesinterten Partikel mit dem Bindemittel den ersten magnetischen Kern ausbilden. Das erhaltene Bauteil mit der mindestens einen Spule und dem ersten magnetischen Kern wird zusammen mit der zweiten Mischung in einer zweiten Form angeordnet. Anschließend wird das Bindemittel in der zweiten Mischung aktiviert, so dass die zweiten gesinterten Partikel mit dem Bindemittel einen zweiten magnetischen Kern ausbilden. Der zweite magnetische Kern umgibt den ersten magnetischen Kern und die mindestens eine Spule zumindest teilweise.Preferably, the sintered particles are separated into a first coarse fraction containing first sintered particles and into a second fine fraction containing second sintered particles which are smaller than the first sintered particles. By separating the sintered particles into a first coarse fraction and a second fine fraction, a first mixture for forming a first magnetic core and a second mixture for forming a second magnetic core can be produced. To create the first mixture, the first sintered particles are mixed with a binder. Similarly, to create the second mixture, the second sintered particles are mixed with a binder. The at least one coil and the first mixture are arranged in a mold and then the binder of the first mixture is activated so that the first sintered particles with the binder form the first magnetic core. The component obtained with the at least one coil and the first magnetic core is arranged in a second mold together with the second mixture. Then the binder is activated in the second mixture, so that the second sintered particles with the binder have a second form a magnetic core. The second magnetic core at least partially surrounds the first magnetic core and the at least one coil.
Für eine minimale Abmessung A1min der ersten gesinterten Partikel gilt vorzugsweise: 500 µm ≤ A1min ≤ 1000 µm, insbesondere 600 µm ≤ A1min ≤ 900 µm, und insbesondere 700 µm ≤ A1min ≤ 800 µm. Für eine minimale Abmessung A2min der zweiten gesinterten Partikel gilt vorzugsweise: 10 µm ≤ A1min ≤ 500 µm, insbesondere 100 µm ≤ A2min ≤ 400 µm, und insbesondere 200 µm ≤ A1min ≤ 300 µm. Vorzugsweise haben mindestens 70 %, insbesondere mindestens 80 %, insbesondere mindestens 90 %, und insbesondere mindestens 95 % der verwendeten gesinterten Partikel die minimale Abmessung A1min bzw. A2min.For a minimum dimension A 1min of the first sintered particles, the following preferably applies: 500 μm≦A 1min ≦1000 μm, in particular 600 μm≦A 1min ≦900 μm, and in particular 700 μm≦A 1min ≦800 μm. For a minimum dimension A 2min of the second sintered particles, the following preferably applies: 10 μm≦A 1min ≦500 μm, in particular 100 μm≦A 2min ≦400 μm, and in particular 200 μm≦A 1min ≦300 μm. Preferably at least 70%, in particular at least 80%, in particular at least 90%, and in particular at least 95% of the sintered particles used have the minimum dimension A 1min or A 2min .
Durch das zweistufige Herstellungsverfahren werden die elektromagnetischen und mechanischen Eigenschaften des induktiven Bauteils optimiert. Durch die Aufteilung der gesinterten Partikel in mehrere Fraktionen und die Auswahl und Aufteilung der gesinterten Partikel können die elektromagnetischen Eigenschaften in gewünschter Weise beeinflusst werden. Vorzugsweise umgibt der erste magnetische Kern die mindestens eine Spule mit Ausnahme von Anschlusskontakten vollständig. Vorzugsweise umgibt der zweite magnetische Kern mit Ausnahme von Anschlusskontakten den ersten magnetischen Kern und die mindestens eine Spule vollständig. Durch das Erzeugen mehrerer magnetischer Kerne mit sich unterscheidenden gesinterten Partikeln können die elektromagnetischen und/oder mechanischen Eigenschaften des Bauteils in gewünschter Weise beeinflusst werden. Dadurch, dass die vergleichsweise kleineren zweiten gesinterten Partikel den außenliegenden zweiten magnetischen Kern ausbilden, hat das Bauteil insbesondere eine glatte Oberfläche.The two-stage manufacturing process optimizes the electromagnetic and mechanical properties of the inductive component. By dividing the sintered particles into several fractions and by selecting and dividing the sintered particles, the electromagnetic properties can be influenced in a desired manner. The first magnetic core preferably completely surrounds the at least one coil, with the exception of connection contacts. The second magnetic core preferably completely surrounds the first magnetic core and the at least one coil, with the exception of connection contacts. The electromagnetic and/or mechanical properties of the component can be influenced in a desired manner by producing a plurality of magnetic cores with different sintered particles. Due to the fact that the comparatively smaller second sintered particles form the second magnetic core lying on the outside, the component has in particular a smooth surface.
Ein Verfahren nach Anspruch 10 gewährleistet eine einfache und kostengünstige Herstellung des induktiven Bauteils mit verbesserten elektromagnetischen Eigenschaften. Das Bindemittel wird in einfacher Weise durch Erhöhen der Temperatur der mindestens einen Mischung und/oder durch Erhöhen des Drucks auf die mindestens eine Mischung aktiviert. Durch das Aktivieren des Bindemittels werden die gesinterten Partikel miteinander zu dem mindestens einen Kern verbunden. Als Binder wird beispielsweise ein Polymermaterial und/oder ein Harz verwendet.A method according to
Ein Verfahren nach Anspruch 11 gewährleistet eine einfache und kostengünstige Herstellung des induktiven Bauteils mit verbesserten elektromagnetischen Eigenschaften. Durch das Massenverhältnis m wird die Dichte und/oder der Luftspalt des induktiven Bauteils in gewünschter Weise eingestellt. Das Massenverhältnis m beschreibt das Verhältnis der Masse mP der gesinterten Partikel zu der Masse mB des Bindemittels. Für das Massenverhältnis m gilt: m = mP/mB. Mit einem höheren Massenanteil der gesinterten Partikel zu dem Bindemittel steigt die Dichte und/oder verringert sich der Luftspalt des induktiven Bauteils und umgekehrt. Die Dichte und/oder der Luftspalt beeinflussen das Sättigungsverhalten des induktiven Bauteils.A method according to claim 11 ensures simple and inexpensive production of the inductive component with improved electromagnetic properties. The mass ratio m adjusts the density and/or the air gap of the inductive component in the desired manner. The mass ratio m describes the ratio of the mass m P of the sintered particles to the mass m B of the binder. The following applies to the mass ratio m: m = m P /m B . With a higher mass fraction of the sintered particles to the binder, the density increases and/or the air gap of the inductive component decreases and vice versa. The density and/or the air gap influence the saturation behavior of the inductive component.
Ein Verfahren nach Anspruch 12 gewährleistet eine einfache und kostengünstige Herstellung des induktiven Bauteils mit verbesserten elektromagnetischen Eigenschaften. Der Grundkörper wird in einfacher Weise durch Pressen des magnetischen Materials erzeugt. Das magnetische Material liegt vorzugsweise als Granulat und/oder Pulver vor. Das magnetische Material umfasst mindestens ein Ferritmaterial. Vorzugsweise wird das magnetische Material derart bereitgestellt, dass mindestens ein Rohmaterial und/oder mindestens ein Abfallmaterial aufbereitet und/oder aktiviert wird. Vorzugsweise werden mehrere Rohmaterialen und/oder mehrere Abfallmaterialien gemischt und/oder aufbereitet. Vorzugsweise werden magnetische Abfallmaterialien wiederaufbereitet.A method according to claim 12 ensures simple and inexpensive production of the inductive component with improved electromagnetic properties. The base body is easily produced by pressing the magnetic material. The magnetic material is preferably in the form of granules and/or powder. The magnetic material includes at least one ferrite material. Preferably, the magnetic material is provided such that at least one raw material and/or at least one waste material is processed and/or activated. Preferably, multiple raw materials and/or multiple waste materials are mixed and/or processed. Preferably, waste magnetic materials are recycled.
Der Erfindung liegt ferner die Aufgabe zugrunde, ein induktives Bauteil zu schaffen, das einfach, kostengünstig und mit verbesserten elektromagnetischen Eigenschaften herstellbar ist.The invention is also based on the object of creating an inductive component that can be produced simply, inexpensively and with improved electromagnetic properties.
Diese Aufgabe wird durch ein induktives Bauteil mit den Merkmalen des Anspruchs 13 gelöst. Die Vorteile des induktiven Bauteils entsprechen den bereits beschriebenen Vorteilen des Verfahrens. Das induktive Bauteil kann insbesondere auch mit den Merkmalen mindestens eines der Ansprüche 1 bis 12 weitergebildet werden. Die gesinterten Partikel sind mit dem aktivierten Bindemittel zu dem mindestens einen Kern verbunden. Die gesinterten Partikel umfassen ein magnetisches Material, insbesondere mindestens ein Ferritmaterial. Die gesinterten Partikel haben eine jeweilige Partikelform, insbesondere ein jeweiliges Aspektverhältnis, und/oder eine jeweilige Partikelgröße, wie dies zu den Ansprüchen 1 bis 12 bereits beschrieben wurde. Auf die entsprechenden Merkmale wird Bezug genommen.This object is achieved by an inductive component having the features of claim 13. The advantages of the inductive component correspond to the advantages of the method already described. The inductive component can in particular also be developed with the features of at least one of
Durch die Ausbildung mehrerer magnetischer Kerne und die Auswahl der hierfür verwendeten gesinterten Partikel können die elektromagnetischen Eigenschaften in gewünschter Weise beeinflusst werden.The electromagnetic properties can be influenced in a desired manner by the formation of a plurality of magnetic cores and the selection of the sintered particles used for this purpose.
Weitere Merkmale, Vorteile und Einzelheiten der Erfindung ergeben sich aus der nachfolgenden Beschreibung eines Ausführungsbeispiels. Es zeigen:
- Fig. 1
- eine Schnittdarstellung eines induktiven Bauteils,
- Fig. 2A und 2B
- ein Ablaufdiagramm mit den Schritten zur Herstellung des induktiven Bauteils gemäß
Fig. 1 , - Fig. 3
- Diagramme des Gütefaktors Q in Abhängigkeit der Zeit t und der Frequenz f, wobei das obere Diagramm ein induktives Bauteil umfassend eine Eisenlegierung nach dem Stand der Technik, das mittlere Diagramm ein erfindungsgemäßes induktives Bauteil mit Ferritmaterial umfassend Mangan und Zink und das untere Diagramm ein erfindungsgemäßes induktives Bauteil mit Ferritmaterial umfassend Nickel und Zink veranschaulicht,
- Fig. 4
- Diagramme der Wechselspannungsverlustleistung PAC in Abhängigkeit der Zeit t und der Frequenz f, wobei das obere Diagramm ein induktives Bauteil umfassend eine Eisenlegierung nach dem Stand der Technik, das mittlere Diagramm ein erfindungsgemäßes induktives Bauteil mit Ferritmaterial umfassend Mangan und Zink und das untere Diagramm ein erfindungsgemäßes induktives Bauteil mit Ferritmaterial umfassend Nickel und Zink veranschaulicht,
- Fig. 5
- ein Diagramm des Gütefaktors Q in Abhängigkeit der Frequenz f und der Zeit t für ein induktives Bauteil umfassend eine Eisenlegierung nach dem Stand der Technik, und
- Fig. 6
- ein Diagramm des Gütefaktors Q in Abhängigkeit der Frequenz f und der Zeit t für ein erfindungsgemäßes induktives Bauteil mit Ferritmaterial umfassend Mangan und Zink.
- 1
- a sectional view of an inductive component,
- Figures 2A and 2B
- a flow chart with the steps for manufacturing the inductive component according to FIG
1 , - 3
- Diagrams of quality factor Q as a function of time t and frequency f, the upper diagram an inductive component comprising an iron alloy according to the prior art, the middle diagram an inductive component according to the invention with ferrite material comprising manganese and zinc and the lower diagram illustrates an inductive component according to the invention with ferrite material comprising nickel and zinc,
- 4
- Diagrams of AC power loss P AC as a function of time t and frequency f, the upper diagram showing an inductive component comprising an iron alloy according to the prior art, the middle diagram an inductive component according to the invention with ferrite material comprising manganese and zinc and the lower diagram an inventive inductive component illustrated with ferrite material comprising nickel and zinc,
- figure 5
- a diagram of the quality factor Q as a function of the frequency f and the time t for an inductive component comprising an iron alloy according to the prior art, and
- 6
- a diagram of the quality factor Q as a function of the frequency f and the time t for an inductive component according to the invention with ferrite material comprising manganese and zinc.
Ein induktives Bauteil 1 umfasst eine Spule 2, einen ersten magnetischen Kern 3 und einen zweiten magnetischen Kern 4. Die Spule 2 ist beispielsweise als Zylinderspule ausgebildet. Die Spule 2 besteht aus einem elektrisch leitfähigen Material. Die Spule 2 weist Anschlusskontakte 5, 6 auf.An
Der erste magnetische Kern 3 umgibt die Spule 2. Der erste magnetische Kern 3 umfasst erste gesinterte Partikel P1, die mittels eines ersten Bindemittels B1 miteinander verbunden sind. Der zweite magnetische Kern 4 umgibt den ersten magnetischen Kern 3 und die Spule 2. Der zweite magnetische Kern 4 umfasst zweite gesinterte Partikel P2, die mittels eines zweiten Bindemittels B2 miteinander verbunden sind. Die Anschlusskontakte 5, 6 sind durch den ersten magnetischen Kern 3 und den zweiten magnetischen Kern 4 nach außen geführt.The first
Die ersten gesinterten Partikel P1 weisen jeweils eine minimale Abmessung A1min und eine maximale Abmessung A1max auf. Die ersten gesinterten Partikel P1 haben ein jeweiliges erstes Aspektverhältnis A1, wobei gilt:
A1 = A1min/A1max. Mindestens 70 %, insbesondere mindestens 80 %, insbesondere mindestens 90 %, und insbesondere mindestens 95 % der ersten gesinterten Partikel P1 haben eine jeweilige minimale Abmessung A1min. wobei gilt: 500 µm ≤ A1min ≤ 1000 µm, insbesondere 600 µm ≤ A1min ≤ 900 µm, und insbesondere 700 µm ≤ A1min ≤ 800 µm. Mindestens 70 %, insbesondere mindestens 80 %, insbesondere mindestens 90 %, und insbesondere mindestens 95 % der ersten gesinterten Partikel P1 haben ein jeweiliges Aspektverhältnis A1, wobei gilt: 0,5 ≤ A1 ≤ 1, insbesondere 0,6 ≤ A1 ≤ 1, insbesondere 0,7 ≤ A1 ≤ 1, insbesondere 0,8 ≤ A1 ≤ 1, und insbesondere 0,9 ≤ A1 ≤ 1. Vorzugsweise gilt für das Aspektverhältnis A1: 0,5 ≤ A1 ≤ 1, insbesondere 0,6 ≤ A1 ≤ 0,9, und insbesondere 0,7 ≤ A1 ≤ 0,8. Das Aspektverhältnis A1 kann in Abhängigkeit der gewünschten Verteilung des magnetischen Flusses gewählt werden. Vorteilhafte Eigenschaften ergeben sich bei einem Aspektverhältnis A1 ≈ 0,75.The first sintered particles P 1 each have a minimum dimension A 1min and a maximum dimension A 1max . The first sintered particles P 1 each have a first aspect ratio A 1 , where:
A 1 = A 1min /A 1max . At least 70%, in particular at least 80%, in particular at least 90%, and in particular at least 95% of the first sintered particles P 1 each have a minimum dimension A 1min . where: 500 μm≦A 1min ≦1000 μm, in particular 600 μm≦A 1min ≦900 μm, and in particular 700 μm≦A 1min ≦800 μm. At least 70%, in particular at least 80%, in particular at least 90%, and in particular at least 95% of the first sintered particles P 1 have a respective aspect ratio A 1 , where the following applies: 0.5≦A 1 ≦1, in particular 0.6≦A 1 ≦1, in particular 0.7≦A 1 ≦1, in particular 0.8≦A 1 ≦1, and in particular 0.9≦A 1 ≦1. The aspect ratio A 1 is preferably 0.5≦A 1 ≦ 1, in particular 0.6≦A 1 ≦0.9, and in particular 0.7≦A 1 ≦0.8. The aspect ratio A 1 can be chosen depending on the desired distribution of the magnetic flux. Advantageous properties result from an aspect ratio A 1 ≈0.75.
Die zweiten gesinterten Partikel P2 weisen jeweils eine minimale Abmessung A2min und eine maximale Abmessung A2max auf. Die zweiten gesinterten Partikel P2 haben ein jeweiliges zweites Aspektverhältnis A2, wobei gilt: A2 = A2min/A2max. Mindestens 70 %, insbesondere mindestens 80 %, insbesondere mindestens 90 %, und insbesondere mindestens 95 % der zweiten gesinterten Partikel P2 haben eine jeweilige minimale Abmessung A2min, wobei gilt: 10 µm ≤ A2min ≤ 500 µm, insbesondere 100 µm ≤ A2min ≤ 400 µm, und insbesondere 200 µm ≤ A2min ≤ 300 µm. Mindestens 70 %, insbesondere mindestens 80 %, insbesondere mindestens 90 %, und insbesondere mindestens 95 % der zweiten gesinterten Partikel P2 haben ein jeweiliges Aspektverhältnis A2, wobei gilt: 0,5 ≤ A2 ≤ 1, insbesondere 0,6 ≤ A2 ≤ 1, insbesondere 0,7 ≤ A2 ≤ 1, insbesondere 0,8 ≤ A2 ≤ 1, und insbesondere 0,9 ≤ A2 ≤ 1. Vorzugsweise gilt für das Aspektverhältnis A2: 0,5 ≤ A2 ≤ 1, insbesondere 0,6 ≤ A2 ≤ 0,9, und insbesondere 0,7 ≤ A2 ≤ 0,8. Das Aspektverhältnis A2 kann in Abhängigkeit der gewünschten Verteilung des magnetischen Flusses gewählt werden. Vorteilhafte Eigenschaften ergeben sich bei einem Aspektverhältnis A2 ~ 0,75.The second sintered particles P 2 each have a minimum dimension A 2min and a maximum dimension A 2max . The second sintered Particles P 2 each have a second aspect ratio A 2 , where A 2 =A 2min /A 2max . At least 70%, in particular at least 80%, in particular at least 90%, and in particular at least 95% of the second sintered particles P 2 have a respective minimum dimension A 2min , where the following applies: 10 μm ≤ A 2min ≤ 500 μm, in particular 100 μm ≤ A 2min ≤ 400 µm, and in particular 200 µm ≤ A 2min ≤ 300 µm. At least 70%, in particular at least 80%, in particular at least 90%, and in particular at least 95% of the second sintered particles P 2 have a respective aspect ratio A 2 , where: 0.5 ≤ A 2 ≤ 1, in particular 0.6 ≤ A 2 ≦1, in particular 0.7≦A 2 ≦1, in particular 0.8≦A 2 ≦1, and in particular 0.9≦A 2 ≦1. The aspect ratio A 2 is preferably 0.5≦A 2 ≦ 1, in particular 0.6≦A 2 ≦0.9, and in particular 0.7≦A 2 ≦0.8. The aspect ratio A 2 can be chosen depending on the desired distribution of the magnetic flux. Advantageous properties result from an aspect ratio A 2 ~0.75.
Die ersten gesinterten Partikel P1 und die zweiten gesinterten Partikel P2 unterscheiden sich in ihrer Partikelform bzw. in ihrem Aspektverhältnis A1 bzw. A2 und/oder in ihrer Partikelgröße bzw. in ihrer minimalen Abmessung A1min bzw. A2min.The first sintered particles P 1 and the second sintered particles P 2 differ in their particle shape or in their aspect ratio A 1 or A 2 and/or in their particle size or in their minimum dimension A 1min or A 2min .
Nachfolgend ist das Verfahren zur Herstellung des induktiven Bauteils 1 anhand von
In einem Schritt S1 werden zunächst Ausgangsmaterialien R1 bis Rn zu einer Ausgangsmaterial-Mischung RM miteinander vermischt. Die Ausgangsmaterialien R1 bis Rn sind beispielsweise Rohmaterialien und/oder Abfallmaterialien, die recycelt bzw. wiederaufbereitet werden sollen. Die Ausgangsmaterialien R1 bis Rn umfassen beispielsweise Zinkoxid (ZnO), Manganoxid (MnO) und/oder Eisenoxid.The method for manufacturing the
In a step S 1 , starting materials R 1 to R n are first mixed together to form a starting material mixture R M . The starting materials R 1 to R n are, for example, raw materials and/or waste materials that are to be recycled or reprocessed. The Starting materials R 1 to R n include, for example, zinc oxide (ZnO), manganese oxide (MnO) and/or iron oxide.
Die Ausgangsmaterial-Mischung RM wird in einem Schritt S2 aktiviert und/oder kalziniert. Beim Kalzinieren wird eine calcium- und magnesiumcarbonathaltige Ausgangsmaterial-Mischung RM zur Entwässerung und/oder zur Zersetzung erhitzt.The starting material mixture R M is activated and/or calcined in a step S 2 . During calcination, a starting material mixture R M containing calcium and magnesium carbonate is heated for dewatering and/or for decomposition.
Die aktivierte Rohmaterial-Mischung RM bildet ein magnetisches Material M aus. Das magnetische Material M ist beispielsweise pulverförmig und/oder granulatförmig. Das magnetische Material M umfasst mindestens ein Ferritmaterial, beispielsweise MnZn-Ferritmaterial und/oder NiZn-Ferritmaterial.The activated raw material mixture R M forms a magnetic material M from. The magnetic material M is, for example, in the form of a powder and/or granules. The magnetic material M comprises at least one ferrite material, for example MnZn ferrite material and/or NiZn ferrite material.
Das magnetische Material M wird in einem Schritt S3 zu einem Grundkörper G gepresst. Der Grundkörper G wird auch als Grünkörper bezeichnet.The magnetic material M is pressed into a base body G in a step S 3 . The base body G is also referred to as a green body.
In einem nachfolgenden Schritt S4 wird der Grundkörper G gesintert. Das Sintern erfolgt bei einer Temperatur TS, wobei gilt: TS ≥ 1000 °C, insbesondere TS ≥ 1100 °C, insbesondere TS ≥ 1200 °C. Der gesinterte Grundkörper wird mit GS bezeichnet.In a subsequent step S 4 the base body G is sintered. The sintering takes place at a temperature T S , where: T S ≧1000° C., in particular T S ≧1100° C., in particular T S ≧1200° C. The sintered body is denoted by G S .
In einem Schritt S5 wird der gesinterte Grundkörper GS zerkleinert. Das Zerkleinern erfolgt beispielsweise mittels einer Brechmaschine bzw. Zerkleinerungsmaschine (crusher). Durch das Zerkleinern entstehen gesinterte Partikel, die allgemein mit P bezeichnet werden. Die gesinterten Partikel P weisen jeweils eine minimale Abmessung Amin und eine maximale Abmessung Amax auf, die ein jeweiliges Aspektverhältnis A definieren. Für das jeweilige Aspektverhältnis gilt: A = Amin/Amax. Nach dem Zerkleinern des gesinterten Grundkörpers GS sind die Aspektverhältnisse A der gesinterten Partikel P breit gestreut. Insbesondere entstehen beim Zerkleinern auch gesinterte Partikel P mit einer länglichen Form, die ein jeweiliges kleines Aspektverhältnis A haben. Für die weitere Verarbeitung der gesinterten Partikel P ist eine Form erwünscht, die im Wesentlichen einer Kugelform und/oder einer Würfelform entspricht.In a step S 5 the sintered base body G S is crushed. The crushing takes place, for example, by means of a crushing machine or crushing machine (crusher). The comminution produces sintered particles, which are generally denoted by P. The sintered particles P each have a minimum dimension A min and a maximum dimension A max that define a respective aspect ratio A . The following applies to the respective aspect ratio: A=A min /A max . After crushing the sintered base body G S , the aspect ratios A of the sintered particles P are widely scattered. In particular, sintered particles P with an elongated shape, which each have a small aspect ratio A, also arise during comminution. For the further processing of the sintered particles P, a shape that essentially corresponds to a spherical shape and/or a cube shape is desired.
In einem Schritt S6 werden die Aspektverhältnisse A der gesinterten Partikel P verkleinert. Das bedeutet, dass die maximale Abmessung Amax des jeweiligen gesinterten Partikels P an die minimale Abmessung Amin angeglichen wird. Hierzu werden die gesinterten Partikel P beispielsweise mittels einer Kugelmühle bearbeitet. Die Kugelmühle umfasst eine Trommel und darin angeordnete Metallkugeln. Die gesinterten Partikel P werden in die Trommel gegeben und aufgrund einer Rotation der Trommel mittels der Metallkugeln durch weitere Zerkleinerung und/oder Reibung bearbeitet, so dass sich die Aspektverhältnisse A der gesinterten Partikel P zumindest teilweise verkleinern.In a step S 6 the aspect ratios A of the sintered particles P are reduced. This means that the maximum dimension A max of each sintered particle P is adjusted to the minimum dimension A min . For this purpose, the sintered particles P are processed, for example, using a ball mill. The ball mill comprises a drum and metal balls arranged therein. The sintered particles P are placed in the drum and processed by further comminution and/or friction due to rotation of the drum by means of the metal balls, so that the aspect ratios A of the sintered particles P are at least partially reduced.
In einem Schritt S7 werden die gesinterten Partikel P anhand ihrer Partikelform und/oder anhand ihrer Partikelgröße separiert. Die gesinterten Partikel P werden in eine erste Fraktion mit ersten gesinterten Partikeln P1 und eine zweite Fraktion mit zweiten gesinterten Partikeln P2 separiert. Die ersten gesinterten Partikel P1 haben die minimale Abmessung A1min und die maximale Abmessung A1max sowie das Aspektverhältnis A1, wohingegen die zweiten gesinterten Partikel P2 die minimale Abmessung A2min, die maximale Abmessung A2max und das Aspektverhältnis A2 haben. Die erste Fraktion umfasst im Vergleich zu der zweiten Fraktion gröbere Partikel. Dementsprechend gilt für mindestens 70 % der gesinterten Partikel P1, P2: A1min > A2min und/oder A1max > A2min und/oder A1min > A2max.In a step S7 , the sintered particles P are separated based on their particle shape and/or based on their particle size. The sintered particles P are separated into a first fraction with first sintered particles P 1 and a second fraction with second sintered particles P 2 . The first sintered particles P 1 have the minimum dimension A 1min and the maximum dimension A 1max and the aspect ratio A 1 , whereas the second sintered particles P 2 have the minimum dimension A 2min , the maximum dimension A 2max and the aspect ratio A 2 . The first fraction comprises coarser particles compared to the second fraction. Accordingly, the following applies to at least 70% of the sintered particles P 1 , P 2 : A 1min >A 2min and/or A 1max >A 2min and/or A 1min >A 2max .
In Schritt S7 aussortierte gesinterte Partikel P, die weder der ersten Fraktion noch der zweiten Fraktion zugehören, können zurückgeführt werden und in Schritt S5 weiter zerkleinert und/oder in Schritt S6 weiter bearbeitet werden. Dies ist in
In einem nachfolgenden Schritt Ssi wird aus den ersten gesinterten Partikeln P1 und dem ersten Bindemittel B1 eine erste Mischung X1 erzeugt. Entsprechend wird in einem Schritt S82 aus den zweiten gesinterten Partikeln P2 und dem zweiten Bindemittel B2 eine zweite Mischung X2 erzeugt. Die Bindemittel B1 und B2 können gleich oder unterschiedlich sein. Die Bindemittel B1, B2 sind beispielsweise ein Polymerkunststoff und/oder ein Harz.In a subsequent step Ssi, a first mixture X 1 is produced from the first sintered particles P 1 and the first binder B 1 . Correspondingly, in a step S 82 , a second mixture X 2 is produced from the second sintered particles P 2 and the second binder B 2 . The binders B 1 and B 2 can be the same or different. The binders B 1 , B 2 are, for example, a polymer plastic and/or a resin.
Die erste Mischung X1 hat ein Massenverhältnis m1 der Masse mP1 der ersten gesinterten Partikel P1 zu der Masse mB1 des ersten Bindemittels B1. Für das Massenverhältnis m1 gilt somit m1 = mP1/mB1. Für das Massenverhältnis m1 gilt vorzugsweise: 75/25 ≤ m1 ≤ 99/1, insbesondere 80/20 ≤ m1 ≤ 98/2, und 85/15 ≤ m1 ≤ 95/5. Die zweite Mischung X2 hat ein Massenverhältnis m2 der Masse mP2 der zweiten gesinterten Partikel P2 zu der Masse mB2 des zweiten Bindemittels B2. Für das Massenverhältnis m2 gilt somit m2 = mP2/mB2. Für das Massenverhältnis m2 gilt vorzugsweise: 75/25 ≤ m2 ≤ 99/1, insbesondere 80/20 ≤ m2 ≤ 98/2, und 85/15 ≤ m2 ≤ 95/5. Das Massenverhältnis wird allgemein mit m bezeichnet.The first mixture X 1 has a mass ratio m 1 of the mass m P1 of the first sintered particles P 1 to the mass m B1 of the first binder B 1 . Thus, m 1 =m P1 /m B1 applies to the mass ratio m 1 . The following preferably applies to the mass ratio m 1 : 75/25≦m 1 ≦99/1, in particular 80/20≦m 1 ≦98/2, and 85/15≦m 1 ≦95/5. The second mixture X 2 has a mass ratio m 2 of the mass m P2 of the second sintered particles P 2 to the mass m B2 of the second binder B 2 . Thus, m 2 =m P2 /m B2 applies to the mass ratio m 2 . The mass ratio m 2 is preferably: 75/25≦m 2 ≦99/1, in particular 80/20≦m 2 ≦98/2, and 85/15≦m 2 ≦95/5. The mass ratio is generally denoted by m.
In einem Schritt S9 werden die erste Mischung X1 und die Spule 2 in einer ersten Form Fi angeordnet. Anschließend wird das erste Bindemittel B1 aktiviert, so dass das erste Bindemittel B1 die ersten gesinterten Partikel P1 zu dem ersten magnetischen Kern 3 verbindet. Zum Aktivieren des ersten Bindemittels B1 wird ein Druck p1 auf die erste Mischung X1 und/oder eine Temperatur T1 der ersten Mischung X1 erhöht. Nach dem Aushärten des ersten Bindemittels B1 wird der erste magnetische Kern 3 mit der Spule 2 entformt.In a step S 9 the first mixture X 1 and the
In einem nachfolgenden Schritt S10 wird der erste magnetische Kern 3 mit der Spule 2 und die zweite Mischung X2 in einer zweiten Form F2 angeordnet. Anschließend wird das zweite Bindemittel B2 aktiviert, so dass das zweite Bindemittel B2 die zweiten gesinterten Partikel P2 zu dem zweiten magnetischen Kern 4 verbindet. Das zweite Bindemittel B2 wird durch ein Erhöhen eines Drucks p2 auf die zweite Mischung X2 und/oder durch Erhöhen einer Temperatur T2 der zweiten Mischung X2 aktiviert. Nach dem Aushärten des zweiten Bindemittels B2 wird der zweite Kern 4 mit dem ersten magnetischen Kern 3 und der Spule 2 entformt.In a subsequent step S 10 the first
Durch das Entformen wird in einem Schritt S11 das induktive Bauteil 1 bereitgestellt.In a step S11, the
In entsprechender Weise veranschaulicht
Die erfindungsgemäßen Bauteile 1 altern thermisch kaum und gewährleisten somit, dass sich das Verhalten einer elektrischen Schaltung mit den erfindungsgemäßen induktiven Bauteilen 1 infolge von sich über der Zeit t ändernden Parameter, wie beispielsweise dem Gütefaktor Q oder der Wechselspannungsverlustleistung PAC nicht ändert und deren Funktion nicht beeinträchtigt ist. Ein Vergleich der Messkurven in
Allgemein gilt:
Das induktive Bauteil 1 weist mindestens eine Spule 2 auf. Vorzugsweise weist das induktive Bauteil 1 genau eine Spule oder genau zwei Spulen auf.In general:
The
Die durch Zerkleinern des gesinterten Grundkörpers Gs entstehenden gesinterten Partikel P können in beliebiger Weise bearbeitet, separiert und/oder ausgewählt werden. Die Reihenfolge der erwähnten Schritte ist hierbei beliebig. Zum Separieren und/oder Auswählen können bekannte Filter und/oder Siebe und/oder Separatoren verwendet werden. Durch das Bearbeiten, Separieren und/oder Auswählen der gesinterten Partikel P können die elektromagnetischen Eigenschaften des induktiven Bauteils 1 in gewünschter Weise eingestellt werden. Insbesondere können die Induktivität, das Sättigungsverhalten und/oder der Luftspalt eingestellt werden.The sintered particles P produced by crushing the sintered base body Gs can be processed, separated and/or selected in any way. The order of the steps mentioned is arbitrary. Known filters and/or sieves and/or separators can be used for separating and/or selecting. By editing, separating and / or selecting the sintered particles P can the electromagnetic properties of the
Das Aktivieren des Bindemittels B kann durch Kaltpressen oder Heißpressen erfolgen.The binder B can be activated by cold pressing or hot pressing.
Das magnetische Material M und somit der mindestens eine magnetische Kern 3, 4 umfasst vorzugsweise mindestens ein Ferritmaterial. Ferritmaterial ist kostengünstig und einfach verfügbar. Durch die Verwendung von Ferritmaterial werden vergleichsweise gute elektromagnetische Eigenschaften des induktiven Bauteils 1 erzielt. Insbesondere weist das induktive Bauteil 1 eine hohe Induktivität, ein gewünschtes Sättigungsverhalten, geringe Verluste auf und/oder kann mit einer hohen Spannung betrieben werden. Derartige induktive Bauteile 1 bestehen beispielsweise einen Hochspannungstest (AC HiPot test) bei einer Spannung von 3 kVAC (3 mA, 3 sec).The magnetic material M and thus the at least one
Die gesinterten Partikel werden allgemein mit P bezeichnet. Das Aspektverhältnis wird allgemein mit A bezeichnet. Die minimale Abmessung wird allgemein mit Amin bezeichnet. Die maximale Abmessung wird allgemein mit Amax bezeichnet.The sintered particles are generally denoted by P. The aspect ratio is generally denoted by A. The minimum dimension is generally denoted A min . The maximum dimension is generally denoted by A max .
Claims (13)
- Method for producing an inductive component with the steps of:- providing a basic body (G) comprising a magnetic material (M),- sintering the basic body (G), wherein the sintering is performed at a temperature Ts, where: TS > 1000°C,- comminuting the sintered basic body (Gs) to form sintered particles (P, P1, P2),- producing a first mixture (X1) from first sintered particles (P1) and a binder (B1),- arranging the first mixture (X1) and at least one coil (2) in a first mould (F1),- activating the binder (B1) in the first mixture (X1), so that the first sintered particles (P1) form with the binder (B1) a first magnetic core (3), which at least partially surrounds the at least one coil (2),- producing a second mixture (X2) from second sintered particles (P2) and a binder (B2), wherein the second sintered particles (P2) are smaller than the first sintered particles (P1),- arranging the second mixture (X2) and the at least one coil (2) with the first magnetic core (3) in a second mould (F2), and- activating the binder (B2) in the second mixture (X2), so that the second sintered particles (P2) form with the binder (B2) a second magnetic core (4), which surrounds the first magnetic core (3) and the at least one coil (2) completely, apart from terminal contacts (5, 6).
- Method according to claim 1, characterized
in that the magnetic material (M) comprises at least one ferrite material. - Method according to claim 1 or 2, characterized
in that the following applies for the temperature TS: TS ≥ 1100°C, in particular TS ≥ 1200°C. - Method according to at least one of the preceding claims,
characterized
in that the sintered particles (P, P1, P2) have a respective aspect ratio (A) and, before producing the mixtures (X1, X2), the aspect ratios (A) are at least partially reduced. - Method according to at least one of the preceding claims,
characterized
in that, before producing the mixtures (X1, X2), the sintered particles (P, P1, P2) are worked by means of a ball mill. - Method according to at least one of the preceding claims,
characterized
in that, before producing the mixtures (X1, X2), the sintered particles (P, P1, P2) are separated on the basis of the particle form and/or the particle size. - Method according to at least one of the preceding claims,
characterized
in that at least 70% of the sintered particles (P, P1, P2) used for producing the at mixtures (X1, X2) have a respective aspect ratio A, for which the following applies: 0.5 ≤ A ≤ 1, in particular 0.6 ≤ A ≤ 1, in particular 0.7 ≤ A ≤ 1, in particular 0.8 ≤ A ≤ 1, and in particular 0.9 ≤ A ≤ 1. - Method according to at least one of the preceding claims,
characterized
in that at least 70% of the sintered particles (P, P1, P2) used for producing the mixtures (X1, X2) have a respective minimum dimension Amin, for which the following applies: 10 µm ≤ Amin ≤ 1000 µm. - Method according to at least one of the preceding claims,
characterized
in that, before producing the mixtures (X1, X2), the sintered particles (P, P1, P2) are separated into a first fraction with first the sintered particles (P1) and into a second fraction with the second sintered particles (P2), which are different from the first sintered particles (P1). - Method according to at least one of the preceding claims,
characterized
in that the binder (B1, B2) is activated by increasing a temperature (T1, T2) and/or by increasing a pressure (p1, p2). - Method according to at least one of the preceding claims,
characterized
in that the mixtures (X1, X2) are produced in such a way that the following applies for a mass ratio m of the sintered particles (P1, P2) to the binder (B1, B2): 75/25 ≤ m ≤ 99/1, in particular 80/20 ≤ m ≤ 98/2, and in particular 85/15 ≤ m ≤ 95/5. - Method according to at least one of the preceding claims,
characterized
in that the basic body (G) is provided by pressing the magnetic material (M). - Inductive component comprising- at least one coil (2) comprising terminal contacts (5,6),- at least one magnetic core (3, 4), which at least partially surrounds the at least one coil (2),characterizedin that the at least one core (3, 4) is formed by means of sintered particles (P1, P2) and a binder (B1, B2),wherein a first magnetic core (3) with first sintered particles (P1) and a binder (B1) at least partially surrounds the at least one coil (2), andwherein a second magnetic core (4) with second sintered particles (P2), which are smaller than the first sintered particles (P1), and a binder (B2) surrounds the first magnetic core (3) and the at least one coil (2) completely, apart from the terminal contacts (5, 6).
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| DE102019211439.3A DE102019211439A1 (en) | 2019-07-31 | 2019-07-31 | Process for manufacturing an inductive component as well as an inductive component |
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| JPH06215968A (en) * | 1993-01-21 | 1994-08-05 | Tokin Corp | Manufacture of magnetic element for high frequency |
| JP3542319B2 (en) * | 2000-07-07 | 2004-07-14 | 昭栄化学工業株式会社 | Single crystal ferrite fine powder |
| JP3975051B2 (en) | 2000-07-11 | 2007-09-12 | Ｔｄｋ株式会社 | Method for manufacturing magnetic ferrite, method for manufacturing multilayer chip ferrite component, and method for manufacturing LC composite multilayer component |
| DE10155898A1 (en) * | 2001-11-14 | 2003-05-28 | Vacuumschmelze Gmbh & Co Kg | Inductive component and method for its production |
| JP4433162B2 (en) | 2004-02-05 | 2010-03-17 | 株式会社村田製作所 | Ceramic slurry, method for producing ceramic slurry, and method for producing multilayer ceramic electronic component |
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| SE533657C2 (en) * | 2007-10-16 | 2010-11-23 | Magnetic Components Sweden Ab | Powder-based, soft magnetic, inductive component and method and apparatus for manufacturing thereof |
| JP5325799B2 (en) | 2009-01-22 | 2013-10-23 | 日本碍子株式会社 | Small inductor and method for manufacturing the same |
| JP5398676B2 (en) * | 2009-09-24 | 2014-01-29 | 日本碍子株式会社 | Coil buried type inductor and manufacturing method thereof |
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| JP2013123007A (en) * | 2011-12-12 | 2013-06-20 | Shindengen Electric Mfg Co Ltd | Inductor, composite magnetic material, and method for manufacturing inductor |
| CN103304186B (en) * | 2013-07-03 | 2014-08-13 | 电子科技大学 | Ferrite-base composite magnetic dielectric antenna substrate material and preparation method thereof |
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| CN103915236A (en) * | 2014-04-01 | 2014-07-09 | 黄伟嫦 | Novel inductor and manufacturing method thereof |
| DE102014207636A1 (en) * | 2014-04-23 | 2015-10-29 | Würth Elektronik eiSos Gmbh & Co. KG | Method for producing an induction component and induction component |
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| KR101813322B1 (en) * | 2015-05-29 | 2017-12-28 | 삼성전기주식회사 | Coil Electronic Component |
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