EP3772070B1 - Verfahren zur herstellung eines induktiven bauteils sowie induktives bauteil - Google Patents

Verfahren zur herstellung eines induktiven bauteils sowie induktives bauteil Download PDF

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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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Prior art keywords
sintered particles
binder
coil
magnetic core
mixture
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German (de)
English (en)
French (fr)
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EP3772070A1 (de
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Arpankumar Patel
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Wuerth Elektronik Eisos GmbH and Co KG
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Wuerth Elektronik Eisos GmbH and Co KG
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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
    • H01F1/12—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
    • 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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/20—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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/34—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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/34—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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00—Fixed inductances of the signal type 
    • H01F17/04—Fixed inductances of the signal type  with magnetic core
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H01F27/255—Magnetic cores made from particles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/32—Insulating of coils, windings, or parts thereof
    • H01F27/327—Encapsulating or impregnating
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/34—Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
    • H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • 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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00—Fixed inductances of the signal type 
    • H01F17/04—Fixed inductances of the signal type  with magnetic core
    • H01F2017/048—Fixed inductances of the signal type  with magnetic core with encapsulating core, e.g. made of resin and magnetic powder

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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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Dispersion Chemistry (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Soft Magnetic Materials (AREA)
  • Coils Or Transformers For Communication (AREA)
  • Magnetic Ceramics (AREA)
EP20184972.6A 2019-07-31 2020-07-09 Verfahren zur herstellung eines induktiven bauteils sowie induktives bauteil Active EP3772070B1 (de)

Applications Claiming Priority (1)

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DE102019211439.3A DE102019211439A1 (de) 2019-07-31 2019-07-31 Verfahren zur Herstellung eines induktiven Bauteils sowie induktives Bauteil

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EP3772070B1 true EP3772070B1 (de) 2023-05-10

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EP (1) EP3772070B1 (ru)
JP (1) JP7213207B2 (ru)
KR (1) KR102364724B1 (ru)
CN (1) CN112309675B (ru)
DE (1) DE102019211439A1 (ru)
ES (1) ES2946688T3 (ru)
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EP4369359A1 (en) * 2022-11-14 2024-05-15 Premo, SL Composite magnetic inductor element and fabrication method thereof

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JPH06215968A (ja) * 1993-01-21 1994-08-05 Tokin Corp 高周波用磁気素子の製造方法
JP3542319B2 (ja) * 2000-07-07 2004-07-14 昭栄化学工業株式会社 単結晶フェライト微粉末
JP3975051B2 (ja) 2000-07-11 2007-09-12 Ｔｄｋ株式会社 磁性フェライトの製造方法、積層型チップフェライト部品の製造方法及びｌｃ複合積層部品の製造方法
DE10155898A1 (de) * 2001-11-14 2003-05-28 Vacuumschmelze Gmbh & Co Kg Induktives Bauelement und Verfahren zu seiner Herstellung
JP4433162B2 (ja) 2004-02-05 2010-03-17 株式会社村田製作所 セラミックスラリー、セラミックスラリーの製造方法、及び積層セラミック電子部品の製造方法
JP2005310694A (ja) 2004-04-26 2005-11-04 Murata Mfg Co Ltd 導電性ペースト及び積層セラミック電子部品の製造方法
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JP5325799B2 (ja) 2009-01-22 2013-10-23 日本碍子株式会社 小型インダクタ及び同小型インダクタの製造方法
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KR101813322B1 (ko) * 2015-05-29 2017-12-28 삼성전기주식회사 코일 전자부품
JP6740817B2 (ja) * 2016-08-30 2020-08-19 Tdk株式会社 フェライト組成物，フェライト焼結体、電子部品およびチップコイル

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CN112309675A (zh) 2021-02-02
TWI751616B (zh) 2022-01-01
EP3772070A1 (de) 2021-02-03
TW202107497A (zh) 2021-02-16
RU2752251C1 (ru) 2021-07-23
US20210035734A1 (en) 2021-02-04
JP2021027345A (ja) 2021-02-22
JP7213207B2 (ja) 2023-01-26
KR20210015691A (ko) 2021-02-10
ES2946688T3 (es) 2023-07-24
KR102364724B1 (ko) 2022-02-17
DE102019211439A1 (de) 2021-02-04

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