WO2017185345A1 - 复合导线及其制备方法和一种功率电感的制备方法 - Google Patents

复合导线及其制备方法和一种功率电感的制备方法 Download PDF

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WO2017185345A1
WO2017185345A1 PCT/CN2016/080727 CN2016080727W WO2017185345A1 WO 2017185345 A1 WO2017185345 A1 WO 2017185345A1 CN 2016080727 W CN2016080727 W CN 2016080727W WO 2017185345 A1 WO2017185345 A1 WO 2017185345A1
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layer
metal
composite wire
nickel
wire
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PCT/CN2016/080727
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English (en)
French (fr)
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夏胜程
李有云
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深圳顺络电子股份有限公司
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Priority to PCT/CN2016/080727 priority Critical patent/WO2017185345A1/zh
Priority to CN201680000392.9A priority patent/CN105934803B/zh
Publication of WO2017185345A1 publication Critical patent/WO2017185345A1/zh
Priority to US15/869,054 priority patent/US10867748B2/en

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    • 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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/0016—Apparatus or processes specially adapted for manufacturing conductors or cables for heat treatment
    • H—ELECTRICITY
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    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/012—Apparatus or processes specially adapted for manufacturing conductors or cables for manufacturing wire harnesses
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06—Insulating conductors or cables
    • H01B13/16—Insulating conductors or cables by passing through or dipping in a liquid bath; by spraying
    • H—ELECTRICITY
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    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/02—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of inorganic substances
    • H01B3/10—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of inorganic substances metallic oxides
    • H—ELECTRICITY
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    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/02—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of inorganic substances
    • H01B3/10—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of inorganic substances metallic oxides
    • H01B3/105—Wires with oxides
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/02—Disposition of insulation
    • H01B7/0208—Cables with several layers of insulating material
    • H01B7/0216—Two layers
    • 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
    • H01F41/041—Printed circuit coils
    • H01F41/046—Printed circuit coils structurally combined with ferromagnetic material
    • H—ELECTRICITY
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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
    • H01F41/06—Coil winding
    • H01F41/061—Winding flat conductive wires or sheets
    • 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
    • H01F41/125—Other insulating structures; Insulating between coil and core, between different winding sections, around the coil
    • 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
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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
    • H01F41/32—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 applying conductive, insulating or magnetic material on a magnetic film, specially adapted for a thin magnetic film
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    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
    • H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
    • H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
    • H01B1/023—Alloys based on aluminium
    • H—ELECTRICITY
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    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
    • H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
    • H01B1/026—Alloys based on copper
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/02—Disposition of insulation
    • H01B7/0291—Disposition of insulation comprising two or more layers of insulation having different electrical properties
    • H—ELECTRICITY
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    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/28—Protection against damage caused by moisture, corrosion, chemical attack or weather
    • 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
    • H01F41/14—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 applying magnetic films to substrates
    • H01F41/24—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 applying magnetic films to substrates from liquids
    • H01F41/26—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 applying magnetic films to substrates from liquids using electric currents, e.g. electroplating

Definitions

  • the invention relates to a composite wire required for the manufacture of a magnetic component and a preparation method thereof, and to a method for preparing the magnetic component.
  • high temperature resistant insulated wires are generally formed by inorganic oxide coating to form an insulating layer, that is, a mesoporous inorganic oxide layer is formed on the surface of the conductor.
  • the high temperature resistant insulated wire using the insulating layer has the following defects: on the one hand, if the inorganic oxide layer is too dense, the inorganic coating layer is easily peeled off during the winding process due to the brittleness of the inorganic oxide layer; On the other hand, if the inorganic oxide layer is not densely coated, moisture resistance and weather resistance are poor; in addition, the manufacturing cost of covering the surface of the conductor with the mesoporous inorganic oxide layer is very expensive.
  • One of the objects of the present invention is to provide a composite wire which is resistant to high temperature, is easy to be wound, and which is not easy to fall off in the practical use, and has good weather resistance, so as to solve the problem that the existing high temperature resistant insulated wire is insulated by a mesoporous inorganic oxide layer.
  • the technical problems brought about by the layer is to provide a composite wire which is resistant to high temperature, is easy to be wound, and which is not easy to fall off in the practical use, and has good weather resistance, so as to solve the problem that the existing high temperature resistant insulated wire is insulated by a mesoporous inorganic oxide layer.
  • a composite wire comprising a metal inner core, an easily passivable metal layer coated on a surface of the metal inner core, and a self-adhesive resin layer coated on the surface of the easily passivable metal layer; wherein the insulating layer of the composite wire is A metal passivation layer obtained by oxidizing an easily passivated metal layer after sintering.
  • the composite wire provided by the technical solution coats the easily passivable metal on the surface of the metal inner core. After the sintering process, the easily passivable metal layer is oxidized to form a metal passivation layer, which can be used as an insulating layer of the composite wire.
  • the easily passivable metal layer as the precursor of the insulating layer should be relatively dense. However, even if it is relatively dense, in the actual use of the composite wire, since the easy passivation metal layer is soft, the composite wire is easy to be wound and the dense and easily passivable metal layer is not easily peeled off;
  • the insulating layer of the composite wire is formed by sintering treatment when it is put into practical use. Before the sintering process, the insulating layer is actually in the form of an insulating layer precursor (i.e., an easily passivable metal layer). Therefore, when the composite wire is applied to, for example, a preparation process of a magnetic member, the composite wire can be wound in accordance with a predetermined shape and number of turns, and then sintered. In this way, the shaped composite wire is easy to passivate the metal passivation layer (ie, the insulating layer) formed by the oxidation of the metal layer during the sintering process, and the denseness and uniformity of the insulating layer are both easy to passivate.
  • the metal passivation layer ie, the insulating layer
  • the metal layers are uniform, and the dense and uniformity of the original easily passivable metal layer when it is formed on the surface of the metal inner core is extremely controllable. That is to say, the composite wire provided by the technical solution adopts the easy passivation metal layer as the precursor of the insulating layer, so that the composite wire can be shaped first in actual use, and then the insulating layer precursor becomes a truly insulating insulation.
  • the technical contradiction is "to ensure good insulation and weather resistance,
  • the mesoporous inorganic oxide layer must be dense, and once dense, when it is wound during use, the inorganic oxide layer of the mesopores is brittle and easily falls off, and the shedding tends to affect the insulation and weather resistance.
  • the composite wire can reach the weather resistance of the standard salt spray of 8H or more, and the insulation withstand voltage of 100V or more.
  • the thickness of the easily passivable metal layer is moderate, the processing cost is not high, and the conductivity of the metal core is not affected.
  • the metal inner core is a nickel-plated copper wire formed by plating nickel on the surface of the copper wire by electroplating or electroless plating, wherein the thickness of the nickel plating layer is 1 of the copper wire diameter /10 to 3/10.
  • the easily passivable metal layer is aluminum or chromium, and is plated on the surface of the nickel-plated copper wire by electroplating or PVD, and has a thickness of 1/10 to 3/10 of the diameter of the copper wire; After the easy passivation metal layer is sintered at 600 to 900 ° C, the surface of the nickel-plated copper wire is oxidized to form a metal passivation layer.
  • the self-adhesive resin layer is nylon, which is formed on the surface of the easily passivable metal layer by multiple coating and drying.
  • Another object of the present invention is to provide a method for preparing the foregoing composite wire, comprising the following steps S1 to S3:
  • the gold formed by the oxidation of the easily passivable metal layer formed in step S2 It is a passivation layer that serves as an insulating layer of the composite wire.
  • the metal inner core is a nickel-plated copper wire formed by plating nickel on the surface of the copper wire by electroplating or electroless plating, wherein the thickness of the nickel plating layer is 1 of the copper wire diameter /10 to 3/10.
  • the easily passivable metal layer is aluminum or chromium, and is plated on the surface of the nickel-plated copper wire by electroplating or PVD, and has a thickness of 1/10 to 3/10 of the diameter of the copper wire; After the easily passivated metal layer is sintered at 600 to 900 ° C, a metal passivation layer is formed on the surface of the nickel-plated copper wire.
  • the step S3 specifically comprises: uniformly coating the self-adhesive resin paint on the surface of the easily passivable metal layer by felt dip coating, each coating thickness is 1 um to 2 um, and the temperature is after each coating.
  • the drying is carried out at 80 to 150 ° C, and the self-adhesive resin layer is formed by multiple coating and drying.
  • Another object of the present invention is to provide a method for preparing a power inductor, comprising the following steps A to E:
  • the composite wire is prepared according to the preparation method of the foregoing composite wire;
  • the composite wire prepared in the step A is wound in a predetermined shape and a number of turns to form a coil
  • the coil is placed in the mold cavity, and then filled into the mold cavity with metal soft magnetic powder, the metal soft magnetic powder and the coil are pressed to form a base body containing the coil;
  • the substrate is subjected to a sintering treatment at 600 to 900 ° C.
  • a sintering treatment at 600 to 900 ° C.
  • the self-adhesive resin layer of the outermost layer of the composite wire is discharged by carbonization and oxidation to form a gas, and at the same time, the passivation is easy Forming a metal passivation layer by oxidation of the metal layer;
  • Electroplating electrodes are plated at both ends of the substrate processed in step D, and the two terminal electrodes are respectively connected to the two ends of the coil to form the power inductor.
  • the method for preparing the power inductor has the following advantages: we know that the electrical performance (for example, magnetic permeability, saturation magnetic flux) of a conventional integrated inductor is mainly determined by a magnetic material (corresponding to the aforementioned metal soft magnetic powder). Under the magnetic material, the magnetic permeability and saturation magnetic flux of the inductor are proportional to the magnetic material density, and in order to improve the electrical performance, the magnetic material density needs to be increased.
  • the method of increasing the density of the magnetic material is to increase the pressure during extrusion molding.
  • the coil of the traditional one-piece inductor is a polyurethane enameled wire. If the pressing force is too large during the extrusion process, the paint film is very easy to be broken and peeled off, resulting in a coil.
  • the interlayer withstand voltage is reduced or even short-circuited.
  • the preparation method is based on "the passivation metal layer is soft, not easy to fall off and can be sintered at a high temperature of 600 to 900 ° C to form a metal passivation layer having high weather resistance and high pressure resistance", using a first pressing and a post sintering process. Pressing process A large pressing force can be used without causing cracking and falling off of the easily passivable metal layer, thereby ensuring good electrical performance of the finally prepared power inductor, and at the same time, forming a good metal foil passivation layer between the coil layers after sintering. Insulation and high withstand voltage performance. Thereby solving the technical contradiction between the electrical performance and the withstand voltage of the conventional one-piece inductor.
  • the metal core used is a silver wire, an aluminum wire or a nickel-plated copper wire, and the easily passivable metal layer is aluminum or chromium, and the easily passivable metal is sintered in the step D.
  • an aluminum oxide layer or a chromium oxide layer is correspondingly coated on the surface of the metal inner core.
  • FIG. 1 is a schematic structural view of a composite wire including an easily passivable metal layer provided by the present invention
  • FIG. 2 is a schematic view showing the structure of a power inductor using the composite wire of the present invention.
  • a specific embodiment of the present invention provides a composite wire comprising an easily passivable metal layer, comprising a metal inner core, an easily passivable metal layer coated on the surface of the metal inner core, and self-adhesive coating on the surface of the easily passivable metal layer a resin layer; wherein the insulating layer of the composite wire is a metal passivation layer obtained by oxidizing the easily passivable metal layer after sintering.
  • the metal core of the composite wire may be, for example, a silver wire, an aluminum wire or a nickel-plated copper wire, preferably a nickel-plated copper wire, which has good high temperature resistance and low electrical conductivity.
  • the composite wire is made of a nickel-plated copper wire as the metal core, the internal structure thereof can be referred to FIG. 1, and the copper wire 10, the nickel layer 20, the easily passivable metal layer 30, and the self-adhesive resin layer 40 are sequentially arranged from the inside to the outside.
  • the nickel-plated copper wire is formed by plating a nickel layer 20 on the surface of the copper wire 10 by electroplating or electroless plating, and the thickness of the plated nickel layer 20 is preferably 1/10 to 3/10 of the wire diameter of the copper wire 10.
  • the material of the easily passivable metal layer 30 is aluminum or chromium, and is plated on the surface of the metal core by electroplating or PVD.
  • the passivation metal layer 30 is formed on the surface of the nickel layer 20 and has a thickness of 1/10 to 3/10 of the wire diameter of the copper wire 10; and the passivable metal layer 30 can be sintered at 600 to 900 ° C.
  • the surface of the metal core, such as a nickel-plated copper wire is oxidized to form a metal passivation layer.
  • the metal passivation layer is an oxide that is easily passivated, such as aluminum oxide or chromium oxide.
  • the passivating metal is chromium
  • the main component of the metal passivation layer is Cr 2 O 3 .
  • the metal passivation layer formed by the easy passivation metal layer 30 after the aforementioned sintering process is an insulating layer of the composite wire.
  • Another embodiment of the present invention provides a method of preparing the foregoing composite wire, the method comprising the following steps S1 to S3:
  • the metal core is mainly considered to be a silver wire, an aluminum wire or a nickel-plated copper wire having a relatively stable electrical resistivity at a high temperature, but it is not excluded to use other commonly used conductors.
  • the metal core is a nickel-plated copper wire
  • the thickness of the easily passivable metal layer is 1/10 to 3/10 of the diameter of the copper wire.
  • the self-adhesive resin layer may be, for example, nylon, formed on the surface of the easily passivable metal layer by multiple coating and drying, for example, by uniformly coating the self-adhesive resin paint by felt dip coating. Covering the surface of the easily passivable metal layer, each coating thickness is 1 um to 2 um, drying is performed at a temperature of 80-150 ° C after each coating, and the self-adhesive resin is formed by multiple coating and drying.
  • a specific embodiment of the present invention provides a novel power inductor using the composite wire as a coil.
  • the power inductor includes: a base 100, a coil 200 inside the base, and a corresponding Terminal electrodes 301 and 302 connected to both ends of the coil.
  • the preparation method of the power inductor is as follows:
  • Step A preparing the composite wire according to the composite wire preparation method disclosed in the foregoing specific embodiment
  • Step B the composite wire prepared in the step A is wound in a predetermined shape and number of turns to form the coil of the power inductor;
  • Step C the coil is placed in a cavity, and then a metal soft magnetic powder is filled into the cavity, and the metal soft magnetic powder and the coil are pressed to form a base body containing the coil;
  • Step D The substrate is subjected to a sintering treatment at 600 to 900 ° C.
  • the self-adhesive resin layer of the outermost layer of the composite wire is discharged by carbonization and oxidation to form a gas, and at the same time, the substrate is easily blunt Forming a metal layer to form the metal passivation layer;
  • Step E plating the end electrodes on both ends of the substrate processed through the step D, and the two end electrodes are respectively connected to the two ends of the coil to form the power inductor.
  • step D After completing step D, if there is a coil protruding from the outer surface of both ends of the substrate, it is polished. Polish and then plate the electrode.

Abstract

本发明公开了复合导线及其制备方法和一种功率电感的制备方法，复合导线包括金属内芯、包覆于金属内芯表面的易钝化金属层以及包覆于易钝化金属层表面的自粘树脂层；其中，所述复合导线的绝缘层为所述易钝化金属层经烧结处理后氧化而成的金属钝化层。该制备方法用于制造所述复合导线。该功率电感的制备方法用于制备包含所述复合导线的一种新型功率电感。本发明的复合导线耐高温、易绕制，且绕制过程中易钝化金属层不易脱落从而保证其钝化后形成的绝缘层耐候性和耐压性俱佳。

Description

复合导线及其制备方法和一种功率电感的制备方法 技术领域
本发明涉及一种磁性元件制造过程中所需的复合导线及其制备方法，还涉及该种磁性元件——功率电感的制备方法。
背景技术
目前，耐高温的绝缘导线一般都是采用无机氧化物包覆的形式来形成绝缘层，即在导体表面形成介孔无机氧化层。采用此种绝缘层的耐高温绝缘导线，具有以下缺陷：一方面如果无机氧化层包覆过于致密，则由于无机氧化层的脆性，在绕制过程中容易造成无机包覆层的脱落；另一方面如果无机氧化层包覆不致密，耐潮、耐候性会较差；此外，在导体表面包覆介孔无机氧化层的制造成本是非常昂贵的。
发明内容
本发明的目的之一在于提出一种耐高温、易绕制且在实际使用中绝缘层不易脱落、耐候性好的复合导线，以解决现有的耐高温绝缘导线采用介孔无机氧化层作为绝缘层所带来的技术问题。
本发明解决上述技术问题的技术方案如下：
一种复合导线，包括金属内芯、包覆于金属内芯表面的易钝化金属层以及包覆于易钝化金属层表面的自粘树脂层；其中，所述复合导线的绝缘层为所述易钝化金属层经烧结处理后氧化而成的金属钝化层。本技术方案提供的复合导线，将易钝化金属镀于金属内芯表面，待烧结处理后该易钝化金属层被氧化，形成金属钝化层，即可作为复合导线的绝缘层。
上述的复合导线相比现有技术具有以下有益效果：
1)为了保证绝缘层良好的绝缘性和耐候性，作为绝缘层前驱体的易钝化金属层应当较为致密。然而，即便其较为致密，在该复合导线的实际使用过程中，由于易钝化金属层较软，也使得该复合导线易于绕制且致密的易钝化金属层不易脱落；
2)该复合导线的绝缘层是在其投入实际使用时通过烧结处理而形成，在烧结处理前，绝缘层实际上是以绝缘层前驱体(即易钝化金属层)的形式存在。 因此将该复合导线应用于例如磁性元件的制备过程中时，可以先将该复合导线按照预定的形状、圈数绕制好，再进行烧结。这样一来，已经定形的复合导线在烧结过程中，其易钝化金属层氧化形成的金属钝化层(即绝缘层)，该绝缘层的致密性、均匀性都是与当初的易钝化金属层一致的，而当初的易钝化金属层在形成于金属内芯表面时，其致密性和均匀性是极易控制的。也就是说，本技术方案提供的复合导线，通过将易钝化金属层作为绝缘层的前驱体，使得该复合导线可以在实际使用时先定形，再使绝缘层前驱体变为真正绝缘的绝缘层，从而克服现有技术中直接包覆于金属内芯表面的介孔无机氧化层(现有技术的绝缘层)存在的技术矛盾，该技术矛盾是“为了保证良好绝缘性和耐候性，该介孔无机氧化层必须致密，而一旦致密，在使用过程中绕制时，由于该介孔无机氧化层较脆，容易脱落，脱落势必影响绝缘性和耐候性”；
3)只要保证形成的金属钝化层厚度为100～500nm，则该复合导线就可达到标准盐雾8H以上的耐候性，以及绝缘耐压能力100V以上。对应于如此厚度要求的金属钝化层，易钝化金属层的厚度适中、处理成本也不高且不影响金属内芯导电性能。
更进一步地，所述金属内芯为镀镍铜线，所述镀镍铜线通过电镀或化学镀的方式在铜线表面镀镍而形成，其中镀镍层的厚度为铜线线径的1/10～3/10。
更进一步地，所述易钝化金属层为铝或铬，通过电镀或PVD方式镀于所述镀镍铜线表面，且厚度为铜线线径的1/10～3/10；且所述易钝化金属层经600～900℃烧结处理后，在所述镀镍铜线表面氧化形成金属钝化层。
更进一步地，所述自粘树脂层为尼龙，通过多次涂覆并烘干的方式形成于所述易钝化金属层的表面。
本发明的另一目的在于提出前述复合导线的制备方法，包括以下步骤S1～S3：
S1、提供一金属内芯作为所述复合导线的导体；
S2、在所述金属内芯表面镀易钝化金属层，并控制所述易钝化金属层的厚度在一预定范围；
S3、在所述易钝化金属层的表面涂覆自粘树脂层；
其中，步骤S2所形成的所述易钝化金属层经烧结处理后氧化而成的金 属钝化层即作为所述复合导线的绝缘层。
更进一步地，所述金属内芯为镀镍铜线，所述镀镍铜线通过电镀或化学镀的方式在铜线表面镀镍而形成，其中镀镍层的厚度为铜线线径的1/10～3/10。
更进一步地，所述易钝化金属层为铝或铬，通过电镀或PVD方式镀于所述镀镍铜线表面，且厚度为铜线线径的1/10～3/10；且所述易钝化金属层经600～900℃烧结后，在所述镀镍铜线表面形成金属钝化层。
更进一步地，所述步骤S3具体包括：通过毛毡浸裹的方式将自粘树脂漆均匀涂覆在易钝化金属层表面，每次涂覆厚度为1um～2um，每次涂覆后以温度80～150℃进行烘干，通过多次涂覆并烘干的方式形成所述自粘树脂层。
本发明的又一目的在于提出一种功率电感的制备方法，包括以下步骤A～E：
A、按照前述复合导线的制备方法，制备前述复合导线；
B、将步骤A制备所得的复合导线按预定形状、圈数进行绕制，形成线圈；
C、将所述线圈放入模腔中，再向模腔中填入金属软磁粉，将所述金属软磁粉与所述线圈进行压制，形成内含线圈的基体；
D、将所述基体进行600～900℃的烧结处理，在该烧结处理过程中，所述复合导线最外层的自粘树脂层经碳化和氧化形成气体而排出，同时，所述易钝化金属层经氧化形成所述金属钝化层；
E、在经过步骤D处理的基体两端镀端电极，两个端电极分别与所述线圈的两个端部连接，形成所述功率电感。
上述提供的功率电感的制备方法具有以下优点：我们知道，传统的一体成型电感，其电气性能(例如磁导率、饱和磁通量)主要是由磁材(相当于前述的金属软磁粉)决定，同种磁材下，电感的磁导率和饱和磁通量与磁材密度成正比，为了提升电气性能，需提升磁材密度。而提升磁材密度的方法是提高挤压成型时的压力，传统的一体成型电感的线圈为聚氨脂漆包线，挤压过程中若挤压力过大则漆膜非常容易破碎、脱落，造成线圈层间耐压降低、甚至短路。然而，本制备方法基于“易钝化金属层质软、不易脱落且在600～900℃高温烧结能形成具有高耐候性和高耐压性的金属钝化层”，采用先压制，后烧结工艺，压制过程 可以采用较大挤压力而不会造成易钝化金属层的开裂、脱落，保证最终制备出的功率电感获得较好的电气性能，同时烧结后使得线圈层间基于金属钝化层形成良好的绝缘以及较高的耐压性能。从而解决了传统的一体成型电感存在的电气性能和耐压之间的技术矛盾。
在步骤A中制备所述复合导线时，采用的金属内芯为银线、铝线或镀镍铜线，易钝化金属层为铝或铬，所述易钝化金属在经步骤D的烧结处理后对应地生成氧化铝层或氧化铬层包覆于所述金属内芯表面。
附图说明
图1是本发明提供的一种包含易钝化金属层的复合导线的结构示意图；
图2是一种采用了本发明的复合导线的功率电感的结构示意图。
具体实施方式
下面结合附图和优选的实施方式对本发明作进一步说明。
本发明的具体实施方式提供一种包含易钝化金属层的复合导线，包括金属内芯、包覆于金属内芯表面的易钝化金属层以及包覆于易钝化金属层表面的自粘树脂层；其中，所述复合导线的绝缘层为所述易钝化金属层经烧结处理后氧化而成的金属钝化层。
该复合导线的金属内芯例如可以是银线、铝线或镀镍铜线，优选采用镀镍铜线，其耐高温性能较好，导电性能受高温影响较小。当该复合导线采用镀镍铜线作为金属内芯时，其内部结构可参考图1，由内而外依次是铜线10、镍层20、易钝化金属层30、自粘树脂层40。所述镀镍铜线即通过电镀或化学镀的方式在铜线10表面镀镍层20而形成，所镀的镍层20的厚度优选为铜线10线径的1/10～3/10。
在优选的实施例中，易钝化金属层30的材质为铝或铬，通过电镀或PVD方式镀于所述金属内芯表面，参考图1，当金属内芯为镀镍铜线时，易钝化金属层30即形成于镍层20表面，且厚度为铜线10线径的1/10～3/10；且所述易钝化金属层30经600～900℃烧结处理后，能够在所述金属内芯例如镀镍铜线的表面氧化形成金属钝化层。该金属钝化层为易钝化金属的氧化物，例如氧化铝或氧化铬。当易钝化金属为铬时，金属钝化层的主成分为Cr2O3。易钝化金属层30在前述的烧结处理后所形成的所述金属钝化层，即为所述复合导线的绝缘层。
本发明的另一具体实施方式提供了前述复合导线的制备方法，该方法包括以下步骤S1～S3：
S1、提供一金属内芯作为所述复合导线的导体。金属内芯如前述，主要考虑采用高温下电阻率较为稳定的银线、铝线或镀镍铜线，但也不排除采用其他常用的导体。
S2、在所述金属内芯表面镀易钝化金属层，并控制所述易钝化金属层的厚度在一预定范围。例如：当金属内芯为镀镍铜线时，该易钝化金属层的厚度为铜线线径的1/10～3/10。
S3、在所述易钝化金属层的表面涂覆自粘树脂层。该自粘树脂层例如可以是尼龙，通过多次涂覆并烘干的方式形成于所述易钝化金属层的表面，具体操作例如是：通过毛毡浸裹的方式将自粘树脂漆均匀涂覆在易钝化金属层表面，每次涂覆厚度为1um～2um，每次涂覆后以温度80～150℃进行烘干，通过多次涂覆并烘干的方式形成所述自粘树脂层。
本发明的一具体实施例提供了一种新型的功率电感，该功率电感是采用前述的复合导线作为线圈，如图2所示，该功率电感包括：基体100，基体内部的线圈200，以及分别与线圈两端连接的端电极301和302。该功率电感的制备方法具体如下：
步骤A、按照前述具体实施方式公开的复合导线制备方法来制备前述的复合导线；
步骤B、将步骤A制备所得的复合导线按预定形状、圈数进行绕制，形成该功率电感的所述线圈；
步骤C、将所述线圈放入模腔中，再向模腔中填入金属软磁粉，将所述金属软磁粉与所述线圈进行压制，形成内含线圈的基体；
步骤D、将所述基体进行600～900℃的烧结处理，在该烧结处理过程中，所述复合导线最外层的自粘树脂层经碳化和氧化形成气体而排出，同时，所述易钝化金属层经氧化形成所述金属钝化层；
步骤E、在经过步骤D处理的基体两端镀端电极，两个端电极分别与所述线圈的两个端部连接，形成所述功率电感。
在完成步骤D后，若存在凸出于基体两端外表面的线圈，则进行打磨 抛光，而后再镀端电极。
以上内容是结合具体的优选实施方式对本发明所作的进一步详细说明，不能认定本发明的具体实施只局限于这些说明。对于本发明所属技术领域的技术人员来说，在不脱离本发明构思的前提下，还可以做出若干等同替代或明显变型，而且性能或用途相同，都应当视为属于本发明的保护范围。

Claims (10)

  1. 一种复合导线，其特征在于：包括金属内芯、包覆于金属内芯表面的易钝化金属层以及包覆于易钝化金属层表面的自粘树脂层；其中，所述复合导线的绝缘层为所述易钝化金属层经烧结处理后氧化而成的金属钝化层。
  2. 如权利要求1所述的复合导线，其特征在于：所述金属内芯为镀镍铜线，所述镀镍铜线通过电镀或化学镀的方式在铜线表面镀镍而形成，其中镀镍层的厚度为铜线线径的1/10～3/10。
  3. 如权利要求2所述的复合导线，其特征在于：所述易钝化金属层为铝或铬，通过电镀或PVD方式镀于所述镀镍铜线表面，且厚度为铜线线径的1/10～3/10；且所述易钝化金属层经600～900℃烧结处理后，在所述镀镍铜线表面氧化形成金属钝化层。
  4. 如权利要求1所述的复合导线，其特征在于：所述自粘树脂层为尼龙，通过多次涂覆并烘干的方式形成于所述易钝化金属层的表面。
  5. 如权利要求1所述的复合导线的制备方法，其特征在于：包括以下步骤S1～S3：
    S1、提供一金属内芯作为所述复合导线的导体；
    S2、在所述金属内芯表面镀易钝化金属层，并控制所述易钝化金属层的厚度在一预定范围；
    S3、在所述易钝化金属层的表面涂覆自粘树脂层；
    其中，步骤S2所形成的所述易钝化金属层经烧结处理后氧化而成的金属钝化层即作为所述复合导线的绝缘层。
  6. 如权利要求5所述的复合导线的制备方法，其特征在于：所述金属内芯为镀镍铜线，所述镀镍铜线通过电镀或化学镀的方式在铜线表面镀镍而形成，其中镀镍层的厚度为铜线线径的1/10～3/10。
  7. 如权利要求6所述的复合导线的制备方法，其特征在于：所述易钝化金属层为铝或铬，通过电镀或PVD方式镀于所述镀镍铜线表面，且厚度为铜线线径的1/10～3/10；且所述易钝化金属层经600～900℃烧结后，在所述镀镍铜线表面形成金属钝化层。
  8. 如权利要求5或6所述的复合导线的制备方法，其特征在于：步骤S3具体包括：通过毛毡浸裹的方式将自粘树脂漆均匀涂覆在易钝化金属层表面，每 次涂覆厚度为1um～2um，每次涂覆后以温度80～150℃进行烘干，通过多次涂覆并烘干的方式形成所述自粘树脂层。
  9. 一种功率电感的制备方法，其特征在于：包括以下步骤A～E：
    A、按照如权利要求5所述的复合导线的制备方法，制备如权利要求1所述的复合导线；
    B、将步骤A制备所得的复合导线按预定形状、圈数进行绕制，形成线圈；
    C、将所述线圈放入模腔中，再向模腔中填入金属软磁粉，将所述金属软磁粉与所述线圈进行压制，形成内含线圈的基体；
    D、将所述基体进行600～900℃的烧结处理，在该烧结处理过程中，所述复合导线最外层的自粘树脂层经碳化和氧化形成气体而排出，同时，所述易钝化金属层经氧化形成所述金属钝化层；
    E、在经过步骤D处理的基体两端镀端电极，两个端电极分别与所述线圈的两个端部连接，形成所述功率电感。
  10. 如权利要求9所述的功率电感的制备方法，其特征在于：在步骤A中制备所述复合导线时，采用的金属内芯为银线、铝线或镀镍铜线，易钝化金属层为铝或铬，所述易钝化金属在经步骤D的烧结处理后对应地生成氧化铝层或氧化铬层包覆于所述金属内芯表面。
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JP7378210B2 (ja) * 2019-01-17 2023-11-13 新光電気工業株式会社 セラミック部材の製造方法
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