A method of manufacturing an integrally formed inductor

Abstract

The invention discloses a method for manufacturing an integrally formed inductor, which includes the following steps: Presetting the coil: placing the prefabricated air-core coil into the mold cavity of the injection mold or placing the prefabricated air-core coil into the soft magnetic core , and then put it into the mold cavity of the injection mold; mixing granulation: soft magnetic powder and binder are mixed and granulated to obtain soft magnetic composite particles, and the average Wardell sphericity of the soft magnetic powder is 75%~100%, Preferably 80%~100%, more preferably 85%~100%; Injection molding: The soft magnetic composite particles are melted by injection molding equipment to form a soft magnetic composite material, and injected into the mold cavity of the mold to obtain an integrated Formed inductors.

Description

technical field [0001] The invention relates to the field of manufacture of inductors, in particular to a method of manufacture of integrally formed inductors. Background technique [0002] At present, most of the one-piece inductors sold on the market are prepared by powder metallurgy process, and are molded by metal powder, so they are also called molded inductors. The specific manufacturing process is as follows: first place the prefabricated hollow coil in the mold cavity. , and then add the metal powder treated by insulation coating, then press and form, and finally carry out low-temperature heat curing treatment to obtain an integrally formed inductor. Although the powder metallurgy process is relatively simple compared to other processes, it also has many technical problems: [0003] 1. During the pressing process, the metal powder is easy to damage the insulating layer of the hollow coil, resulting in a short circuit and a potential safety hazard, so only relatively...

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Problems solved by technology

Recently, there are also new reports that add a small amount of spherical or spherical particles of alloy metal powder dry powder to the carbon-based iron powder to improve product performance. Due to the high proportion of pure iron powder, its overall performance is limited. ;

[0005] 3. The powder metallurgy process can generally only be applied to low-power inductors, and it is impossible to prepare high-power integrated inductors. Therefore, it cannot meet the market demand for medium and large inductors

[0009] When too much binder is added to the soft magnetic powder, it will lead to low density of the produced magnetic material

Although the published patents also have high-density soft magnetic composite materials made by injection technology, in fact, due to the high proportion of binder, the proportion of non-magnetic substances is also high, even if the density of the prepared soft magnetic composite material is High, the actual effective magnetic material ratio is still very low under the same volume, so the actual performance of the product is poor

[0010] In summary, the above technical problems explain why the patented injection molding process has not replaced the traditional powder metallurgy process in the current market. Based on the technical problems of the injection molding process disclosed in the prior art, the present invention is dedicated to solving the current The injection molding process has been improved so that it can be truly applied to the actual production of one-piece inductors

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