WO2023133994A1 - 一种一体成型电感器的制造方法及应用其制备的电感器 - Google Patents

一种一体成型电感器的制造方法及应用其制备的电感器 Download PDF

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WO2023133994A1
WO2023133994A1 PCT/CN2022/079895 CN2022079895W WO2023133994A1 WO 2023133994 A1 WO2023133994 A1 WO 2023133994A1 CN 2022079895 W CN2022079895 W CN 2022079895W WO 2023133994 A1 WO2023133994 A1 WO 2023133994A1
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powder
inductor
magnetic powder
magnetic
integrally formed
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PCT/CN2022/079895
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English (en)
French (fr)
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蔡平平
王立诚
陆金辉
王嘉俊
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宁波磁性材料应用技术创新中心有限公司
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00—Fixed inductances of the signal type 
    • H01F17/02—Fixed inductances of the signal type  without magnetic core
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/16—Metallic particles coated with a non-metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/02—Compacting only
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/12—Both compacting and sintering
    • B22F3/14—Both compacting and sintering simultaneously
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24—After-treatment of workpieces or articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/08—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools with one or more parts not made from powder
    • 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
    • H01F1/147—Alloys characterised by their composition
    • 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
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/24—After-treatment of workpieces or articles
    • B22F2003/248—Thermal after-treatment
    • 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
    • H01F2027/348—Preventing eddy currents
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the invention belongs to the technical field of inductors, and in particular relates to a method for manufacturing an integrally formed inductor and an inductor prepared by using the same.
  • the base with a boss is prefabricated, the hollow coil is assembled on the base, and then the powder is filled and pressed, and finally a single inductor is obtained by cutting.
  • This method effectively improves the production efficiency of inductors, but this method still has the following disadvantages: the prefabrication of the base is difficult and the cost of the mold is high.
  • the object of the present invention is to provide a method for manufacturing an integrally formed inductor and an inductor prepared by using the same, so as to optimize the performance of the inductor under the conditions of improving the production efficiency of the inductor and reducing equipment investment.
  • a method for manufacturing an integrally formed inductor comprising the following steps: S1. Fill the mold with magnetic powder to cover the bottom of the mold, and the number of times of filling is not less than one time; S2. Pressing the magnetic powder filled in the mould, so that the magnetic powder is preformed into a powder block, the density of the powder block is not higher than 5g/cm 3 ; S3. Transfer the N hollow coils to the mold, and place the hollow coils Press into the preformed powder so that the magnetic powder forming the powder is tightly filled on the inner and outer surfaces of the hollow coil; S4.
  • the mold Fill the mold with magnetic powder again until the hollow coil is filled with magnetic powder Buried, the number of times of filling is not less than 1 time, and the magnetic powder filled in the mold is pressed to form the blank of the inductor matrix; S5. Hot pressing the blank of the inductor matrix, and then heat-treated to obtain the blank of the inductor matrix; S6. Cutting the inductor
  • the blank of the parent body is to obtain an inductance matrix containing at least one hollow coil; S. Carry out surface insulation treatment on the surface of the inductance matrix; S8. Remove the insulating material of the conductive terminal part of the hollow wire, so that the conductive terminal part is exposed, and the exposed conductive In the terminal part, electrode terminals are produced to obtain finished inductors.
  • the inventor found that in the method of prefabricating the mold with magnetic powder, the hollow coil and the boss of the base are in clearance fit, the positioning of the coil is not accurate, and it is easy to shift during pressing, which affects the pass rate during cutting. , and it is difficult for the powder to flow into the gap when filling the powder, which affects the product performance after pressing.
  • the present invention has the following advantages: the production efficiency of the inductor is effectively improved by forming the whole board and then cutting into individual products, and the complex base prefabrication process is canceled, which further reduces the process difficulty and production cost . At the same time, there is no gap between the coil and the base.
  • the inductor can increase the overall density of the inductor and ensure the high performance of the inductor.
  • it improves the positioning accuracy of the coil and avoids the inconsistency between the cutting position and the actual position of the coil. Defective and unqualified products, improve process stability and product qualification rate.
  • surface insulation treatment may be achieved by uniformly coating a layer of insulating varnish on the surface of the inductor substrate.
  • the shape of the hollow coil includes but not limited to circle, ellipse and racetrack.
  • Hollow coils are wound from wires.
  • the cross section of the wire includes but is not limited to a circle and a rectangle.
  • the number of times of filling the magnetic powder can be one or more times, and the type of magnetic powder can be the same or different each time.
  • the upper surface of the hollow coil is not lower than the upper surface of the magnetic powder filled in the mold.
  • the pre-pressed magnetic powder plays a restrictive role on the air-core coil, preventing the air-core coil from being displaced during the subsequent secondary pressing and hot pressing.
  • the number of times of filling the magnetic powder can be one or more times, and the type of magnetic powder can be the same or different each time.
  • the method of putting the hollow coil into the mold is not limited, it can be directly put into the mold after the winding is completed, or can be transferred to the mold by a coil transfer jig.
  • the hot-pressing pressure is 100-1000 MPa
  • the hot-pressing temperature is 80-200° C.
  • the holding time is 10-300 seconds.
  • P represents the hot pressing pressure
  • T represents the hot pressing temperature
  • t represents the holding time
  • P, T, and t satisfy the following quantitative relationship: 2 ⁇
  • the operation unit of P is MPa
  • the operation unit of T is °C
  • the operation unit of t is s.
  • the hot pressing pressure does not exceed 600MPa.
  • the heat treatment temperature is 150-200° C.
  • the heat treatment time is 1-3 hours.
  • the manufactured inductor has good electrical properties (reflected by inductance, DC resistance, saturation current, temperature rise current or other electrical performance parameters).
  • the particle size of the magnetic powder used is 50-400 microns.
  • the particle size of the magnetic powder used is 80-260 microns, the fluidity is 30-55 seconds/50 grams, and the bulk density is 1.5-2.5 grams/cubic centimeter.
  • the magnetic powder is prepared from magnetic raw powder, adhesive, and lubricant according to the following method: (a) inorganic coating is carried out on the magnetic raw powder to achieve surface insulation modification to obtain a mixture A; (b) in the mixture A A mixed solution of adhesive and acetone is added to the mixture, calculated according to the mass percentage, the amount of adhesive added is 1% to 10% of the original magnetic powder, and mixed evenly to obtain a mixture B; (c) use the mixture B to granulate to obtain a particle size of 50 ⁇ 400 micron semi-finished powder; (d) dry the semi-finished powder, and add lubricant to the semi-finished powder, calculated according to mass percentage, the amount of lubricant added is 0.01% ⁇ 0.5% of the semi-finished powder, thus Prepared magnetic powder.
  • the magnetic raw powder is subjected to phosphating treatment to achieve surface insulation modification, and the amount of phosphating agent added is 0.02% to 0.2% according to the mass percentage, to obtain Mixture A.
  • a mixed solution of an adhesive and acetone is added to the mixture A, the adhesive is a modified epoxy resin and a curing agent thereof, and the amount of the adhesive added is 1.8% to 3.2% of the original magnetic powder, mixed to obtain the mixture B.
  • the mixture B is used for granulation to obtain a semi-finished powder with a particle size of 80-260 microns.
  • the semi-finished powder is dried at a drying temperature of 60-100° C., and the drying time is 1-2 hours, and a lubricant is added to the semi-finished powder,
  • the kind of lubricant is lithium stearate, calculated according to mass percentage, the additive amount of lubricant is 0.1%-0.3% of the semi-finished powder, thus the magnetic powder is prepared.
  • the particle size of the magnetic raw powder is 1-30 microns
  • the magnetic raw powder includes carbonyl iron powder, iron silicon powder, iron silicon chromium powder, sendust aluminum powder, iron nickel powder, iron-based amorphous powder, iron-based nano At least one of crystal powder.
  • one or more layers of coating modification can also be performed on the used magnetic raw powder.
  • the method for inorganic coating is to form an inorganic coating film on the surface of the magnetic raw powder, and the materials forming the inorganic coating film include phosphate, silicate, nitrate, oxidation One or more of silicon, titanium oxide, and aluminum oxide.
  • the lubricant used includes one or more of zinc stearate, lithium stearate, magnesium stearate, graphite fluoride, and molybdenum disulfide.
  • an inductor is provided: it is prepared according to the manufacturing method of the above integrally formed inductor.
  • the manufacturing process of the inductor provided by the present invention adopts multiple pressings to obtain the inductor with integral bonding and partial lamination structure.
  • the stacked structure of the inductor is composed of multiple magnetic layers, and the soft magnetic material between the magnetic layers shows a discontinuous distribution, which can reduce the mutual interference of the magnetic field.
  • the inductor prepared by the above process has the characteristics of continuously adjustable inductance, loss and saturation current.
  • developers can design the material, thickness and number of stacked layers of the magnetic layer according to different application scenarios to meet the optimal requirements of the circuit.
  • the prepared high-frequency low-loss power inductor can be used in many occasions, especially in the application of high-frequency DC-DC converters, which can effectively reduce the eddy current loss of the magnetic layer at light loads; Large DC superimposed saturation current, thereby effectively improving the efficiency of the DC-DC converter and achieving the goal of green energy saving.
  • Fig. 1 is a schematic diagram of an air-core coil of the present invention.
  • Fig. 2 is a schematic diagram of the combined structure of the powder block and the coil of the present invention.
  • Fig. 3 is a schematic diagram of the blank of the inductor matrix of the present invention.
  • Fig. 4 is a schematic diagram of the inductor matrix blank of the present invention.
  • Fig. 5 is a schematic diagram of cutting in the present invention.
  • Fig. 6 is a schematic diagram of the structure of the inductor matrix of the present invention.
  • Fig. 7 is a schematic diagram of the structure of the inductor substrate coated with insulating varnish according to the present invention.
  • Fig. 8 is a schematic diagram of the structure of the inductor substrate for removing insulating varnish according to the present invention.
  • Fig. 9 is a schematic diagram of the structure of the finished inductor of the present invention.
  • Fig. 10 is a schematic diagram of the combined structure of powder block and coil according to Embodiment 5 of the present invention.
  • Fig. 11 is a schematic diagram of an inductor matrix blank according to Embodiment 5 of the present invention.
  • 1 to 11 are: hollow coil 1, coil pin 1a, powder block 2, powder block bottom layer 2a, powder block center layer 2b, inductor matrix blank 3, inductor matrix blank 4, inductor matrix 5, The inductance substrate 6 coated with insulating varnish, the inductance substrate 7 removed from the insulating varnish, the finished inductor 8, and the electrode terminal 8a.
  • the copper wire is wound into a hollow coil 1 as shown in Figure 1, with pins 1a at both ends of the coil, the cross-section of the copper wire is rectangular, and the shape of the hollow coil is a racetrack shape;
  • carbonyl iron powder is used as the magnetic raw powder, and the magnetic powder is compounded from carbonyl iron powder, epoxy resin and lithium stearate, and the particle size of the magnetic powder is 150-200 Micron, the particle size of carbonyl iron powder is 3-8 microns.
  • the production process of the magnetic powder is:
  • Mixture B is granulated and sieved by a oscillating granulator to obtain a semi-finished magnetic powder with a particle size of 150 to 200 microns;
  • the inductor produced by the treatment group in this embodiment has the characteristics of low DC resistance and high rated current. Taking the inductor specification of 2.0*1.6*1.0mm in size and 1.0 microhenry inductance as an example, the performance is shown in Table 1.
  • Table 1 The performance test results of the inductors made by the treatment group in this embodiment
  • Control group based on the manufacturing method of the molded surface mount inductor disclosed in the prior art CN105355408A, the inductor was manufactured.
  • the copper wire is wound into a hollow coil 1 as shown in Figure 1, with pins 1a at both ends of the coil;
  • the base is made of magnetic powder, and the base includes a base and N bosses arranged on the base and arranged in an array at intervals, N ⁇ 2;
  • the magnetic powder used in the control group of this embodiment is the same as the magnetic powder used in the treatment group of this embodiment.
  • the set treatment group is the specific implementation of the technical solution claimed in the present invention
  • the set control group is the implementation of the technical solution reported in the prior art CN105355408A. Comparing the data shown in Table 1 and Table 2, the results show that the performance of the inductors prepared by the treatment group is better, which is specifically reflected in the fact that, under the premise of setting the same inductance, the inductors prepared by the control group are comparable. Compared with the inductors made by the treatment group, they have lower DC resistance, higher saturation current and temperature rise current.
  • the copper wire is wound into a hollow coil 1 as shown in Figure 1, with pins 1a at both ends of the coil, the cross-section of the copper wire is rectangular, and the shape of the hollow coil is a racetrack shape;
  • carbonyl iron powder and iron silicon chromium powder are used as magnetic raw powder, and the magnetic powder is compounded by carbonyl iron powder, iron silicon chromium powder, epoxy resin and zinc stearate.
  • the particle size of the magnetic powder is 180-250 microns, the particle size of the carbonyl iron powder is 3-8 microns, and the particle size of the iron silicon chromium powder is 5-15 microns.
  • the production process of the magnetic powder is:
  • the mixture B is granulated and sieved by a oscillating granulator to obtain a semi-finished magnetic powder with a particle size of 180-250 microns;
  • the inductor produced by the treatment group in this embodiment has the characteristics of low DC resistance and high rated current. Taking the inductor specification of 2.5*2.0*1.2mm in size and 1.0 microhenry inductance as an example, the performance is shown in Table 3.
  • Control group based on the manufacturing method of the molded surface mount inductor disclosed in the prior art CN105355408A, the inductor was manufactured.
  • the copper wire is wound into a hollow coil 1 as shown in Figure 1, with pins 1a at both ends of the coil;
  • the base is made of magnetic powder, and the base includes a base and N bosses arranged on the base and arranged in an array at intervals, N ⁇ 2;
  • the magnetic powder used in the control group of this embodiment is the same as the magnetic powder used in the treatment group of this embodiment.
  • the set treatment group is the specific implementation of the technical solution claimed in the present invention
  • the set control group is the implementation of the technical solution reported in the prior art CN105355408A. Comparing the data shown in Table 3 and Table 4, the results show that the performance of the inductors prepared by the treatment group is better, which is specifically reflected in the fact that, under the premise of setting the same inductance, the inductors prepared by the control group are comparable. Compared with that, the inductor made by the treatment group has lower DC resistance, higher saturation current and temperature rise current.
  • the copper wire is wound into a hollow coil 1 as shown in Figure 1, with pins 1a at both ends of the coil, the cross-section of the copper wire is rectangular, and the shape of the hollow coil is a racetrack shape;
  • iron-silicon powder is used as the magnetic raw powder, and the magnetic powder is compounded by iron-silicon powder, epoxy resin and lithium stearate, and the particle size of the composite magnetic powder is 180-250 microns , The particle size of iron-silicon powder is 5-8 microns.
  • the production process of the magnetic powder is:
  • the mixture B is granulated and sieved by a oscillating granulator to obtain a semi-finished magnetic powder with a particle size of 180-250 microns;
  • the inductors produced by this treatment group have the characteristics of low DC resistance and high rated current. Taking the inductor specification of 2.5*2.0*1.2mm and inductance of 2.2 microhenries as an example, the performance is shown in Table 5 below.
  • Control group based on the manufacturing method of the molded surface mount inductor disclosed in the prior art CN105355408A, the inductor was manufactured.
  • the copper wire is wound into a hollow coil 1 as shown in Figure 1, with pins 1a at both ends of the coil;
  • the base is made of magnetic powder, and the base includes a base and N bosses arranged on the base and arranged in an array at intervals, N ⁇ 2;
  • the magnetic powder used in the control group of this embodiment is the same as the magnetic powder used in the treatment group of this embodiment.
  • the set treatment group is the specific implementation of the technical solution claimed in the present invention
  • the set control group is the implementation of the technical solution reported in the prior art CN105355408A. Comparing the data shown in Table 5 and Table 6, the results show that the performance of the inductors made by the treatment group is better, which is specifically reflected in the fact that, under the premise of setting the same inductance, the inductors made by the control group are comparable. Compared with the inductors made by the treatment group, they have lower DC resistance, higher saturation current and temperature rise current.
  • the copper wire is wound into a hollow coil 1 as shown in Figure 1, with pins 1a at both ends of the coil, the cross-section of the copper wire is rectangular, and the shape of the hollow coil is a racetrack shape;
  • Table 7 The hot-pressing parameter combinations of each treatment group in this embodiment
  • Control group 2 200 100 90 1.8 Control group 3 180 100 100 1.8 Control group 4 350 250 130 11.375 5 groups of control treatment 400 240 120 11.52
  • the magnetic powder used in this embodiment is the same as the magnetic powder used in the treatment group of Embodiment 1.
  • the formed inductor can still be made Inductors, but the corresponding finished inductors within this range have slight cracks.
  • ⁇ 9 the pressing effect of the corresponding inductors is better.
  • ⁇ 2 the DC resistance of the manufactured inductor is obviously too large, and when
  • the copper wire is wound into a hollow coil 1 as shown in Figure 1, with pins 1a at both ends of the coil, the cross-section of the copper wire is rectangular, and the shape of the hollow coil is a racetrack shape;
  • the loose powder block 2 is composed of two parts, which are the bottom layer 2a formed by magnetic powder A and the central layer 2b formed by magnetic powder B, as shown in the figure as shown in 10;
  • the magnetic powder A uses carbonyl iron powder as the magnetic raw powder, and the magnetic powder A is compounded from carbonyl iron powder, epoxy resin and lithium stearate.
  • the magnetic powder A The particle size is 150-200 microns, and the carbonyl iron powder has a particle size of 3-8 microns.
  • the production process of described magnetic powder material A is:
  • Mixture B is granulated and sieved by a oscillating granulator to obtain a semi-finished magnetic powder with a particle size of 150 to 200 microns;
  • the magnetic powder B is made of carbonyl iron powder and iron-based nanocrystalline powder as the magnetic raw powder, and the magnetic powder B is composed of carbonyl iron powder, iron-based nanocrystalline powder, epoxy resin and lithium stearate Compounded, the magnetic powder B has a particle size of 150-200 microns, the carbonyl iron powder has a particle size of 3-8 microns, and the iron-based nanocrystalline powder has a particle size of 3-6 microns.
  • the production process of described magnetic powder material B is:
  • Mixture B is granulated and sieved by a oscillating granulator to obtain a semi-finished magnetic powder with a particle size of 150 to 200 microns;
  • the inductor produced by the treatment group in this embodiment has the characteristics of low DC resistance, large rated current, and high quality factor. Taking the inductor specification of 2.0*1.6*1.0mm in external dimensions and 1.0 microhenry inductance as an example, the performance is shown in Table 9. Show.
  • Inductors were fabricated in the manner described for the treatment group in Example 1 of the present invention.
  • the copper wire is wound into a hollow coil 1 as shown in Figure 1, with pins 1a at both ends of the coil, the cross-section of the copper wire is rectangular, and the shape of the hollow coil is a racetrack shape;
  • carbonyl iron powder is used as the magnetic raw powder, and the magnetic powder is compounded from carbonyl iron powder, epoxy resin and lithium stearate, and the particle size of the magnetic powder is 150-200 Micron, the particle size of carbonyl iron powder is 3-8 microns.
  • the production process of the magnetic powder is:
  • Mixture B is granulated and sieved by a oscillating granulator to obtain a semi-finished magnetic powder with a particle size of 150 to 200 microns;
  • the set treatment group and the control group are both specific implementations of the technical solution claimed in the present invention.
  • the main material of the layer is replaced by carbonyl iron powder with composite magnetic powder of carbonyl iron powder and iron-based amorphous powder. Comparing the data shown in Table 9 and Table 10, the results show that the performance of the inductors made by the treatment group is better, which is specifically reflected in the fact that, under the premise of setting the same inductance, the inductors made by the control group are comparable. Compared with, the inductor made by the treatment group has higher saturation current and quality factor.

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Abstract

本发明提供一种一体成型电感器的制造方法，与现有技术相比，本发明具有以下优点：通过整板成型，再切割成单品的方式，有效提高电感器生产效率，且取消了复杂的底座预制工序，进一步降低了工艺难度和生产成本。同时，线圈不存在和底座的配合间隙问题，一方面可以提升电感器整体的密度，保证了电感器的高性能，另一方面，提高了线圈的定位精度，避免切割位置和线圈实际位置不一致导致的次品和不合格品，提升工艺稳定性和产品合格率。

Description

一种一体成型电感器的制造方法及应用其制备的电感器 技术领域
本发明属于电感器技术领域，具体地，涉及一种一体成型电感器的制造方法及应用其制备的电感器。
背景技术
近年来，由于5G通信技术的发展和成熟，为适应消费类电子产品小型化、轻薄化的趋势，市场对小尺寸、高性能电感器的需求量骤增。在保持高性能的前提下，如何提高电感器的生产效率，降低生产成本成为了各大厂商研究的重点课题。传统的一体成型电感，采用单模腔填粉压制成型的方式，这种方式在制造小尺寸电感时局限性很大，生产效率低、设备和模具投入大。公开号为CN105355408A的专利介绍了一种N颗电感整板成型的方式，先预制带凸台的底座，将空心线圈装配到底座上，再填粉成型压制，最后通过切割的方式得到单颗电感器，该方式有效提高了电感器的生产效率，但该方式仍存在以下缺点：底座预制难度大、模具成本高。
发明内容
本发明的目的在于提供一种一体成型电感器的制造方法及应用其制备的电感器，以在提高电感器生产效率、降低设备投入的条件下，优化电感器的性能。
根据本发明的一个方面，提供一种一体成型电感器的制造方法，包括以下步骤：S1.在模具中填入磁性粉料至铺满模具的底部，填充次数不少于1次；S2.预压填充在模具中的磁性粉料，以使磁性粉料预成型成粉块，粉块的密度不高于5g/cm 3；S3.将N个空心线圈转移至是模具中，并将空心线圈压入预成型的粉块中，以使构成粉块的磁性粉料紧密填充在空心线圈的内表面和外表面；S4.再次向模具中填入磁性粉料，至空心线圈被磁性粉料填埋，填充次数不少于1次，压制填充于模具中的磁性粉料至成型电感母体初坯；S5.对电感母体初坯进行热压，再经热处理制得电感母体毛坯；S6.切割电感母体毛坯，得到内含至少一个空心线圈的电感基体；S.对电感基体的表面进行表面绝缘化处理；S8.去除空心导线的 导电端子部分的绝缘物料，使导电端子部分外露，利用外露的导电端子部分制作出电极端子，得到电感器成品。
本发明人在长期的生产操作中发现，采用磁性粉料预制成型模具的方法中，空心线圈和底座凸台为间隙配合，线圈定位不精确，压制时容易发生移位，影响切割时的合格率，且填粉时间隙处粉末难以流入，影响压制后的产品性能。与现有技术相比，本发明具有以下优点：通过整板成型，再切割成单品的方式，有效提高电感器生产效率，且取消了复杂的底座预制工序，进一步降低了工艺难度和生产成本。同时，线圈不存在和底座的配合间隙问题，一方面可以提升电感器整体的密度，保证了电感器的高性能，另一方面，提高了线圈的定位精度，避免切割位置和线圈实际位置不一致导致的次品和不合格品，提升工艺稳定性和产品合格率。
可选地，在上述S7中，可通过在电感基体表面均匀涂覆一层绝缘漆以实现表面绝缘化处理。
可选地，空心线圈的形状包括但不限于圆形、椭圆形和跑道形。
空心线圈由导线绕制而成。可选地，导线的横截面包括但不限于圆形、矩形。
在S1中，填入磁性粉料的次数可以为1次或多次，每次填入的磁性粉料种类可以相同，也可以不同。
优选地，在S3中，将空心线圈压入填充在模具中的磁性粉料后，空心线圈的上表面不低于填充在模具中的磁性粉料的上表面。在上述状态下，预压的磁性粉料对空心线圈起到限制作用，避免空心线圈在后续的二次压制和热压过程中发生位移。
在S3中，放入空心线圈的数量不低于2个，空心线圈在所述模具中呈等间距阵列排布。等间距阵列的排布形式有利于对坯体进行整齐切割。
在S4中，填入磁性粉料的次数可以为1次或多次，每次填入的磁性粉料种类可以相同，也可以不同。
可选地，空心线圈放入模具的方式不限，可以为绕线完成后直接放入模具，也可以通过线圈移载治具转移至模具中。
优选地，在S5中，热压压力为100～1000MPa,热压温度为80～200℃，保压时间为10～300秒。
优选地，在S5中，以P表示热压压力，以T表示热压温度，以t表示保压时间，P、T、t满足以下数量关系：2≤|P*T*t/1000000|≤11，式中，P的运算单位为MPa，T的运算单位为℃，t的运算单位为s。
优选地，在S5中，P、T、t满足以下数量关系：|P*T*t/1000000|＜9
优选地，在S5中，热压压力不超过600MPa。
优选地，在S5所涉及的热处理操作中，热处理的温度为150～200℃，热处理的时间为1～3小时。
在S5中，当热压操作的参数满足上述条件时，所制得的电感器具有良好的电学性能(通过电感量、直流电阻、饱和电流以及温升电流或者其他电学性能参数体现)。
优选地，在S1～S4中，所采用的磁性粉料的粒径为50～400微米。
优选地，在S1～S4中，所采用的磁性粉料的粒径为80～260微米，流动性30～55秒/50克，松装密度1.5～2.5克/立方厘米。
优选地，磁性粉料由磁性原粉、胶粘剂、润滑剂按照如下方法制得：(a)对磁性原粉进行无机包覆，以达到表面绝缘改性，得到混合物A；(b)在混合物A中加入胶粘剂和丙酮的混合溶液，按照质量百分比计算，胶粘剂的添加量为磁性原粉的1％～10％，混匀，得到混合物B；(c)利用混合物B造粒，得到粒径为50～400微米的半成品粉料；(d)烘干半成品粉料，并向半成品粉料中加入润滑剂，按照质量百分比计算，润滑剂的添加量为半成品粉料的0.01％～0.5％，由此制得磁性粉料。
优选地，在制备上述磁性粉料的步骤(a)中，对磁性原粉进行磷化处理，以达到表面绝缘改性，按照质量百分比计算，磷化剂添加量为0.02％～0.2％，得到混合物A。
优选地，在制备上述磁性粉料的步骤(b)中，在混合物A中加入胶粘剂和丙酮的混合溶液，胶粘剂为改性环氧树脂及其固化剂，按照质量百分比计算，胶粘剂的添加量为磁性原粉的1.8％～3.2％，混匀，得到混合物B。
优选地，在制备上述磁性粉料的步骤(c)中，利用混合物B造粒，得到粒径为80～260微米的半成品粉料。
优选地，在制备上述磁性粉料的步骤(d)中，烘干半成品粉料，烘干温度 为60～100℃，烘干时间为1～2小时，并向半成品粉料中加入润滑剂，润滑剂种类为硬脂酸锂，按照质量百分比计算，润滑剂的添加量为半成品粉料的0.1％～0.3％，由此制得磁性粉料。
优选地，磁性原粉的粒径为1～30微米，磁性原粉包括羰基铁粉、铁硅粉、铁硅铬粉、铁硅铝粉、铁镍粉、铁基非晶粉、铁基纳米晶粉中的至少一种。在一些具体的实施方式中，还可以对所采用的磁性原粉进行一层或多层的包覆改性。
优选地，磁性原粉为羰基铁粉与铁基纳米晶粉混合物，按照质量百分比计算，它们之间的比例为羰基铁粉:铁基纳米晶粉＝9:1～3:7。
可选地，在上述步骤(a)中，进行无机包覆的方法为在磁性原粉的表面形成无机包覆膜，形成无机包覆膜的物料包括磷酸盐、硅酸盐、硝酸盐、氧化硅、氧化钛、氧化铝中的一种或几种。
可选地，在上述步骤(d)中，所采用的润滑剂包括硬脂酸锌、硬脂酸锂、硬脂酸镁、氟化石墨、二硫化钼中的一种或几种。
根据本发明的另一个方面，提供一种电感器：按照如上一体成型电感器的制造方法制备得到。
本发明所提供的电感器制造工艺采用多次压制得到整体粘合、局部叠层结构的电感。电感的叠层结构由多个磁性层组成，磁性层之间的软磁材料呈现非连续分布，该结构可减少磁场互扰。
上述工艺制备的电感与传统电感相比，具有电感值、损耗以及饱和电流连续可调的特点。在具体电感设计中，开发者可根据不同的应用场景设计磁性层的材质、厚度和叠层数量来满足电路最优需求。通过优化设计，制备的高频低损耗功率电感器可适合多场合应用，特别是在高频DC-DC转换器应用中，轻载时可有效减少磁性层的涡流损耗；重载时可有效增大直流重叠饱和电流，从而有效提高DC-DC转换器的效率，达到绿色节能的目的。
附图说明
图1是本发明的空心线圈示意图。
图2是本发明的粉块、线圈组合结构示意图。
图3是本发明的电感母体初坯示意图。
图4是本发明的电感母体毛坯示意图。
图5是本发明的切割示意图。
图6是本发明的电感基体结构示意图。
图7是本发明的涂绝缘漆电感基体结构示意图。
图8是本发明的去除绝缘漆的电感基体结构示意图。
图9是本发明的电感器成品结构示意图。
图10是本发明实施例5的粉块、线圈组合结构示意图。
图11是本发明实施例5的电感母体初坯示意图。
图1至图11的附图标记为：空心线圈1、线圈引脚1a、粉块2、粉块底层2a、粉块中心层2b、电感母体初坯3、电感母体毛坯4、电感基体5、涂绝缘漆电感基体6、去除绝缘漆的电感基体7、电感器成品8、电极端子8a。
具体实施方式
以下将结合附图及实施例对本发明做进一步说明。需要指出的是，以下所述实施例旨在便于对本发明的理解，而对其不起任何限定作用。
实施例1
处理组：
S0.根据设计要求将铜线绕制成如图1所示的空心线圈1，线圈两端带有引脚1a，铜线横截面为矩形，空心线圈形状为跑道形；
S1.在模具中填入一层磁性粉料至铺满模具的底部；
S2.用50MPa压力预成型出疏松的粉块2；
S3.将空心线圈1转移至模具中，线圈在模具中呈等距阵列排布，并将线圈压入预成型的粉块2中，使线圈1的上表面与粉块2的上表面齐平；
S4.再向模具中填入磁性粉料至空心线圈1被磁性粉料完全填埋，然后压制填充模具中的磁性粉料得到电感母体初坯3；
S5.将电感母体初坯3转移至热压模具中，进行热压，热压压力为200MPa，热压温度为160℃，保压时间为120秒，再经180℃下2小时热处理得到电感母体毛坯4；
S6.如图5所示，根据设计尺寸切割电感母体毛坯4，得到若干内含线圈1的电感基体5，切割完成后，电感基体5两端的线圈引脚1a直接外露；
S7.如图7所示，在电感基体5表面滚涂黑色绝缘漆，得到涂绝缘漆的电感基体6；
S8.如图8所示，用激光去除导电端子部分的绝缘漆，再对去除绝缘漆的电感基体7作电镀处理，在导电端子部分制作出电极端子8a(电极端子由内到外分别为铜、镍、锡)，得到电感器成品8。电极端子8a其中一侧与线圈引脚1a相连，另一侧引出至电感器焊接面。
本实施例中，以羰基铁粉为磁性原粉，所述的磁性粉料由羰基铁粉、环氧树脂和硬脂酸锂复配而成，所述磁性粉料的粒径为150～200微米，羰基铁粉的粒径为3～8微米。
所述磁性粉料的制作流程为：
(a)在羰基铁粉中加入适量磷酸的丙酮溶液(磷酸质量：羰基铁粉质量为0.1％)，充分搅拌至溶液挥发，粉末干燥，得到混合物A；
(b)在混合物A中加入环氧树脂和丙酮的混合溶液(环氧树脂质量：羰基铁粉质量为2％)，充分搅拌均匀，得到混合物B；
(c)混合物B用摇摆颗粒机造粒、筛分，得到粒径为150～200微米的半成品磁粉；
(d)半成品磁粉烘干，烘干温度为100℃，时间为60min；
(e)在烘干后的半成品磁粉中，加入0.1％硬脂酸锂，得到磁性粉料成品。
本实施例处理组制作的电感器具有直流电阻低、额定电流大的特点，以外形尺寸2.0*1.6*1.0mm，电感量1.0微亨的电感规格为例，性能如表1所示。
表1本实施例处理组所制得的电感器的性能测试结果
Figure PCTCN2022079895-appb-000001
对照组：以现有技术CN105355408A所披露的模压表面贴装电感的制造方法为基础，制作电感器。
(1)根据设计要求将铜线绕制成如图1所示的空心线圈1，线圈两端带有引脚1a；
(2)采用磁性粉料制造底座，底座包括基座和设置在基座上且成阵列间隔排列的N个凸台，N≥2；
(3)组装空心线圈1和底座：将N个空心线圈1一一对应套在N个凸台的外侧，得到N个空心线圈1与底座的装配体，N个空心线圈1与底座的装配体中N个空心线圈1也成阵列状排列，相邻两个空心线圈1之间具有一段距离；
(4)将N个空心线圈1与底座的装配体置于冷压模具的模腔之内，向模腔中填入磁性粉料后进行冷压处理，得到电感母体初坯，冷压处理的压力为100MPa，冷压处理的温度不高于50℃；
(5)将电感母体初坯转移至热压模具内依次进行热压处理和保压处理，热压压力为300MPa，热压温度为160℃，保压时间为120秒，再经180℃下2小时热处理得到电感母体毛坯；
(6)根据设计尺寸切割电感母体毛坯，得到若干内含线圈1的电感基体，切割完成后，电感基体两端的线圈引脚1a直接外露；
(7)采用喷涂方式在电感基体5表面覆盖黑色绝缘漆，得到涂绝缘漆的电感基体；
(8)用激光去除导电端子部分的绝缘漆，再对去除绝缘漆的电感基体作电镀处理，在导电端子部分制作出电极端子(电极端子由内到外分别为铜、镍、锡)，得到电感器成品。电极端子其中一侧与线圈引脚1a相连，另一侧引出至电感器焊接面。
在上述制作电感器的工序中，本实施例的对照组所采用的磁性粉料与本实施例的处理组所采用的磁性粉料相同。
以外形尺寸2.0*1.6*1.0mm，电感量1.0微亨的电感规格为例，本实施例对照组制作的电感器的性能如表2所示。
表2 本实施例对照组所制得的电感器的性能测试结果
Figure PCTCN2022079895-appb-000002
在本实施例中，所设置的处理组为本发明要求保护的技术方案的具体实施方式，所设置的对照组为现有技术CN105355408A所报道的技术方案的实施方式。对比表1和表2所展示的数据，结果表明，处理组所制得的电感器的性能更佳，具体体现为，在设定相同电感量的前提下，与对照组制得的电感器相比，处理组制得的电感器具有更低的直流电阻、更高的饱和电流和温升电流。
实施例2
处理组：
S0.根据设计要求将铜线绕制成如图1所示的空心线圈1，线圈两端带有引脚1a，铜线横截面为矩形，空心线圈形状为跑道形；
S1.在模具中填入一层磁性粉料至铺满模具的底部；
S2.用60MPa压力预成型出疏松的粉块2；
S3.将空心线圈1转移至模具中，线圈在模具中呈等距阵列排布，并将线圈压入预成型的粉块2中，使线圈1的上表面与粉块2的上表面齐平；
S4.再向模具中填入磁性粉料至空心线圈1被磁性粉料完全填埋，然后压制填充模具中的磁性粉料得到电感母体初坯3；
S5.将电感母体初坯3转移至热压模具中，进行热压，热压压力为400MPa，热压温度为100℃，保压时间为90秒，再经180℃下2小时热处理得到电感母体毛坯4；
S6.如图5所示，根据设计尺寸切割电感母体毛坯4，得到若干内含线圈1的电感基体5，切割完成后，电感基体5两端的线圈引脚1a直接外露；
S7.如图7所示，在电感基体5表面滚涂黑色绝缘漆，得到涂绝缘漆的电感基体6；
S8.如图8所示，用激光去除导电端子部分的绝缘漆，再对去除绝缘漆的电感基体7作电镀处理，在导电端子部分制作出电极端子8a(电极端子由内到外分别为铜、镍、锡)，得到电感器成品8。电极端子8a其中一侧与线圈引脚1a相连，另一侧引出至电感器焊接面。
本实施例中，以羰基铁粉和铁硅铬粉作为磁性原粉，所述的磁性粉料由羰基铁粉、铁硅铬粉、环氧树脂和硬脂酸锌复配而成，所述磁性粉料的粒径为180～250微米，羰基铁粉的粒径为3～8微米，铁硅铬粉的粒径为5～15微米。
所述磁性粉料的制作流程为：
(a)将羰基铁粉和铁硅铬粉按1：1的质量比混合，得到混合原粉，加入适量磷酸的丙酮溶液(磷酸质量：混合原粉质量为0.2％)，充分搅拌至溶液挥发，粉末干燥，得到混合物A；
(b)在混合物A中加入环氧树脂和丙酮的混合溶液(环氧树脂质量：混合原粉质量为3％)，充分搅拌均匀，得到混合物B；
(c)混合物B用摇摆颗粒机造粒、筛分，得到粒径为180～250微米的半成品磁粉；
(d)半成品磁粉烘干，烘干温度为60℃，时间为60min；
(e)在烘干后的半成品磁粉中，加入0.1％硬脂酸锌，得到磁性粉料成品。
本实施例处理组制作的电感器具有直流电阻低、额定电流大的特点，以外形尺寸2.5*2.0*1.2mm，电感量1.0微亨的电感规格为例，性能如表3所示。
表3 本实施例处理组所制得的电感器的性能测试结果
Figure PCTCN2022079895-appb-000003
对照组：以现有技术CN105355408A所披露的模压表面贴装电感的制造方法为基础，制作电感器。
(1)根据设计要求将铜线绕制成如图1所示的空心线圈1，线圈两端带有引脚1a；
(2)采用磁性粉料制造底座，底座包括基座和设置在基座上且成阵列间隔排列的N个凸台，N≥2；
(3)组装空心线圈1和底座：将N个空心线圈1一一对应套在N个凸台的外侧，得到N个空心线圈1与底座的装配体，N个空心线圈1与底座的装配体中N个空心线圈1也成阵列状排列，相邻两个空心线圈1之间具有一段距离；
(4)将N个空心线圈1与底座的装配体置于冷压模具的模腔之内，向模腔中填入磁性粉料后进行冷压处理，得到电感母体初坯，冷压处理的压力为120MPa，冷压处理的温度不高于50℃；
(5)将电感母体初坯转移至热压模具内依次进行热压处理和保压处理，热压压力为400MPa，热压温度为100℃，保压时间为90秒，再经180℃下2小时热处理得到电感母体毛坯；
(6)根据设计尺寸切割电感母体毛坯，得到若干内含线圈1的电感基体，切割完成后，电感基体两端的线圈引脚1a直接外露；
(7)采用喷涂方式在电感基体5表面覆盖黑色绝缘漆，得到涂绝缘漆的电感基体；
(8)用激光去除导电端子部分的绝缘漆，再对去除绝缘漆的电感基体作电镀处理，在导电端子部分制作出电极端子(电极端子由内到外分别为铜、镍、锡)，得到电感器成品。电极端子其中一侧与线圈引脚1a相连，另一侧引出至电感器焊接面。
在上述制作电感器的工序中，本实施例的对照组所采用的磁性粉料与本实施例的处理组所采用的磁性粉料相同。
以外形尺寸2.5*2.0*1.2mm，电感量1.0微亨的电感规格为例，对照组制作的电感器的性能如表4所示。
表4 本实施例对照组所制得的电感器的性能测试结果
Figure PCTCN2022079895-appb-000004
在本实施例中，所设置的处理组为本发明要求保护的技术方案的具体实施方式，所设置的对照组为现有技术CN105355408A所报道的技术方案的实施方式。对比表3和表4所展示的数据，结果表明，处理组所制得的电感器的性能更佳，具体体现为，在设定相同电感量的前提下，与对照组制得的电感器相比，处理组制得的电感器具有更低的直流电阻、更高的饱和电流和温升电流。
实施例3
处理组：
S0.根据设计要求将铜线绕制成如图1所示的空心线圈1，线圈两端带有引脚1a，铜线横截面为矩形，空心线圈形状为跑道形；
S1.在模具中填入一层磁性粉料至铺满模具的底部；
S2.用60MPa压力预成型出疏松的粉块2；
S3.将空心线圈1转移至模具中，线圈在模具中呈等距阵列排布，并将线圈压入预成型的粉块2中，使线圈1的上表面与粉块2的上表面齐平；
S4.再向模具中填入磁性粉料至空心线圈1被磁性粉料完全填埋，然后压制填充模具中的磁性粉料得到电感母体初坯3；
S5.将电感母体初坯3转移至热压模具中，进行热压，热压压力为350MPa，热压温度为100℃，保压时间为120秒，再经180℃下2小时热处理得到电感母体毛坯4；
S6.如图5所示，根据设计尺寸切割电感母体毛坯4，得到若干内含线圈1的电感基体5，切割完成后，电感基体5两端的线圈引脚1a直接外露；
S7.如图7所示，在电感基体5表面滚涂黑色绝缘漆，得到涂绝缘漆的电感基体6；
S8.如图8所示，用激光去除导电端子部分的绝缘漆，再对去除绝缘漆的电感基体7作电镀处理，在导电端子部分制作出电极端子8a(电极端子由内到外分别为铜、镍、锡)，得到电感器成品8。电极端子8a其中一侧与线圈引脚1a相连，另一侧引出至电感器焊接面。
本实施例中，以铁硅粉作为磁性原粉，所述的磁性粉料由铁硅粉、环氧树脂和硬脂酸锂复配而成，所述复合磁粉的粒径为180～250微米，铁硅粉的粒径为5～8微米。
所述磁性粉料的制作流程为：
(a)在铁硅粉中加入适量磷酸的丙酮溶液(磷酸质量：铁硅粉质量为0.2％)，充分搅拌至溶液挥发，粉末干燥，得到混合物A；
(b)在混合物A中加入环氧树脂和丙酮的混合溶液(环氧树脂质量：铁硅粉质量为3％)，充分搅拌均匀，得到混合物B；
(c)混合物B用摇摆颗粒机造粒、筛分，得到粒径为180～250微米的半成品磁粉；
(d)半成品磁粉烘干，烘干温度为120℃，时间为30min；
(e)在烘干后的半成品磁粉中，加入0.05％硬脂酸锂，得到磁性粉料成品。
本实施处理组制作的电感器具有直流电阻低、额定电流大的特点，以外形尺寸2.5*2.0*1.2mm，电感量2.2微亨的电感规格为例，性能如下表5所示。
表5 本实施例处理组所制得的电感器的性能测试结果
Figure PCTCN2022079895-appb-000005
对照组：以现有技术CN105355408A所披露的模压表面贴装电感的制造方法为基础，制作电感器。
(1)根据设计要求将铜线绕制成如图1所示的空心线圈1，线圈两端带有引脚1a；
(2)采用磁性粉料制造底座，底座包括基座和设置在基座上且成阵列间隔排列的N个凸台，N≥2；
(3)组装空心线圈1和底座：将N个空心线圈1一一对应套在N个凸台的外侧，得到N个空心线圈1与底座的装配体，N个空心线圈1与底座的装配体中N个空心线圈1也成阵列状排列，相邻两个空心线圈1之间具有一段距离；
(4)将N个空心线圈1与底座的装配体置于冷压模具的模腔之内，向模腔中填入磁性粉料后进行冷压处理，得到电感母体初坯，冷压处理的压力为150MPa，冷压处理的温度不高于50℃；
(5)将电感母体初坯转移至热压模具内依次进行热压处理和保压处理，热压压力为350MPa，热压温度为100℃，保压时间为120秒，再经180℃下2小时热处理得到电感母体毛坯；
(6)根据设计尺寸切割电感母体毛坯，得到若干内含线圈1的电感基体，切割完成后，电感基体两端的线圈引脚1a直接外露；
(7)采用喷涂方式在电感基体5表面覆盖黑色绝缘漆，得到涂绝缘漆的电感基体；
(8)用激光去除导电端子部分的绝缘漆，再对去除绝缘漆的电感基体作电镀处理，在导电端子部分制作出电极端子(电极端子由内到外分别为铜、镍、锡)，得到电感器成品。电极端子其中一侧与线圈引脚1a相连，另一侧引出至电感器焊接面。
在上述制作电感器的工序中，本实施例的对照组所采用的磁性粉料与本实施例的处理组所采用的磁性粉料相同。
以外形尺寸2.5*2.0*1.2mm，电感量2.2微亨的电感规格为例，对照组所述方法制作的电感器的性能如表6所示。
表6 本实施例对照组所制得的电感器的性能测试结果
Figure PCTCN2022079895-appb-000006
在本实施例中，所设置的处理组为本发明要求保护的技术方案的具体实施方式，所设置的对照组为现有技术CN105355408A所报道的技术方案的实施方式。对比表5和表6所展示的数据，结果表明，处理组所制得的电感器的性能更佳，具体体现为，在设定相同电感量的前提下，与对照组制得的电感器相比，处理组制得的电感器具有更低的直流电阻、更高的饱和电流和温升电流。
实施例4
本实施例各处理组制备电感器的方法步骤如下：
S0.根据设计要求将铜线绕制成如图1所示的空心线圈1，线圈两端带有引脚1a，铜线横截面为矩形，空心线圈形状为跑道形；
S1.在模具中填入一层磁性粉料至铺满模具的底部；
S2.用60MPa压力预成型出疏松的粉块2；
S3.将空心线圈1转移至模具中，线圈在模具中呈等距阵列排布，并将线圈压入预成型的粉块2中，使线圈1的上表面与粉块2的上表面齐平；
S4.再向模具中填入磁性粉料至空心线圈1被磁性粉料完全填埋，然后压制填充模具中的磁性粉料得到电感母体初坯3；
S5.将电感母体初坯3转移至热压模具中，进行热压，以P表示热压压力，以T表示热压温度，以t表示保压时间，再经180℃下2小时热处理得到电感母体毛坯4；
S6.如图5所示，根据设计尺寸切割电感母体毛坯4，得到若干内含线圈1的电感基体5，切割完成后，电感基体5两端的线圈引脚1a直接外露；
S7.如图7所示，在电感基体5表面滚涂黑色绝缘漆，得到涂绝缘漆的电感基体6；
S8.如图8所示，用激光去除导电端子部分的绝缘漆，再对去除绝缘漆的电感基体7作电镀处理，在导电端子部分制作出电极端子8a(电极端子由内到外分别为铜、镍、锡)，得到电感器成品8。电极端子8a其中一侧与线圈引脚1a相连，另一侧引出至电感器焊接面。
在本实施例中，以电感器制备过程中所涉及的热压操作的热压压力P、热压温度T、保压时间t这三个参数所构成的不同组合作为变量，设置不同的处理组，以探究热压操作参数组合对所制得的电感器的性能所产生的影响。各处理组的编号及其所对应的热压参数组合如表7所示。
表7本实施例各处理组的热压参数组合
组别 P(MPa) T(℃) t(s) |P*T*t/1000000|
处理1组 150 160 90 2.16
处理2组 180 150 100 2.70
处理3组 200 100 100 2.00
处理4组 300 160 120 5.76
处理5组 350 120 110 4.62
处理6组 400 120 110 5.28
处理7组 400 100 150 6.00
处理8组 350 160 140 7.84
处理9组 350 160 160 8.96
对照处理1组 150 180 60 1.62
对照处理2组 200 100 90 1.8
对照处理3组 180 100 100 1.8
对照处理4组 350 250 130 11.375
对照处理5组 400 240 120 11.52
在上述制作电感器的工序中，本实施例所采用的磁性粉料与实施例1的处理组所采用的磁性粉料相同。
以外形尺寸2.0*1.6*1.0mm(规格201610-1R0)，电感量1.0微亨的电感规格为例，本实施例各处理组制作的电感器的性能如表8所示。测试结果说明，在制作电感器的热压步骤中，当热压压力P、热压温度T、保压时间t这三个参数满足2≤|P*T*t/1000000|≤11，能够制得成型的电感器成品，并且所制得的电感器的直流电阻量较小，具备良好的电学性能，其中，当9≤|P*T*t/1000000|≤11时，依然能够制得成型的电感器，但是在该范围内对应的电感器成品有轻微开裂，当|P*T*t/1000000|＜9时，对应的电感器的压合效果更佳。当|P*T*t/1000000|＜2，所制得的电感器的直流电阻明显偏大，而当|P*T*t/1000000|＞11时，无法获得成型的电感器成品。
表8 本实施例各处理组的性能测试结果
Figure PCTCN2022079895-appb-000007
Figure PCTCN2022079895-appb-000008
实施例5
处理组：
S0.根据设计要求将铜线绕制成如图1所示的空心线圈1，线圈两端带有引脚1a，铜线横截面为矩形，空心线圈形状为跑道形；
S1.先在模具中均匀填入一层磁性粉料A，再在磁性粉料A的上方填入一层磁性粉料B，直至铺满模具的底部；
S2.用50MPa压力预成型出疏松的粉块2，此时，疏松的粉块2由两部分构成，分别为磁性粉料A形成的底层2a和磁性粉料B形成的中心层2b，如图10所示；
S3.将空心线圈1转移至模具中，线圈在模具中呈等距阵列排布，并将线圈压入预成型的粉块2中，使线圈1的上表面与粉块2的上表面齐平，线圈位于磁性粉料B形成的中心层2b内，如图11所示；
S4.再向模具中填入磁性粉料A至空心线圈1被磁性粉料完全填埋，然后压制填充模具中的磁性粉料得到电感母体初坯3；
S5.将电感母体初坯3转移至热压模具中，进行热压，热压压力为200MPa，热压温度为160℃，保压时间为120秒，再经180℃下2小时热处理得到电感母体毛坯4；
S6.如图5所示，根据设计尺寸切割电感母体毛坯4，得到若干内含线圈1的电感基体5，切割完成后，电感基体5两端的线圈引脚1a直接外露；
S7.如图7所示，在电感基体5表面滚涂黑色绝缘漆，得到涂绝缘漆的电感基体6；
S8.如图8所示，用激光去除导电端子部分的绝缘漆，再对去除绝缘漆的电感基体7作电镀处理，在导电端子部分制作出电极端子8a(电极端子由内到外分别为铜、镍、锡)，得到电感器成品8。电极端子8a其中一侧与线圈引脚1a相连，另一侧引出至电感器焊接面。
本实施例中，磁性粉料A以羰基铁粉为磁性原粉，所述的磁性粉料A由羰基铁粉、环氧树脂和硬脂酸锂复配而成，所述磁性粉料A的粒径为150～200微米，羰基铁粉的粒径为3～8微米。
所述磁性粉料A的制作流程为：
(a)在羰基铁粉中加入适量磷酸的丙酮溶液(磷酸质量：羰基铁粉质量为0.1％)，充分搅拌至溶液挥发，粉末干燥，得到混合物A；
(b)在混合物A中加入环氧树脂和丙酮的混合溶液(环氧树脂质量：羰基铁粉质量为2％)，充分搅拌均匀，得到混合物B；
(c)混合物B用摇摆颗粒机造粒、筛分，得到粒径为150～200微米的半成品磁粉；
(d)半成品磁粉烘干，烘干温度为100℃，时间为60min；
(e)在烘干后的半成品磁粉中，加入0.1％硬脂酸锂，得到磁性粉料A成品。
本实施例中，磁性粉料B以羰基铁粉、铁基纳米晶粉为磁性原粉，所述的磁性粉料B由羰基铁粉、铁基纳米晶粉、环氧树脂和硬脂酸锂复配而成，所述磁性粉料B的粒径为150～200微米，羰基铁粉的粒径为3～8微米，铁基纳米晶粉的粒径为3～6微米。
所述磁性粉料B的制作流程为：
(a)将羰基铁粉和铁基纳米晶粉均匀混合得到原粉混合物，羰基铁粉和铁基纳米晶粉质量比为8：2，在原粉混合物中加入适量磷酸的丙酮溶液(磷酸质量：原粉混合物质量为0.1％)，充分搅拌至溶液挥发，粉末干燥，得到混合物A；
(b)在混合物A中加入环氧树脂和丙酮的混合溶液(环氧树脂质量：原粉混合物质量为2％)，充分搅拌均匀，得到混合物B；
(c)混合物B用摇摆颗粒机造粒、筛分，得到粒径为150～200微米的半成品磁粉；
(d)半成品磁粉烘干，烘干温度为100℃，时间为60min；
(e)在烘干后的半成品磁粉中，加入0.1％硬脂酸锂，得到磁性粉料B成品。
本实施例处理组制作的电感器具有直流电阻低、额定电流大、品质因数高的特点，以外形尺寸2.0*1.6*1.0mm，电感量1.0微亨的电感规格为例，性能如表9所示。
表9 本实施例处理组所制得的电感器的性能测试结果
Figure PCTCN2022079895-appb-000009
对照组：
以本发明实施例1处理组所述的方式，制作电感器。
S0.根据设计要求将铜线绕制成如图1所示的空心线圈1，线圈两端带有引脚1a，铜线横截面为矩形，空心线圈形状为跑道形；
S1.在模具中填入一层磁性粉料至铺满模具的底部；
S2.用50MPa压力预成型出疏松的粉块2；
S3.将空心线圈1转移至模具中，线圈在模具中呈等距阵列排布，并将线圈压入预成型的粉块2中，使线圈1的上表面与粉块2的上表面齐平；
S4.再向模具中填入磁性粉料至空心线圈1被磁性粉料完全填埋，然后压制填充模具中的磁性粉料得到电感母体初坯3；
S5.将电感母体初坯3转移至热压模具中，进行热压，热压压力为200MPa，热压温度为160℃，保压时间为120秒，再经180℃下2小时热处理得到电感母体毛坯4；
S6.如图5所示，根据设计尺寸切割电感母体毛坯4，得到若干内含线圈1的电感基体5，切割完成后，电感基体5两端的线圈引脚1a直接外露；
S7.如图7所示，在电感基体5表面滚涂黑色绝缘漆，得到涂绝缘漆的电感基体6；
S8.如图8所示，用激光去除导电端子部分的绝缘漆，再对去除绝缘漆的电感基体7作电镀处理，在导电端子部分制作出电极端子8a(电极端子由内到外分别为铜、镍、锡)，得到电感器成品8。电极端子8a其中一侧与线圈引脚1a相连，另一侧引出至电感器焊接面。
本实施例中，以羰基铁粉为磁性原粉，所述的磁性粉料由羰基铁粉、环氧树脂和硬脂酸锂复配而成，所述磁性粉料的粒径为150～200微米，羰基铁粉的粒径为3～8微米。
所述磁性粉料的制作流程为：
(a)在羰基铁粉中加入适量磷酸的丙酮溶液(磷酸质量：羰基铁粉质量为0.1％)，充分搅拌至溶液挥发，粉末干燥，得到混合物A；
(b)在混合物A中加入环氧树脂和丙酮的混合溶液(环氧树脂质量：羰基铁粉质量为2％)，充分搅拌均匀，得到混合物B；
(c)混合物B用摇摆颗粒机造粒、筛分，得到粒径为150～200微米的半成品磁粉；
(d)半成品磁粉烘干，烘干温度为100℃，时间为60min；
(e)在烘干后的半成品磁粉中，加入0.1％硬脂酸锂，得到磁性粉料成品。
表10本实施例对照组所制得的电感器的性能测试结果
Figure PCTCN2022079895-appb-000010
在本实施例中，所设置的处理组和对照组均为本发明要求保护的技术方案的具体实施方式，区别在于，所设置的处理组采用了多层不同类型粉末填压的方式，将中心层主材料由羰基铁粉替换为羰基铁粉和铁基非晶粉的复合磁粉。对比表9和表10所展示的数据，结果表明，处理组所制得的电感器的性能更佳，具体体现为，在设定相同电感量的前提下，与对照组制得的电感器相比，处理组制得的电感器具有更高的饱和电流和品质因数。
以上实施例仅用以说明本发明的技术方案而非对本发明保护范围的限制，尽管参照较佳实施例对本发明作了详细说明，本领域的普通技术人员应当理解，可以对本发明的技术方案进行修改或者等同替换，而不脱离本发明技术方案的实质和范围。

Claims (12)

  1. 一种一体成型电感器的制造方法，其特征在于，包括以下步骤：
    S1.在模具中填入磁性粉料至铺满所述模具的底部；
    S2.预压填充在所述模具中的磁性粉料，以使磁性粉料预成型成粉块，所述粉块的密度不高于5g/cm 3；
    S3.将N个空心线圈转移至是模具中，并将所述空心线圈压入预成型的粉块中，以使构成所述粉块的磁性粉料紧密填充在所述空心线圈的内表面和外表面；
    S4.再次向所述模具中填入磁性粉料，至所述空心线圈被磁性粉料填埋，压制填充于所述模具中的磁性粉料至成型电感母体初坯；
    S5.对所述电感母体初坯进行热压，再经热处理制得电感母体毛坯；
    S6.切割所述电感母体毛坯，得到内含至少一个所述空心线圈的电感基体；
    S7.对所述电感基体的表面进行表面绝缘化处理；
    S8.去除所述空心导线的导电端子部分的绝缘物料，使所述导电端子部分外露，利用外露的所述导电端子部分制作出电极端子，得到电感器成品。
  2. 如权利要求1所述一体成型电感器的制造方法，其特征在于：在所述S1中，填入磁性粉料的次数可以为1次或多次，每次填入的磁性粉料种类可以相同，也可以不同。
  3. 如权利要求1所述一体成型电感器的制造方法，其特征在于：在所述S3中，将所述空心线圈压入填充在所述模具中的磁性粉料后，所述空心线圈的上表面不低于填充在所述模具中的磁性粉料的上表面。
  4. 如权利要求1所述一体成型电感器的制造方法，其特征在于：在所述S3中，放入所述空心线圈的数量不低于2个，所述空心线圈在所述模具中呈等间距阵列排布。
  5. 如权利要求1所述一体成型电感器的制造方法，其特征在于：在所述S4中，填入磁性粉料的次数可以为1次或多次，每次填入的磁性粉料种类可以相同，也可以不同。
  6. 如权利要求1所述一体成型电感器的制造方法，其特征在于：在所述S5中，热压压力为100～1000MPa,热压温度为80～200℃，保压时间为10～300秒。
  7. 如权利要求1所述一体成型电感器的制造方法，其特征在于：在S5中，以P表示所述热压压力，以T表示所述热压温度，以t表示所述保压时间，P、T、t满足以下数量关系：2≤|P*T*t/1000000|≤11，式中，P的运算单位为MPa，T的运算单位为℃，t的运算单位为s。
  8. 如权利要求7所述一体成型电感器的制造方法，其特征在于：在所述S5中，热压压力不超过600MPa。
  9. 如权利要求1所述一体成型电感器的制造方法，其特征在于：在所述S1～所述S4中，所采用的所述磁性粉料的粒径为50～400微米。
  10. 如权利要求9所述一体成型电感器的制造方法，其特征在于，所述磁性粉料由磁性原粉、胶粘剂、润滑剂按照如下方法制得：
    (a)对所述磁性原粉进行无机包覆，以达到表面绝缘改性，得到混合物A；
    (b)在所述混合物A中加入所述胶粘剂和丙酮的混合溶液，按照质量百分比计算，所述胶粘剂的添加量为所述磁性原粉的1％～10％，混匀，得到混合物B；
    (c)利用所述混合物B造粒，得到粒径为50～400微米的半成品粉料；
    (d)烘干所述半成品粉料，并向所述半成品粉料中加入所述润滑剂，按照质量百分比计算，所述润滑剂的添加量为所述半成品粉料的0.01％～1.0％，由此制得所述磁性粉料。
  11. 如权利要求10所述一体成型电感器的制造方法，其特征在于：所述磁性原粉的粒径为1～30微米，所述磁性原粉包括羰基铁粉、铁硅粉、铁硅铬粉、铁硅铝粉、铁镍粉、铁基非晶粉、铁基纳米晶粉中的至少一种。
  12. 一种电感器，其特征在于：按照如权利要求1～11任一项所述一体成型电感器的制造方法制备得到。
PCT/CN2022/079895 2022-01-13 2022-03-09 一种一体成型电感器的制造方法及应用其制备的电感器 WO2023133994A1 (zh)

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