A method for manufacturing an integrally formed inductor electrode

Abstract

The present invention discloses a method for manufacturing an integrally formed inductor electrode, and relates to the field of inductor technology. The present invention includes the following steps: magnetic core primary forming, winding, magnetic core secondary forming, roller spraying, electrode coating, grinding, metallization, testing, and packaging. The present invention is a method for manufacturing an integrally formed inductor electrode. After coating the electrode with glue, a typesetting device is used to neatly arrange the products into a precision fixture, and then the fixture is arranged on the work surface of a precision surface grinder. The single feed is 0.005mm, and the electrodes at both ends of the product are repeatedly ground multiple times at the same time, and the grinding time is 40min. After observation, it is found that the grinding surface of the electrode copper wire rarely extends, breaks, or breaks, and the electrode size integrity consistency yield is improved by 10%; after the product is electroplated, the electrode adhesion is compared with the traditional process, and the bonding force is improved by 30%; the incidence of yellowing of the product electrode and PCT high-voltage accelerated aging and rusting is also greatly reduced.

Description

Technical Field

[0001] The present invention relates to the field of inductor technology, and in particular to a method for manufacturing an integrally formed inductor electrode. Background Art

[0002] Inductance is a property of a closed loop and a physical quantity. When current passes through a coil, a magnetic field is induced in the coil, and the induced magnetic field generates an induced current to resist the current passing through the coil. It is a circuit parameter that describes the induced electromotive force effect caused in the coil or in another coil due to the change of coil current. Inductance is a general term for self-inductance and mutual inductance. The device that provides inductance is called an inductor.

[0003] The traditional integrated inductor manufacturing on the market currently includes molding I, winding, molding II, rolling spraying, grinding, metallization, testing, and packaging. In the traditional process, when stripping the glue, the copper wire grinding surface will show obvious extension, damage, and fracture, and the electrode size integrity consistency is low, resulting in a high electrode appearance defect rate; in addition, when removing the coating layer, if part of the copper electrode is over-grinded, the magnetic powder around the copper wire is exposed. In the electroplating acid environment or high temperature and high humidity environment, the metallization layer cannot completely protect the exposed iron powder and magnetic powder, resulting in the product electrode layer being prone to yellowing and PCT rusting; the traditional process has a low product yield and high production cost, which is not conducive to large-scale production and cannot meet market demand. Summary of the invention

[0004] The main purpose of the present invention is to provide a method for manufacturing an integrally formed inductor electrode, which can effectively solve the problems of low consistency in electrode dimensional integrity in the background technology and the inability of the metallization layer to completely protect the exposed iron powder and magnetic powder, resulting in the product electrode layer being prone to yellowing and PCT rusting.

[0005] To achieve the above object, the technical solution adopted by the present invention is: a method for manufacturing an integrally formed inductor electrode, comprising the following steps:

[0006] S1. One-step forming of magnetic core: establishing an automatic feeding mechanism and a first forming mechanism, and pushing magnetic powder into the forming mechanism through the automatic feeding mechanism to form a formed blank;

[0007] S2. Winding: Establish a winding mechanism, and use the winding mechanism to neatly wind the enameled copper wire on the formed blank;

[0008] S3, secondary molding of magnetic core: establish a second molding mechanism, put the molded blank with the coil wound into the mold of the second molding mechanism, and inject micron-grade magnetic powder into the mold cavity to complete the molding to obtain the product;

[0009] S4, roller spraying: establish a roller spraying mechanism, use the roller spraying mechanism to carry out insulation coating on the surface of the product for 2 to 3 hours, and then place it in a 120-300°C oven for at least 1 hour to solidify and form an insulation layer;

[0010] S5. Electrode coating: Automatic glue scraping equipment is used to fix the product on the workbench of the equipment with the electrode facing upward. The equipment then automatically fits the screen printing steel mesh to the surface of the product for glue scraping. The scraped product passes through a continuous baking device and is cured at 50-300°C.

[0011] S6, grinding: Use typesetting equipment to neatly arrange the products into a precision fixture, fix them with a clamp, and then move the clamp to the worktable of a precision surface grinder. Feed the electrodes at both ends of the product repeatedly for multiple times at a distance of 0.005mm per time, so that the electrode end surfaces exposed at both ends of the product are complete and consistent in size;

[0012] S7, Metallization: Use typesetting equipment to neatly arrange the products into a precision fixture, use multi-arc ion plating to plate the Cr metal layer on the surface of the product electrode, then use DC magnetron sputtering to plate Ni and Ag metal layers on the surface of the Cr metal layer, and finally use water plating to plate Ni and Sn metal layers on the outer surface of the Ni and Ag metal layers;

[0013] S8, Testing and Packaging: Fully automatic testing and packaging equipment is used to conduct fully automatic electrical testing on products according to specification and performance requirements, and products with defective dimensions and characteristics are eliminated, and qualified products are automatically packaged.

[0014] Preferably, the automatic feeding mechanism in S1 is an automatic powder feeding machine, the first molding mechanism is an integrated inductor molding machine, and the magnetic powder is filtered through a filter screen with a mesh size of 80 to 200.

[0015] Preferably, the winding mechanism in S2 is an inductor coil winding machine.

[0016] Preferably, the micron-sized magnetic powder in S3 is filtered through a filter screen with a mesh size of 80 to 200.

[0017] Preferably, the rolling spraying mechanism in S4 is a rolling spraying machine, and its working parameters are 3-5cc / min flow rate, 0.2-0.4Mpa atomizing air pressure, 90-120℃ constant temperature space, 6-8r / min rolling speed. During rolling spraying, a cycle of spraying for 6 seconds and staying for 2 seconds is adopted. The thickness of the insulating layer in S4 is 7-15um.

[0018] Preferably, the roller spraying machine uses polyimide-based nanomaterials as spraying raw materials.

[0019] Preferably, the automatic glue scraping device in S5 adopts a screen glue scraper, the glue adopts epoxy glue or silicone, the workbench is a double-sided adhesive alumina ceramic plate, and it is fixed by sticking it to the electrode bridge of the product with tape.

[0020] Preferably, the grinding time in S6 is 30-50 min, and the grinding speed is 200-400 r / min.

[0021] Compared with the prior art, the present invention has the following beneficial effects:

[0022] 1. In the present invention, epoxy glue or silicone is used to cover the electrode copper wire, so that when it is ground, the ground surface of the copper wire rarely stretches, breaks, or fractures, and the electrode dimensional integrity consistency yield is improved by 10%, thereby greatly reducing the incidence of yellowing and PCT rust.

[0023] 2. In the present invention, a Cr metal layer is plated on the surface of the product electrode by multi-arc ion plating, and then Ni and Ag metal layers are plated on the surface of the Cr metal layer by DC magnetron sputtering, and finally Ni and Sn metal layers are plated on the outer surfaces of the Ni and Ag metal layers by water plating, so as to improve the electrode adhesion by 30%. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 A schematic diagram of the process structure of a method for manufacturing an integrally formed inductor electrode according to the present invention;

[0025] Figure 2 A schematic diagram of a product after electrode coating in a method for manufacturing an integrally formed inductor electrode of the present invention;

[0026] Figure 3 A schematic diagram of a product after grinding in a method for manufacturing an integrally formed inductor electrode of the present invention;

[0027] Figure 4 It is a schematic diagram of a finished product of a method for manufacturing an integrally formed inductor electrode of the present invention. DETAILED DESCRIPTION

[0028] In order to make the technical means, creative features, objectives and effects achieved by the present invention easy to understand, the present invention is further explained below in conjunction with specific implementation methods.

[0029] In the description of the present invention, it should be noted that the terms "upper", "lower", "inner", "outer", "front end", "rear end", "two ends", "one end", "the other end" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first" and "second" are used for descriptive purposes only and cannot be understood as indicating or implying relative importance.

[0030] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "provided with", "connected", etc. should be understood in a broad sense. For example, "connected" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0031] Please refer to Figure 1 As shown in FIG. 4 , the present invention is a method for manufacturing an integrally formed inductor electrode, comprising the following steps:

[0032] S1. One-step forming of magnetic core: establishing an automatic feeding mechanism and a first forming mechanism, and pushing magnetic powder into the forming mechanism through the automatic feeding mechanism to form a formed blank;

[0033] S2. Winding: Establish a winding mechanism, and use the winding mechanism to neatly wind the enameled copper wire on the formed blank;

[0034] S3, secondary molding of magnetic core: establish a second molding mechanism, put the molded blank with the coil wound into the mold of the second molding mechanism, and inject micron-grade magnetic powder into the mold cavity to complete the molding to obtain the product;

[0035] S4, roller spraying: establish a roller spraying mechanism, use the roller spraying mechanism to carry out insulation coating on the surface of the product for 2 to 3 hours, and then place it in a 120-300°C oven for at least 1 hour to solidify and form an insulation layer;

[0036] S5. Electrode coating: Automatic glue scraping equipment is used to fix the product on the workbench of the equipment with the electrode facing upward. The equipment then automatically fits the screen printing steel mesh to the surface of the product for glue scraping. The scraped product passes through a continuous baking device and is cured at 50-300°C.

[0037] S6, grinding: Use typesetting equipment to neatly arrange the products into a precision fixture, fix them with a clamp, and then move the clamp to the worktable of a precision surface grinder. Feed the electrodes at both ends of the product repeatedly for multiple times at a distance of 0.005mm per time, so that the electrode end surfaces exposed at both ends of the product are complete and consistent in size;

[0038] S7, Metallization: Use typesetting equipment to neatly arrange the products into a precision fixture, use multi-arc ion plating to plate the Cr metal layer on the surface of the product electrode, then use DC magnetron sputtering to plate Ni and Ag metal layers on the surface of the Cr metal layer, and finally use water plating to plate Ni and Sn metal layers on the outer surface of the Ni and Ag metal layers;

[0039] S8, Testing and Packaging: Fully automatic testing and packaging equipment is used to conduct fully automatic electrical testing on products according to specification and performance requirements, and products with defective dimensions and characteristics are eliminated, and qualified products are automatically packaged.

[0040] Example 1

[0041] The 0.075-0.180mm magnetic powder is pushed into the mold of the integrated inductor forming machine by the automatic powder feeding machine to obtain a molded body, and then the enameled copper wire is neatly wound on the molded body by the inductor coil winding machine, and the molded body with the coil wound is placed in the mold of another integrated inductor forming machine, and the 0.075-0.180mm magnetic powder is injected into the mold cavity again to complete the molding to obtain the product, and then the product is placed in the roller spraying machine, and its working parameters are set to 3cc / min flow rate, 0.2Mpa atomization air pressure, 90℃ constant temperature space, 6r / min rolling speed, and polyimide nanomaterials are used as raw materials. The spraying is 6 seconds and the dwelling time is 2 seconds. The cycle is 2 hours. After the roller spraying is completed, it is placed in a 120℃ oven for baking for 1 hour to solidify to form a 7um thick insulating layer, and then the product is placed with the electrode facing up by a robot and arranged on a fixed double-sided On the glued alumina ceramic plate, stick tape in the product electrode bridge, and after silk-screening epoxy glue or silicone, tear off the tape, cure it through continuous baking equipment, and cure it at 150℃, then fix it with a clamp, and move the clamp to the worktable of the precision surface grinder, feed 0.005mm at a single time to grind the electrodes at both ends of the product repeatedly for 40 minutes, so that the electrode end faces exposed at both ends of the product are complete and consistent in size. When the grinding is completed, use multi-arc ion plating to plate the Cr metal layer on the surface of the product electrode, and then use DC magnetron sputtering to plate Ni and Ag metal layers on the surface of the Cr metal layer, and finally use water plating to plate Ni and Sn metal layers on the outer surface of the Ni and Ag metal layers. Finally, use fully automatic testing and packaging equipment to perform fully automatic electrical testing on the products according to the specifications and performance requirements, remove defective products with size and characteristics, and automatically package qualified products.

[0042] Example 2

[0043] The 0.075-0.180mm magnetic powder is pushed into the mold of the integrated inductor forming machine by the automatic powder feeding machine to obtain a molded body, and then the enameled copper wire is neatly wound on the molded body by the inductor coil winding machine, and the molded body with the coil wound is placed in the mold of another integrated inductor forming machine, and the 0.075-0.180mm magnetic powder is injected into the mold cavity again to complete the molding to obtain the product, and then the product is placed in the roller spraying machine, and its working parameters are set to 4cc / min flow rate, 0.3Mpa atomization air pressure, 105℃ constant temperature space, 7r / min rolling speed, and polyimide nanomaterials are used as raw materials. The spraying is 6 seconds and the dwelling time is 2 seconds. The cycle is 2 hours. After the roller spraying is completed, it is placed in a 210℃ oven for baking for 1 hour to solidify to form a 11um thick insulating layer. Then, the product is placed in a robot with the electrode facing up and arranged in a fixed position with double On the surface adhesive alumina ceramic plate, tape is pasted in the product electrode bridge, and after silk-screening epoxy glue or silicone, the tape is torn off, and it is cured by continuous baking equipment and cured at 150°C. Then it is fixed by a clamp, and the clamp is moved to the worktable of the precision surface grinder. The electrodes at both ends of the product are repeatedly ground for 40 minutes at a single feed distance of 0.005mm, so that the electrode end faces exposed at both ends of the product are complete and consistent in size. When the grinding is completed, the Cr metal layer is plated on the surface of the product electrode by multi-arc ion plating, and then the Ni and Ag metal layers are plated on the surface of the Cr metal layer by DC magnetron sputtering. Finally, the Ni and Sn metal layers are plated on the outer surface of the Ni and Ag metal layers by water plating. Finally, the fully automatic testing and packaging equipment is used to perform fully automatic electrical tests on the products according to the specifications and performance requirements, and the defective products in size and characteristics are eliminated, and the qualified products are automatically packaged.

[0044] Example 3

[0045] The magnetic powder of 0.075-0.180mm is pushed into the mold of the integrated inductor forming machine by the automatic powder feeding machine to form a molded body, and then the enameled copper wire is neatly wound on the molded body by the inductor coil winding machine, and the molded body with the coil wound is placed in the mold of another integrated inductor forming machine, and 0.075-0.180mm magnetic powder is injected into the mold cavity again to complete the molding to obtain the product, and then the product is placed in the roller spraying machine, and its working parameters are set to 5cc / min flow rate, 0.4Mpa atomization air pressure, 120℃ constant temperature space, 8r / min rolling speed, and polyimide nanomaterials are used as raw materials. The spraying is 6 seconds and the dwelling time is 2 seconds. The cycle is 2 hours. After the roller spraying is completed, it is placed in a 300℃ oven for baking for 1 hour to solidify to form a 15um thick insulating layer. Then, the product is placed with the electrode facing up by a robot and arranged in a fixed double On the surface adhesive alumina ceramic plate, tape is pasted in the product electrode bridge, and after silk-screening epoxy glue or silicone, the tape is torn off, and it is cured by continuous baking equipment and cured at 150°C. Then it is fixed by a clamp, and the clamp is moved to the worktable of the precision surface grinder. The electrodes at both ends of the product are repeatedly ground for 40 minutes at a single feed distance of 0.005mm, so that the electrode end faces exposed at both ends of the product are complete and consistent in size. When the grinding is completed, the Cr metal layer is plated on the surface of the product electrode by multi-arc ion plating, and then the Ni and Ag metal layers are plated on the surface of the Cr metal layer by DC magnetron sputtering. Finally, the Ni and Sn metal layers are plated on the outer surface of the Ni and Ag metal layers by water plating. Finally, the fully automatic testing and packaging equipment is used to perform fully automatic electrical tests on the products according to the specifications and performance requirements, and the defective products in size and characteristics are eliminated, and the qualified products are automatically packaged.

[0046] Comparative Example

[0047] The comparative example is a product produced by traditional technology.

[0048] Electrical Characteristics of Inductors

[0049] L value: inductance;

[0050] Q value: the quality factor of an inductor;

[0051] DCR: internal resistance of the inductor.

[0052] Table 1 Comparison of electrical characteristics between the present invention and traditional process products

[0053]

[0054] From Table 1 above, it can be concluded that the electrical properties of the epoxy resin coated samples, such as L value, Q value, DCR, and saturation current characteristics, are comparable to those of normal products.

[0055] Table 2 Comparison of electrode adhesion of the present invention and traditional process

[0056]

[0057] From Table 2 above, it can be concluded that the electrode adhesion is improved by 30%.

[0058] Table 3 Comparison of the yield rate of the grinding surface of the inductor electrode of the present invention and the traditional process

[0059]

[0060] From Table 3 above, it can be concluded that by using epoxy glue or silicone to cover the electrode copper wire, the copper wire grinding surface rarely shows extension, damage, and breakage during grinding, and the electrode dimensional integrity consistency yield is improved by 10%.

[0061] The above shows and describes the basic principles and main features of the present invention and the advantages of the present invention. It should be understood by those skilled in the art that the present invention is not limited to the above embodiments. The above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, which fall within the scope of the present invention to be protected. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. A method for manufacturing an integrally formed inductor electrode, characterized in that: The following steps are involved: S1. One-step forming of magnetic core: establishing an automatic feeding mechanism and a first forming mechanism, and pushing magnetic powder into the forming mechanism through the automatic feeding mechanism to form a formed blank; S2. Winding: Establish a winding mechanism, and use the winding mechanism to neatly wind the enameled copper wire on the formed blank; S3, secondary molding of magnetic core: establish a second molding mechanism, put the molded blank with the coil wound into the mold of the second molding mechanism, and inject micron-grade magnetic powder into the mold cavity to complete the molding to obtain the product; S4, roller spraying: establish a roller spraying mechanism, use the roller spraying mechanism to carry out insulation coating on the surface of the product for 2 to 3 hours, and then place it in a 120-300°C oven for at least 1 hour to solidify and form an insulation layer; S5. Electrode coating: Automatic glue scraping equipment is used to fix the product on the workbench of the equipment with the electrode facing upward. The equipment then automatically fits the screen printing steel mesh to the surface of the product for glue scraping. The scraped product passes through a continuous baking device and is cured at 50-300°C. S6, grinding: Use typesetting equipment to neatly arrange the products into a precision fixture, fix them with a clamp, and then move the clamp to the worktable of a precision surface grinder. Feed the electrodes at both ends of the product repeatedly for multiple times at a distance of 0.005mm per time, so that the electrode end surfaces exposed at both ends of the product are complete and consistent in size; S7, Metallization: Use typesetting equipment to neatly arrange the products into a precision fixture, use multi-arc ion plating to plate the Cr metal layer on the surface of the product electrode, then use DC magnetron sputtering to plate Ni and Ag metal layers on the surface of the Cr metal layer, and finally use water plating to plate Ni and Sn metal layers on the outer surface of the Ni and Ag metal layers; S8, Testing and Packaging: Fully automatic testing and packaging equipment is used to conduct fully automatic electrical testing on products according to specification and performance requirements, and products with defective dimensions and characteristics are eliminated, and qualified products are automatically packaged.

2. The method for manufacturing an integrally formed inductor electrode according to claim 1, characterized in that: The automatic feeding mechanism in S1 is an automatic powder feeding machine, the first molding mechanism is an integrated inductor molding machine, and the magnetic powder is filtered through a filter screen with a mesh size of 80 to 200.

3. The method for manufacturing an integrally formed inductor electrode according to claim 2, characterized in that: The winding mechanism in S2 is an inductor coil winding machine.

4. The method for manufacturing an integrally formed inductor electrode according to claim 3, characterized in that: The micron-sized magnetic powder in S3 is filtered through a filter screen with a mesh size of 80 to 200.

5. The method for manufacturing an integrally formed inductor electrode according to claim 4, characterized in that: The rolling spraying mechanism in the S4 is a rolling spraying machine, and its working parameters are 3-5cc / min flow rate, 0.2-0.4Mpa atomizing air pressure, 90-120℃ constant temperature space, 6-8r / min rolling speed. During rolling spraying, a cycle of spraying for 6 seconds and staying for 2 seconds is adopted. The thickness of the insulating layer in the S4 is 7-15um.

6. The method for manufacturing an integrally formed inductor electrode according to claim 5, characterized in that: The roller spraying machine uses polyimide series nano materials as spraying raw materials.

7. The method for manufacturing an integrally formed inductor electrode according to claim 6, characterized in that: The automatic glue scraping device in S5 adopts a screen glue scraper, the glue adopts epoxy glue or silicone, the workbench is a double-sided adhesive alumina ceramic plate, and it is fixed by sticking it on the electrode bridge of the product through tape.

8. The method for manufacturing an integrally formed inductor electrode according to claim 7, characterized in that: The grinding time in S6 is 30-50 min, and the grinding speed is 200-400 r / min.

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