Coil and magnetic powder integrated inductor and manufacturing method thereof

A molding and magnetic powder technology, applied in coil manufacturing, inductance/transformer/magnet manufacturing, inductors, etc., can solve problems such as easy damage to the insulation layer, particle fragmentation, and device heating

Inactive Publication Date: 2012-10-17
ZHEJIANG JIAKANG ELECTRONICS CO LTD
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

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Problems solved by technology

But its disadvantage is that it is difficult to achieve high magnetic permeability compared to ferrite core inductors
In order to improve the magnetic permeability, it is necessary to increase the volume occupancy of the metal magnetic powder, so the density of the molded body has to be increased. Due to the friction between the powder particles, the unit must be formed from several tons to tens of tons per square centimeter. Pressure, under the action of this molding pressure, the metal magnetic powder of the molded body will be deformed by force; when the pressure is too high, the particles will be broken; when subjected to an external magnetic field, the loss increases and the device will heat up, which is used in DC / DC converters The power inductance in the medium will weaken the loop efficiency; at the same time, the air-core coil in the inductance device also bears a relatively large molding pressure. When the wire is in contact with the powder, the insulation layer of the wire is easily damaged, which is likely to cause a short circuit problem.

Method used

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  • Coil and magnetic powder integrated inductor and manufacturing method thereof
  • Coil and magnetic powder integrated inductor and manufacturing method thereof
  • Coil and magnetic powder integrated inductor and manufacturing method thereof

Examples

Experimental program
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Effect test

Embodiment 1

[0023] Fe with an average particle diameter of 23 μm and 4.6 μm 89 Si 6.5 Cr 2.5 B 2 The iron-based amorphous metal magnetic powder is mixed in three ratios of 100 to 0, 75 to 25 and 50 to 50, respectively. Add E5284 single-component high-temperature curing high-temperature-resistant epoxy resin (produced by Beijing Hangtongzhou Technology Co., Ltd.) with 4.8% of the weight of the magnetic powder to each magnetic powder, and mix. Mix magnetic powder and resin into a clay-like dough. Preheat the clay-like dough to 100°C and fill it into a ring mold. Compressed with a pressure of 1 kgf per square centimeter. The sample size is 17mm in outer diameter, 7.0mm in inner diameter, and 5.0mm in height. Keep the highest pressure state, heat the mold to 140-160°C, keep warm for 8-15 minutes, and cure the resin. Use the B-H analyzer to measure the performance of the magnetic material under the condition of 300Khz-40mT, and the test results are shown in Table 1.

[0024] Table 1 Eff...

Embodiment 2

[0036] The method of the present invention is used to make an inductor with an external dimension of 6.7*7.4*3.0mm, the inductance is 1.0 μH, and the magnetic powder used is Fe 88.5 Si 6.5 Cr 2.5 B 2.5The amorphous alloy magnetic powder has an average particle diameter of 23μm and 5μm, and the weight ratio is 75:25. The amount of epoxy resin added is 4.8% of the weight of the magnetic powder. The enameled wire of the coil used is flat, with a width of 1.8mm and a thickness of 0.25mm. The specification is 220-Ⅱ (produced by Jiangxi Jiateng Wire Co., Ltd.). Heat the forming mold and lower punch to 100°C, heat the magnetic powder mass to 100°C, fill the coil and magnetic powder mass into the mold, pressurize, the pressure is 120±1kgf, heat up to 150±2°C, pressurize and keep warm 9-10 minutes, take out the finished product. Polish the end face with Φ500 diamond fine sand, and then vacuum sputter platinum to form the lead-out electrode.

[0037] Inductors with the same dimensi...

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Abstract

The invention provides a coil and magnetic powder integrated inductor. The coil and magnetic powder integrated inductor comprises a cubic magnetic material block (5) which is internally provided with an embedded coil (4), wherein an end electrode (6) is arranged on each of two opposite sides, each of the end electrodes is connected with one end of the coil, the magnetic material block consists of more than two kinds of magnetic powder in different average particle sizes and insulation resin, and the general formula of the compositions of the magnetic powder is Fe100-x-y-z SixCryBz. A manufacturing method comprises the following steps: (I) uniformly mixing the magnetic powder in different particle sizes; (II) mixing the magnetic powder and the insulation resin into a compound magnetic material group; (III) manufacturing the hollow coil; (IV) heating a forming mold and a lower punch, filling the compound magnetic material group and the hollow coil, molding in compression, preserving heat till the resin is solidified, and then demolding; (V) polishing the two end faces; and (VI) performing vacuum sputtering to prepare the electrode. The compression molding operation can be carried out with relatively low pressure, and the magnetic particle and the coil are barely damaged in the compressing process.

Description

technical field [0001] The invention relates to a coil magnetic powder integral molding inductor for electronic products and a manufacturing method thereof. Background technique [0002] In recent years, as the processing speed of MPUs for notebook PCs and servers has increased, the supply current has been increased. Among them, the power inductors used in DC / DC converters, due to the need for miniaturization and high current, figure 1 The unibody inductor shown is also moving toward productization. Chinese patent CN1304145A describes the manufacturing method of this type of inductor in detail. The magnetic material used in this type of inductor is usually made of a combination of metal magnetic powder and insulating materials such as resin. The powder particles obtained by mixing and kneading metal magnetic powder and resin are pressed by mold cold pressing powder forming method to obtain an inductor. , this method is commonly used. [0003] In the existing inductors of...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): H01F1/09H01F37/00H01F41/00H01F41/04H01F27/29
Inventor 童元丰朱金良戴黎明张兴元
Owner ZHEJIANG JIAKANG ELECTRONICS CO LTD
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