TW201036004A - The hot-forming fabrication method and product of magnetic component - Google Patents

Abstract

The present invention provides a hot-forming fabrication method of a magnetic component and a hot-formed magnetic component fabricated by the same. More particularly, the present invention provides a magnetic powder hot-forming technique, along with a hot-formed magnetic component fabricated by the hot-forming technique so as to achieve high inductance, low core loss, and high EMI shielding. This invention has a magnetic core of low core loss in a common basic magnetic component be shielded by a single-layer or multi-layer EMI shielding material, thus producing an enhanced magnetic component with high inductance, low core loss, and low electromagnetic wave interference.

Description

201036004 VI. Description of the Invention: [Technical Field] The present invention relates to a method and a product for manufacturing a thermoformed magnetic component for use in a high current energy storage inductor, an electronic component, and an electromagnetic control component. [Prior Art]

In order to overcome the problem of traditional magnetic component winding, the industry has gradually changed the cylindrical core. As shown in the ninth diagram and the traditional open cylindrical core element, the product can form a magnetic line back in addition to the current carrying coil (i). Outside the circle, most of them radiate radially from the center of the core (2). This is the main source of EMI, and its magnetic line paths are exposed to the air, and there is no function of enhancing the magnetic field induction. In order to improve the shortcomings of open magnetic components, the market mostly relies on the external magnetic core (2) - the outer cover (3), commonly known as the combined core element (Drum Core), see the tenth figure, the traditional combined core element As shown in the cross-sectional view, the combined core element has two distinct advantages over the open type element: it can enhance the overall magnetic field growth plus the magnetic field line output strength of the magnetic material path. 2. The outer cover will magnetically (four) guide the 绮 巾 towel, reduce the magnetic force line, but this design still has the component gap (Gap) problem, because there must be component gap (31) in the component (as shown in the slash line in the figure), this Some of the voids will cause magnetic losses above. 3 201036004 [Invention] The technical improvement of the present invention is focused on: 1. Applying the hot pressing technology of the present invention to a basic magnetic component, tightly encapsulating and coating a magnetic material, so that the finished product of the reinforced magnetic energy storage component can be solved according to the conventional opening Dispersion and component clearance problems. 2. The use of low magnetic loss high-sensitivity materials and high electromagnetic waves • shielding materials developed by the present invention to improve the performance of the final reinforced component. Comparison of old and new technologies: 热 The hot pressing technology of the invention: mainly by heating and pressing, the pear powder is heated to soften and melt, and the powder is molded into the mold, which can be far into complex molding such as corner, hollow and minute size. Conventional cold pressing technology: generally refers to powder press-in forming (press), mainly through mechanical pressure forming, and then annealing and sintering to complete the finished product. Conventional magnetic components are produced by powder cold press forming, and the following is a comparison of the hot press forming of the present invention with the conventional cold press forming magnetic technique.

--_ ____-η Item Cold press forming Hot note of the invention—~~--- Pressing forming element/monomer at room temperature into high temperature molding needs to be matched with the high temperature type of the invention, temperature resistance (>180), temperature Bonding agent, poor wettability, high temperature resistivity component resistivity --- use lower _______ more molding powder is heated, insulation every ^ 4 201036004 better Eddy Current higher because of higher resistivity Eddy current Lower Core Loss is lower. The higher the cracking problem, the higher the proportion of plastic in the lower component, the better the combination. The complex molding is only suitable for axial molding. It can be complicated, and the molding possibilities are impossible. Cocoa and heat sink are not possible. The design of the foot and the like combined with the density uniformity is better. The hot-pressed plastic heat-softening and winding is relatively easy to be used. It is better not to open the jig, and the winding is easy to break. EMI Noise Size EMI shielding material can be used for external cladding. Annealing process requires no component aging. Faster molding temperature is higher than temperature aging. Corrosion resistance is better. The proportion of plastic in the component is higher. 201036004 *, [Embodiment] The term "component" as used in the present invention generally refers to a magnetic material that can be applied by an additional device such as a coil, a line, or a coating, which can be used as an inductor, an electromagnetic force, or the like; The so-called "magnetic core" generally refers to the magnetic core rod coated in the magnetic element. i, as shown in the cross-sectional view of the thermoformed magnetic element of the present invention, the "thermocompression molded magnetic element" of the present invention comprises: a magnetic core (2), a current carrying coil (1) surrounding the periphery of the magnetic core (2), and A thermoformed magnetic component made of a magnetic shielding material (4) is thermally encapsulated on the periphery of the magnetic core (2) and the 〇 current carrying coil (1). The magnetic core (2) referred to in the present invention may comprise a single magnetic magnetic core (2) having a low magnetic loss (c〇re Loss) and a good magnetic permeability (Permeabi丨丨ty). The magnetic shielding material (4) refers to a composite magnetic material magnetic shielding material (4) having a single or magnetic property with high electromagnetic shielding (EMI Shielding). ❹ β When the current-carrying coil (1) passes current, an applied magnetic field is generated to cause electromagnetic induction of the magnetic material of the surrounding magnetic core (2) and the magnetic shielding material (4) to strengthen the overall magnetic field output. As is known in the art, the central region of the current-carrying coil (1) is the region with the highest magnetic flux density. The present invention uses a single or composite magnetic material having different magnetic properties to form a magnetic core (2) having a low magnetic loss characteristic, which is located at a current carrying current. The coil (1) in the ~ region 'provides the best magnetic field line induction. When the core magnetic flux density is increased, the magnetic core (2) low magnetic 6 201036004 loss characteristic can effectively suppress the magnetic loss rise, and the magnetic shielding material (4) having a high electromagnetic wave characteristic is coated with a magnetic line guiding characteristic to effectively accommodate Magnetic lines of force are placed in the component to suppress electromagnetic interference. It can be seen from the above that the hot-pressed magnetic component of the present invention has the following three characteristics: a. Effectively utilizing the material properties of the low magnetic loss magnetic core (2) and the high electromagnetic wave magnetic shielding material (4) to maximize the magnetic field lines of the component, but not It will cause too much electromagnetic interference and magnetic loss. b. By properly controlling the volume ratio of the low magnetic loss core (2) and the high electromagnetic wave magnetic 〇 shielding material (4), the inductance required for the design and the appropriate magnetic loss control, usually high magnetic permeability, can be obtained. Low magnetic loss materials are more expensive than general magnetic materials, and finished products can also be controlled at an appropriate cost. c. The low magnetic loss core (2) and the high electromagnetic wave magnetic shielding material (4) are tightly coated to avoid the problem of magnetic field disturbance and magnetic loss caused by the joint gap. The hot-pressed magnetic component of the present invention has the following extension changes, which can develop different magnetic core (2) and magnetic shielding material (4) material ratios according to design and specifications, as shown in the second to fifth figures, Magnetic volume, (2) material volume increase, can effectively increase the component sense and reduce magnetic loss. As shown in the second figure, the combination of the magnetic core and the current-carrying coil of the present invention is not a small magnetic core (2) and a large magnetic shielding material (4). The volume ratio is designed to be suitable for low-sensitivity components and high EMI shielding. effect. The second picture shows the core (2) protruding current-carrying coil (work) design. 201036004 It is found that the magnetic core (2) protrudes from the current-carrying coil (i), which can effectively avoid the magnetic line choking problem' and has a sensitivity of 2〇. ~5〇% improvement effect. The fourth figure shows that the magnetic core (2) has a τ shape. This design has the advantages of increasing the surface area of the magnetic core (2) and the magnetic shielding material (4) and the material volume ratio, which can effectively avoid the magnetic core (2) and Magnetic shielding 'material (4) joint magnetic field loss and lifting sensation. The fifth picture shows the material volume ratio of the enlarged magnetic core (2), which can be height f) to enhance the inductance and reduce the magnetic loss design. Therefore, the shape of the magnetic core (2) can be a shape of a work shape, a τ shape, a column shape, etc., and the coating of the magnetic shielding material (4) can be fully or partially covered by the size of the component. The hot-press molding manufacturing method of the magnetic component of the present invention comprises: ^Hot-press molding powder preparation engineering: The hot-press molding powder preparation of the present invention comprises the following raw material preparation: q A, magnetic powder: magnetic powder is contained as Hogonas SC200, SC100. 26 north Ticket Shenglong BF200.27, BF100.27 and other iron powder or alloy iron powder (Fe, Al, Si, Cr, Ni, Co) or other similar magnetically conductive mixed powder (such as

Sendust,

Amorphous, MPP, Hi-Flux). B. Bonding agent: The magnetic powder powder uses 4% to 20% of a single or a plurality of specific resins' as a magnetic molecular bonding agent during hot pressing. C, Lubricant: According to the magnetic powder 0.05% ~ 3% of the lubricant (such as white soil, a vulcanized turn, PTFE), etc., so that the lubrication effect during hot pressing is helpful to demoulding" 8 201036004 2. Mixing powder project The mixing powder project of the invention uses the general single-axis or multi-axial mixer in the industry, and the stirring is carried out according to the following steps: a. Add a single magnetic powder or a plurality of magnetic powders and stir until uniform. b. Repeat a. Process until all magnetic powder has been added and stirred evenly. c. Add binder or multiple binders and mix until uniform. If the combined agent is a wet binder (containing solvent), it should be mixed to a dry, unblocked condition. O d. Repeat c. Process until all binders have been added and stirred evenly. e. Add lubricant and stir evenly. f. Repeat e. Process until all lubricants have been added and stirred evenly. 3. Finished powder production project: a. Confirmation of powder characteristics: After the powder is evenly mixed, the magnetic permeability, resistance value, hysteresis curve and other characteristics of the powder will be measured to confirm the powder characteristics. b. Powder sieving: The powder will pass through a sifter and sieved to different sizes of powder according to the magnetic requirements.

Q C. Heat treatment: Consider the magnetic properties of the powder, the packing density of the powder, the fluidity of the powder, the strength of the green body after molding, and sometimes the heat treatment of the powder to improve its magnetic properties and processing characteristics. 4. Magnetic powder hot press manufacturing: As shown in the sixth figure, the brief steps of manufacturing the hot press formed magnetic component of the present invention are as follows: A. The current carrying coil (1) is wrapped around the periphery of the magnetic core (2) to combine the two. The magnetic energy storage element (A) is produced. 201036004 B. Fill in the magnetic powder and put in the magnetic shielding material (4), and heat-press the plastic forming process to obtain the reinforced thermoformed magnetic element (B) which is hot-pressed with the magnetic shielding material (4). Therefore, the present invention can change or adjust the ratio of the current carrying coil (1) and the material surrounding the magnetic core (2) with reference to the aforementioned component design to achieve the required product specifications. This section describes the magnetic powder hot pressing manufacturing operation and related attention, and the parameters include 'as shown in the seventh figure, the magnetic powder hot-pressed magnetic element manufacturing process diagram and the eighth figure, and the hot-pressing apparatus of the present invention. The manufacturing process is divided into the following operations: 1. Powder barrel (81), material tube (82) and mold (83) plus (71): To ensure the maintenance of the hot pressing characteristics of the powder, the powder barrel (8 1 ), the material tube (8 2) and the mold (83) need to be installed with heaters. The heating temperature varies from 140 to 350 °C depending on the area. Ο 2. The 6-bonded low magnetic loss core (2) and the current-carrying coil (1) magnetic energy storage element (A) to be coated in the cavity (7 2): = magnetic energy storage component (A) To be coated into the cavity, the magnetic storage 旎 件 (A) to be coated design needs to consider the following points: a • magnetic energy components (A) when to be coated or clamped. b. Magnetic storage element (a) where the coating is to be placed and the hot pressed powder fills the inlet direction. C. Magnetic energy storage element (A) The material to be coated can withstand the strength design. d. Magnetic energy storage element (A) The mold release design of the object to be coated. 201036004 3. Pressing device (8 4 ) for hot pressing (7 3 ): The action during hot pressing is divided as follows: a. Upper mold (8 5 ) closed mold (7 3 1 ): upper mold (8 5 ) device with two The side guide device (8 6) closes the mold. b. Powder (7 3 2 ): Magnetic powder is placed in the filling area. » c· upper mold press unit (84) press-fit (733): actuate with the press-fit device, apply pressure to fill the powder in the mold cavity, and over-mold with the magnetic energy storage component (A) to be coated. Due to the heating and enthalpy characteristics, the magnetic powder exhibits softening/melting at this time, and can be tightly coated on the surface of the magnetic energy storage element (A) to be coated. d. Upper mold holding pressure (7 4 ): The upper mold pressing device is kept still, so that the pressing area is kept under pressure, and the molding time is not enough to cause lamination. 5. Demolding action (7 5 ): The action of demolding is divided as follows: a. Upper mold opening (7 5 1 ): The upper mold unit opens the mold with the guide rods on both sides. b. Demoulding ejector product demoulding (7 5 2 ): The demoulding device is actuated upwards to allow the product to come out of the cavity with the demoulding device for subsequent manual or automated pick-up. When the magnetic powder hot pressing technology of the present invention is used, attention should be paid to the following points: a. Heat resistance of magnetic powder: Since all the powder pipelines in this patent need to be heated and kept, it is necessary to consider heating temperature when using magnetic raw materials.

II 201036004 Whether the magnetic condition is degraded. b. Thermal properties of additives (binders, lubricants): Since all the powder lines in this patent need to be heated and insulated, when using additives, it is necessary to consider whether the heating temperature causes high temperature oxidative decomposition. c. Cavity inlet design: Main influence factors of mold inlet design > As follows: 1. Finished molding density: Appropriate inlet size can achieve high molding density. 〇2. Magnetic energy storage component (A) Abrasion resistance of the coating to be coated: The molding powder will rub the magnetic energy storage component (A) to be coated at high speed under pressure, resulting in a monomer or component interior. damage. Therefore, it is necessary to proceed from the inlet port angle, position, size, and magnetic energy storage component (A) to be coated. 3. Demolding burrs: Appropriate inlet design helps reduce finished burrs. Q [Simplified description of the drawings] The first figure is a cross-sectional view of a thermoformed magnetic element of the present invention. The second figure is a cross-sectional view showing the combination of the magnetic core and the current-carrying coil of the present invention. Fig. 3 is a cross-sectional view showing another embodiment of the combination of the magnetic core and the current-carrying coil of the present invention. The fourth figure is a cross-sectional view showing another embodiment of the combination of the magnetic core and the current-carrying coil of the present invention. The fifth figure is another embodiment of the combination of the magnetic core and the current-carrying coil of the present invention. 12 201036004 A cross-sectional view. Figure 6 is a schematic diagram showing the steps of manufacturing a thermoformed magnetic component of the present invention. Figure 7 is a diagram showing the manufacturing process of the magnetic powder hot-pressed magnetic component of the present invention. s The eighth figure is a cross-sectional view of the conventional open cylindrical core element of the heat press apparatus of the present invention. The tenth figure is a cross-sectional view of the conventional combined core element. [Main component symbol description] Current-carrying coil (1) Core (2) Cover (3) Component gap (3 1) Magnetic shielding material (4) Heating (7 1) Place the object to be placed in the cavity (7 2) 〇 hot pressing (7 3) closing mold (7 3 1 ) into powder (7 3 2 ). pressing (7 3 3 ) upper mold holding pressure (7 4) demoulding action (7 5) upper mold opening (7 5 1) Demoulding ejector product demoulding (7 5 2 ) 13 201036004 Powder tank (8 1 ) Tube (8 2) Mold (8 3) Pressing device (8 4) Upper die (8 5) Guide bar Device (8 6) Magnetic Energy Storage Element (A) Hot Pressed Magnetic Element (B)

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Claims (1)

201036004 VII. Patent application scope: 1. A method for manufacturing a magnetic component by thermoforming, comprising: placing a current carrying coil (1) around a periphery of a magnetic core (2) to form a magnetic energy storage component (A), and placing it The magnetic shielding material (4) is placed in the mold outside the magnetic energy storage element (A), and the hot-pressed magnetic element (b) coated with the magnetic shielding material (4) is obtained by a thermoforming process. 2. The method of manufacturing a magnetic element hot press forming according to claim 1, wherein the magnetic core (2) comprises a magnetic core rod coated in a general magnetic element or has a low magnetic loss (Core Loss). And a composite magnetic material having a single or magnetic property of good magnetic permeability (Permeabi lity). 3. The magnetic component hot-press molding manufacturing method according to the invention of claim 2, wherein the magnetic shielding material (4) comprises a general magnetic shielding material which is mixed and stirred by the magnetic powder, the human agent and the lubricant, and has a crucible. EMI Shielding A single or composite magnetic material with different magnetic properties. ❹4. The method of hot-press forming 1 of the magnetic element described in the scope of claim 1; the magnetic powder includes: Hog〇nasSC200, SC100.26 Beipiao Shenglong, BF200.27, BF100.27, etc. Alloy iron powder (Fe, A1, Si, Cr, Ni, Co) or other similar magnetically conductive mixed powder (such as Sendust, Amorphous, MPP, Hi-Flux); wherein the binder comprises: magnetic powder powder using 4%~2 0% single or multiple unique resins, as a magnetic molecular bond during hot pressing; 201036004 where the lubricant contains: according to magnetic powder 〇 〇 5% ~ 3% of the lubricant used (such as white wax, molybdenum disulfide, PTFE) Etc., so that the lubrication effect during hot pressing helps to release the mold. 5. The method of manufacturing a magnetic element according to the first aspect of the invention, wherein the hot-press molding process refers to heating the magnetic shielding material (4) to a softening state of 140 to 350 ° C, Then, the magnetic shielding material (4) is pressed by the pressing device, so that the current-carrying coil (1) and the magnetic core (2) are encapsulated in the magnetic shielding material (4) to achieve a corner, a hollow, a small size, and the like. Complex molding" 6. A magnetic component hot-pressed product comprising a magnetic core (2), a current-carrying coil (1) surrounding the periphery of the magnetic core (2), and a magnetic core (2), a current-carrying coil (1) A thermoformed magnetic component product produced by encapsulating a magnetic shielding material (4) on the periphery. 7. The magnetic component hot-pressed product according to claim 6, wherein the magnetic core (2) comprises a magnetic core ferrule coated with a general magnetic component or has a low magnetic loss (Core Loss) and A composite magnetic material having a single or magnetic property with good magnetic permeability (Permeab 11 ty). 8. The magnetic component hot-pressed product according to claim 6, wherein the magnetic shielding material (4) comprises a general magnetic shielding material which is mixed and stirred by a magnetic powder, a binder and a lubricant or has Highly EMI Shielding single or magnetic composite materials with different magnetic properties. 9. For the magnetic component hot-pressed product according to item 6 of the patent scope, the magnetic shielding material (4) of 201036004, which covers the current-carrying coil (1) and the magnetic tolerance (2), can be The component dimensions are fully or partially coated. 10. If the magnetic element hot press forming product described in claim 6 is adjusted, the volume ratio design of the magnetic core (2) and the magnetic shielding material (4) is adjusted, and the required inductance value, magnetic loss, and related electromagnetic characteristics can be obtained. U*, as described in the scope of claim 6 of the magnetic component, the hot-pressed product D product, in which the magnetic core (2) can be designed to protrude the current-carrying coil (1), so as to effectively avoid the problem of magnetic line choking, and the sense of The amount has a lifting effect of 2〇~50%. 12. The hot-pressed product of the magnetic component according to claim 6, wherein the magnetic core (2) can have a T-shape, so as to increase the surface area and material volume ratio of the magnetic core (2) and the magnetic shielding material (4). According to the magnetic core (2) and the magnetic shielding material (4), the magnetic flux loss and the lifting inductance are effectively avoided. q If the magnetic element (2) of the magnetic element hot-molding product described in the scope of claim 6 is added, the volume ratio can be increased to increase the sensitivity and reduce the magnetic loss design. 14. The hot-pressed product of a magnetic component according to claim 6, wherein the magnetic core (2) is shaped to have a shape, a T shape, a column shape, or the like.