Preparation method of amorphous nanocrystalline inductor with quasi-circular cross section

Abstract

The invention provides a preparation method of an amorphous nanocrystalline inductor with a quasi-circular cross section, and relates to the technical field of inductor preparation, an amorphous nanocrystalline magnetic core with a quasi-circular cross section is placed on winding equipment, and stress-free winding of the magnetic core is completed under mutual cooperation of a coil winding mechanism, a magnetic core supporting mechanism, a wire conveying mechanism and a wire shearing mechanism. And assembling, soldering, dispensing, baking and shaping to obtain the target inductor. The manufacturing method has the advantages that the magnetic core with the quasi-circular cross section is directly selected to manufacture the inductor, and compared with a rectangular or square cross section magnetic core commonly used in the current industry, the inductor has the minimum cross section perimeter under the condition of the same cross section area. The length of the enameled wire required for preparing electronic devices such as inductors and transformers with the same technical parameters is shorter, the consumption of copper wire materials can be greatly saved, the resistance and the weight of the electronic devices are smaller, and the production cost is also remarkably reduced.

Description

Technical Field

[0001] The invention relates to the technical field of inductor preparation, and in particular to a method for preparing an amorphous nanocrystalline inductor with a quasi-circular cross-section. Background Art

[0002] With the rapid development and application of new energy vehicles, 5G communications and third-generation semiconductor technology, the number of electromagnetic components in circuit boards is increasing. Many of these electromagnetic components will generate a large amount of high-frequency current or electrical signals during use. These high-frequency currents or electrical signals will affect the normal operation of other electronic components through the connecting wires or circuit boards in the circuit. In order to eliminate various interferences of these high-frequency signals and currents in the circuit, it is necessary to reasonably arrange the filter circuit to filter these interferences. As an important component of the filter circuit, the inductor plays a decisive role in the back-end application of the filter device. Amorphous and nanocrystalline inductors are filter inductor devices that are widely used in current circuits.

[0003] Due to the brittle mechanical properties of amorphous nanocrystalline strips after heat treatment and the strip-shaped material form, the preparation of existing amorphous nanocrystalline inductors is usually to wind, heat treat, and shape strips of equal width to obtain magnetic cores, and then wind and assemble the magnetic cores. Most of the magnetic cores obtained by the above process are as follows Figure 4 The rectangular cross section shown has the following technical problems:

[0004] 1) Under the same cross-sectional area, when winding the same number of turns of coils, the length of enameled wire required for the magnetic core with a rectangular cross-sectional area is longer than that used for the magnetic core with a circular cross-sectional area, which means that the inductor prepared by the rectangular cross-sectional magnetic core uses a higher amount of copper and cannot meet the requirements of high-efficiency and low-cost production;

[0005] 2) For conventional rectangular cross-section magnetic cores, the edges of the magnetic cores are subjected to severe stress during the winding process, resulting in deformation of the magnetic cores and severe attenuation of magnetic properties. In addition, if the inductance requirements are to be met, more turns of coils need to be wound, which is not conducive to cost savings and improving production efficiency. Summary of the invention

[0006] In view of the problems existing in the prior art, the present invention provides a method for preparing an amorphous nanocrystalline inductor with a quasi-circular cross-section, wherein an amorphous nanocrystalline magnetic core with a quasi-circular cross-section is placed on a winding device, and a coil winding mechanism, a magnetic core supporting mechanism, a wire conveying mechanism and a wire shearing mechanism in the winding device cooperate with each other to complete stress-free winding of the magnetic core, and then the target inductor is obtained through subsequent assembly, soldering, dispensing, baking, shaping and other processes.

[0007] Preferably, the coil winding mechanism is provided with an extending connecting rod which can move forward and backward, and a enameled wire bending disk is provided at the front end of the extending connecting rod. The enameled wire bending disk is used to bend the enameled wire into a coil according to a set winding direction and a preset curvature radius, and wind it around the outer periphery of the magnetic core.

[0008] Preferably, the preset curvature radius R1 is greater than or equal to the outer contour radius R0 of the cross section of the magnetic core.

[0009] Preferably, the magnetic core supporting mechanism is arranged at the rear end of the enameled wire bending disk, and is used to support the magnetic core and can rotate along the magnetic circuit direction.

[0010] Preferably, the wire conveying mechanism is used to load the enameled wire and convey the enameled wire according to a preset enameled wire length in each inductor, and the wire feeding port of the wire conveying mechanism faces the enameled wire bending disk.

[0011] Preferably, the wire cutting mechanism is arranged close to the wire outlet end of the enameled wire bending disk, and is used for cutting the enameled wire.

[0012] Preferably, the magnetic core supporting mechanism comprises:

[0013] A base is slidably disposed on a slide rail;

[0014] A magnetic core clamping device is arranged above the base through an elastic component, the magnetic core clamping device comprises a rotating component and a baffle, the rotating component is in contact with the lower end of the magnetic core, and the baffle is arranged on both sides of the lower end of the magnetic core;

[0015] The driving device is arranged on the base and can drive the base to move in a direction away from or close to the magnetic core.

[0016] Preferably, the winding step specifically includes:

[0017] Step S1, placing the magnetic core on the magnetic core supporting mechanism, and loading the enameled wire onto the wire conveying mechanism;

[0018] Step S2, starting the coil winding mechanism and the wire feeding mechanism, wherein the coil winding mechanism drives the enameled wire bending disk to move toward the magnetic core to a winding position, and the enameled wire is bent and wound around the outer periphery of the magnetic core at a preset curvature radius under the joint action of the wire feeding mechanism and the enameled wire bending disk;

[0019] Step S3, when the number of turns of the enameled wire around the outer periphery of the magnetic core reaches a preset number of turns, the wire cutting mechanism cuts the enameled wire to obtain the semi-finished inductor.

[0020] Preferably, a vertical rotating shaft is provided at the front end of the extending connecting rod, and the enameled wire bending disk is sleeved on the vertical rotating shaft and is rotatably connected to the vertical rotating shaft.

[0021] Preferably, an annular limiting groove is opened in the middle of the enameled wire bending disk, the size of the annular limiting groove is matched with the outer diameter of the enameled wire, and the wire feeding port of the wire conveying mechanism is opposite to the annular limiting groove.

[0022] Preferably, in step S3, during the winding process of the enameled wire, the magnetic core is supported by the magnetic core support mechanism and drives the magnetic core to rotate along its central axis until the winding is completed.

[0023] Preferably, the winding steps S1-S3 can be repeated multiple times according to the requirement of the number of coils in the inductor.

[0024] The above technical solution has the following advantages:

[0025] (1) The present invention directly uses a magnetic core with a quasi-circular cross section to prepare amorphous nanocrystalline inductors, which has the smallest cross-sectional perimeter under the same cross-sectional area compared to the commonly used rectangular or square cross-sectional magnetic cores in the current industry. The enameled wire length required for preparing amorphous nanocrystalline inductors, transformers and other electronic devices with the same technical parameters is shorter, which can greatly save the amount of copper wire material. The electronic devices prepared have the advantages of high energy density and low interstitial void ratio. In addition, the resistance and weight of the electronic devices are smaller, and the production cost is also significantly reduced;

[0026] (2) The present invention adopts stress-free winding equipment for winding, the magnetic core is not in direct contact with the enameled wire, the winding process hardly generates stress on the magnetic core, the performance attenuation of the magnetic core is smaller, and the performance of the electronic device is better. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is an overall schematic diagram of a magnetic core with a quasi-circular cross section in a preferred embodiment of the present invention;

[0028] Figure 2 It is a structural schematic diagram of a magnetic core stress-free or low-stress winding device in a preferred embodiment of the present invention;

[0029] Figure 3 This is a schematic diagram of the overall structure of a magnetic core with a quasi-circular cross section after winding in a preferred embodiment of the present invention;

[0030] Figure 4 It is an overall schematic diagram of the existing rectangular cross-section magnetic core after winding.

[0031] 1. Coil winding mechanism; 11. Extending connecting rod; 2. Enameled wire bending disk; 21. Annular limit groove; 3. Wire conveying mechanism; 4. Enameled wire; 5. Central control console; 6. Magnetic core supporting mechanism; 61. Magnetic core clamping device; 611. Rotating assembly; 612. Baffle; 62. Elastic assembly; 63. Base; 64. Driving device; 65. Slide rail; 7. Wire cutting mechanism; 71. Fixing assembly; 72. Cutting assembly; 100. Annular magnetic core; 101. Lead wire. DETAILED DESCRIPTION

[0032] The present invention is described in detail below in conjunction with the accompanying drawings and specific embodiments. The present invention is not limited to this embodiment, and other embodiments may also fall within the scope of the present invention as long as they conform to the gist of the present invention.

[0033] In a preferred embodiment of the present invention, based on the above-mentioned problems existing in the prior art, a method for preparing an amorphous nanocrystalline inductor with a quasi-circular cross-section is provided, wherein an amorphous nanocrystalline magnetic core with a quasi-circular cross-section is placed on a winding device, and the coil winding mechanism, the magnetic core supporting mechanism, the wire conveying mechanism and the wire shearing mechanism in the winding device cooperate with each other to complete stress-free winding of the magnetic core, and then the target inductor is obtained through subsequent assembly, soldering, gluing, baking and shaping processes.

[0034] In a preferred embodiment of the present invention, Figure 1 As shown, the magnetic core is a toroidal soft magnetic core with a circular cross section; Figure 2 As shown, it is a schematic structural diagram of a magnetic core stress-free winding device.

[0035] In a preferred embodiment of the present invention, the coil winding mechanism 1 is provided with an extending connecting rod 11 which can move forward and backward, and the front end of the extending connecting rod 11 is provided with an enameled wire bending disk 2, which is used to bend the enameled wire 4 into a coil according to a preset winding direction and a preset curvature radius, and wind it around the outer periphery of the magnetic core.

[0036] In a preferred embodiment of the present invention, the preset curvature radius R1 is greater than or equal to the outer contour radius R0 of the cross section of the magnetic core.

[0037] In a preferred embodiment of the present invention, the magnetic core supporting mechanism 6 is disposed at the rear end of the enameled wire bending disk 2, and is used to support the magnetic core and can rotate along the magnetic circuit direction.

[0038] In a preferred embodiment of the present invention, the wire conveying mechanism 3 is used to load the enameled wire 4 and convey the enameled wire 4 according to the preset length of the enameled wire 4 in each inductor, and the wire feeding port of the wire conveying mechanism 3 faces the enameled wire bending disk 2.

[0039] Specifically, in this embodiment, the magnetic core is still taken as an annular magnetic core 100. The coil winding mechanism 1, the magnetic core supporting mechanism 6, the wire feeding mechanism 3 and the wire cutting mechanism 7 are all connected to the central control console 5, and the central control console 5 controls the coil winding mechanism 1, the magnetic core supporting mechanism 6, the wire feeding mechanism 3 and the wire cutting mechanism 7 to cooperate with each other to achieve stress-free winding.

[0040] Further specifically, in the embodiment of the present invention, the extended connecting rod 11 can be a telescopic rod, and the enameled wire bending disk 2 is arranged above the end of the telescopic rod. The coil winding mechanism 1 can drive the telescopic rod to retract, so that the enameled wire bending disk 2 moves away from the annular magnetic core 100, and drive the telescopic rod to extend, so that the enameled wire bending disk 2 moves toward the annular magnetic core 100. During the entire winding process, the enameled wire bending disk 2 provides a radial driving force. Under the power of the wire conveying mechanism 3, the enameled wire 4 contacts the annular limit groove 21 outside the enameled wire bending disk 2, and continues to rotate forward under inertia conditions, and is wound on the magnetic core in turn. During winding, the enameled wire 4 is not in close contact with the magnetic core, but the enameled wire 4 is wound on the magnetic core by an external driving mechanism, thereby achieving stress-free or low-stress winding. In addition, since the magnetic core is a quasi-circular cross-section magnetic core, the outer shell of the magnetic core is smooth, which is compatible with the wound circular coil, which is more conducive to stress-free or low-stress winding.

[0041] In a preferred embodiment of the present invention, the wire cutting mechanism 7 is disposed close to the wire outlet end of the enameled wire bending disk 2 and is used to fix and cut the enameled wire 4 .

[0042] Specifically, the wire cutting mechanism 7 is arranged close to the outlet end of the enameled wire bending disk 2, and includes a fixing component 71 and a cutting component 72. The fixing component 71 and the cutting component 72 are respectively connected to the cylinder. After the winding of the enameled wire 4 is completed, the cylinder can drive the fixing component 71 and the cutting component 72 to extend to the outlet area of ​​the enameled wire 4. The fixing component 71 clamps one end of the enameled wire 4, and then the cutting component 72 cuts the enameled wire 4.

[0043] In a preferred embodiment of the present invention, the magnetic core supporting mechanism 6 comprises:

[0044] A base 63 is slidably disposed on a slide rail 65;

[0045] The magnetic core clamping device 61 is arranged above the base 63 through an elastic component 62. The magnetic core clamping device 61 includes a rotating component 611 and a baffle 612. The rotating component 611 is in contact with the lower end of the magnetic core, and the baffle 612 is arranged on both sides of the lower end of the magnetic core.

[0046] The driving device 64 is disposed on the base 63 and can drive the base 63 to move in a direction away from or close to the magnetic core.

[0047] Specifically, the magnetic core support mechanism 6 is disposed below the magnetic core, and is used to support and fix the magnetic core and assist the magnetic core in rotating along the central axis. Figure 2 As shown, in this embodiment, the magnetic core rotates in the clockwise direction, and the enameled wire 4 is bent into a specific curvature by the enameled wire bending disk 2 and then wound around the outer periphery of the magnetic core in sequence, and the subsequently wound enameled wire will continuously drive the magnetic core to rotate in the clockwise direction. The magnetic core support mechanism 6 includes a rotating component 611, a baffle 612, an elastic component 62, a base 63, a driving device 64 and a slide rail 65. Among them, the rotating component 611 is arranged under the magnetic core and fits with the outer ring side of the magnetic core. The driving component is not limited to a series of driven components such as a conveyor belt and a driven roller. Two baffles 612 are also provided on both sides of the magnetic core to prevent the position of the magnetic core from shifting when rotating, so that it always maintains a good contact with the rotating component 611; an elastic component 62 is also provided under the magnetic core clamping device 61. The outer diameter of the magnetic core will increase accordingly after the enameled wire 4 is wound. The elastic component 62 can ensure that the magnetic core clamping device 61 has a certain activity space to ensure that the magnetic core wound with the enameled wire 4 can stably enter the area of ​​the magnetic core clamping device 61. At the same time, the reaction force of the elastic component 62 can ensure that the rotating component 611 is for the magnetic core to rotate. Provide a better fixing effect; the driving device 64 is arranged on the base 63, and can drive the base 63 to move in the direction away from or close to the magnetic core. When the magnetic core area wound with the enameled wire 4 enters the magnetic core clamping device, the driving device 64 can drive the base 63 away from the magnetic core. Correspondingly, a pressure sensor can be set in the connection area of ​​the elastic component 62. When the magnetic core area wound with the enameled wire 4 enters the magnetic core clamping device, the pressure value will increase. At this time, since the enameled wire 4 has basically covered most of the magnetic core, the enameled wire 4 is sufficient to fix the magnetic core. The base 63 can be evacuated to avoid further contact between the rotating component 611 and the enameled wire 4, which is also convenient for unloading the magnetic core after winding.

[0048] In a preferred embodiment of the present invention, the winding step specifically includes:

[0049] Step S1, placing the magnetic core on the magnetic core support mechanism 6, and loading the enameled wire 4 onto the wire conveying mechanism 3;

[0050] Step S2, starting the coil winding mechanism 1 and the wire feeding mechanism 3, the coil winding mechanism 1 drives the enameled wire bending disk 2 to move toward the magnetic core to the winding position, and the enameled wire 4 is bent and wound around the outer periphery of the magnetic core according to a preset curvature radius under the joint action of the wire feeding mechanism 3 and the enameled wire bending disk 2;

[0051] Step S3, when the number of turns of the enameled wire 4 around the outer periphery of the magnetic core reaches a preset number of turns, the wire cutting mechanism 7 cuts the enameled wire 4 to obtain a semi-finished inductor.

[0052] Specifically, in the present embodiment, the winding position is a position where the distance between the enameled wire bending disk 2 and the outside of the magnetic core is the width dimension of the enameled wire 4. When the coil winding mechanism 1 is not started, its extended connecting rod 11 is in a retracted state. The driving speed of the coil winding mechanism 1 and the wire feeding speed of the wire conveying mechanism 3 can be pre-set in the central control console 5, and then when the coil winding mechanism 1 and the wire conveying mechanism 3 are started, the extended connecting rod 11 of the coil winding mechanism 1 is controlled to drive the enameled wire bending disk 2 toward the magnetic core at the above-mentioned driving speed, and at the same time, the wire conveying mechanism 3 is controlled to output the enameled wire 4 at the above-mentioned wire feeding speed, and the conveying direction of the enameled wire 4 is also toward the magnetic core. Figure 2 It can be seen that the moving direction of the enameled wire bending disk 2 is opposite to the conveying direction of the enameled wire 4, and can intersect near the magnetic core. When winding the wire, the end of the coil needs to leave a lead wire 101 of a preset coil lead length. Based on this, by reasonably setting the above-mentioned driving speed and wire feeding speed, when the wire length of the enameled wire 4 conveyed by the wire conveying mechanism 3 reaches the preset coil lead length, the enameled wire bending disk 2 can just move to a position that can contact the edge of the enameled wire 4.

[0053] Furthermore, a vertical rotating shaft (not shown in the figure, preferably arranged at a position coincident with the central axis of the enameled wire bending disk 2) is provided at the front end of the extended connecting rod 11, and the enameled wire bending disk 2 is sleeved on the vertical rotating shaft and rotatably connected to the vertical rotating shaft;

[0054] In step S3, the enameled wire 4 contacts the enameled wire bending disk 2 to drive the enameled wire bending disk 2 to rotate around the vertical rotation axis, and then the rotation of the enameled wire bending disk 2 drives the enameled wire 4 to continue to bend toward the magnetic core.

[0055] Furthermore, an annular limiting groove 21 is opened in the middle of the enameled wire bending disk 2 , the size of the annular limiting groove 21 is adapted to the outer diameter of the enameled wire 4 , and the wire feeding port of the wire feeding mechanism 3 is opposite to the annular limiting groove 21 .

[0056] Specifically, when the enameled wire bending disk 2 just moves to a position where it can contact the edge of the enameled wire 4, the enameled wire 4 is just stuck between the enameled wire bending disk 2 and the magnetic core 100 and is located in the annular limit groove 21. At this time, the output enameled wire 4 is still in a straight line as a whole and has not yet been bent. Then the enameled wire bending disk 2 continues to move toward the magnetic core 100, so that the enameled wire 4 is bent at the contact point with the enameled wire bending disk 2, until it moves to a preset position and stops, as shown in FIG. Figure 2As shown, during this process, the enameled wire 4 is always fed at the above-mentioned wire feeding speed. When the enameled wire 4 is fed to the contact position with the enameled wire bending disk 2, it can drive the enameled wire bending disk 2 to rotate around the vertical rotation axis, and the rotation of the enameled wire bending disk 2 can continuously feed the enameled wire 4 that has not yet contacted the enameled wire bending disk 2 to the contact position with the enameled wire bending disk 2, and then continue to bend toward the magnetic core 100 at the contact position, thereby realizing stress-free winding.

[0057] In a preferred embodiment of the present invention, in step S2, during the winding process of the enameled wire 4, the magnetic core is supported by the magnetic core support mechanism 6 and the bent enameled wire 4 drives the magnetic core to rotate along its central axis until the winding is completed.

[0058] Specifically, in this embodiment, Figure 2 As shown, it can be seen that due to the outlet direction of the enameled wire 4 and the position limitation of the enameled wire bending disk 2, the winding position of the enameled wire 4 is relatively fixed. In order to enable the entire magnetic core to be completely wound, during the winding process, the front position of the enameled wire 4 will drive the magnetic core 100 to rotate synchronously until it rotates one circle and completes the winding.

[0059] In a preferred embodiment of the present invention, the winding steps S1-S3 can be repeated multiple times according to the number of coils in the inductor.

[0060] Example 1

[0061] This embodiment is a nanocrystalline common mode inductor, such as Figure 3 As shown, the main components are a circular magnetic core and two coils wound around the magnetic core.

[0062] In this embodiment, the magnetic core is an overall circular ring, and the soft magnetic material is a nanocrystalline soft magnetic alloy strip with the composition of Fe-Si-B-Nb-Cu, and the strip thickness is 20μm. A circular cross-section magnetic core with a size of 30 (outer diameter) * 16 (inner diameter) * 7mm (cross-sectional profile diameter) is selected, and the size of the magnetic core protective box is 32mm (outer diameter) * 14mm (inner diameter) * 9mm (cross-sectional profile diameter), and the wall thickness is 0.8mm; 10 magnetic cores with protective boxes are placed on a balance and weighed, and the average weight of the magnetic core is 16.9g. Each magnetic core is wound with a single-turn coil, and its single-turn inductance AL is tested under 100kHz / 0.3V conditions using an impedance analyzer. The measured average AL values ​​are summarized in Table 1.

[0063] In this embodiment, the number of turns of a single coil is 10, and the selected enameled wire is a round enameled wire with a wire diameter of 1.5 mm.

[0064] Step S1, placing the magnetic core with the protective box on the magnetic core support mechanism 6, and loading the enameled wire 4 onto the wire conveying mechanism 3;

[0065] Step S2, starting the coil winding mechanism 1 and the wire feeding mechanism 3, the coil winding mechanism 1 drives the enameled wire bending disk 2 to move toward the magnetic core to the winding position, and the enameled wire 4 is bent and wound around the outer periphery of the magnetic core according to a preset curvature radius under the joint action of the wire feeding mechanism 3 and the enameled wire bending disk 2;

[0066] Step S3, after winding 10 turns of the enameled wire 4 around the outer periphery of the magnetic core, the enameled wire 4 is sheared by the wire shearing mechanism 7; wherein, 15 mm ends are left at both ends of the coil;

[0067] Step S4, removing the wound magnetic core prepared in step S3 from the magnetic core support mechanism 6, placing the wound part of the magnetic core on the magnetic core support mechanism 6 (i.e. placing the other half of the unwound part in the winding position), and repeating the above steps S1-S3 to obtain a semi-finished inductor;

[0068] The 10 prepared semi-finished inductors were placed on a balance and weighed to obtain the average weight of the semi-finished inductors, and the average weight of the enameled copper wire wound around a single inductor was calculated and summarized in Table 1.

[0069] Step S5, shaping, soldering, gluing, baking and trimming the obtained semi-finished inductor to obtain a finished inductor.

[0070] The finished inductor of the above embodiment 1 was tested by using an impedance analyzer to test its single-phase inductance under the condition of 100kHz / 0.3V. The measured inductance performance parameters are shown in Table 1 below. The measured value of single-phase inductance (L R ) and through N 2 Theoretical value calculated by AL (L T ) between the difference rate δ(δ=(L R -L T ) / L T ) are also listed in Table 1.

[0071] Example 2

[0072] This embodiment is also a nanocrystalline common-mode inductor, and its main components are consistent with those in Embodiment 1, but the sizes are different.

[0073] In this embodiment, the magnetic core is an overall circular ring, and the soft magnetic material is a nanocrystalline soft magnetic alloy strip, the composition is: Fe-Si-B-Nb-Cu, the strip thickness is 20μm, the size is 20 (outer diameter) * 10 (inner diameter) * 5mm (cross-sectional profile diameter) of the quasi-circular cross-section magnetic core, the size of the magnetic core protection box is 22mm (outer diameter) * 8mm (inner diameter) * 7mm (cross-sectional profile diameter), and the wall thickness is 0.8mm; 10 magnetic cores with protection boxes are placed on a balance, and their weight is weighed, and the weight of a single magnetic core is 7.1g. Each magnetic core is wound with a single-turn coil, and the single-turn inductance AL under 100kHz / 0.3V is tested using an impedance analyzer. The average AL value measured is summarized in Table 1.

[0074] In this embodiment, the number of turns of the coil is 10, and the selected enameled wire is a round enameled wire with a wire diameter of 1.0 mm.

[0075] Step S1, placing the magnetic core with the protective box on the magnetic core support mechanism 6, and loading the enameled wire 4 onto the wire conveying mechanism 3;

[0076] Step S2, starting the coil winding mechanism 1 and the wire feeding mechanism 3, the coil winding mechanism 1 drives the enameled wire bending disk 2 to move toward the magnetic core to the winding position, and the enameled wire 4 is bent and wound around the outer periphery of the magnetic core according to a preset curvature radius under the joint action of the wire feeding mechanism 3 and the enameled wire bending disk 2;

[0077] Step S3, after winding 10 turns of the enameled wire 4 around the outer periphery of the magnetic core, the enameled wire 4 is sheared by the wire shearing mechanism 7; wherein, 15 mm ends are left at both ends of the coil;

[0078] Step S4, removing the wound magnetic core prepared in step S3 from the magnetic core support mechanism 6, placing the wound part of the magnetic core on the magnetic core support mechanism 6 (i.e. placing the other half of the unwound part in the winding position), and repeating the above steps S1-S3 to obtain a semi-finished inductor;

[0079] The 10 prepared semi-finished inductors were placed on a balance and weighed to obtain the average weight of the semi-finished inductors, and the average weight of the enameled copper wire wound around a single inductor was calculated and summarized in Table 1.

[0080] Step S5, shaping, soldering, gluing, baking and trimming the obtained semi-finished inductor to obtain a finished inductor.

[0081] The inductor of the above-mentioned embodiment 2 was tested, and its single-phase inductance was measured under the condition of 100kHz / 0.3V using an impedance analyzer. The measured inductance performance parameters are shown in Table 1 below. The measured value of the single-phase inductance (L R ) and through N 2 Theoretical value calculated by AL (LT ) between the difference rate δ(δ=(L R -L T ) / L T ) are also listed in Table 1.

[0082] Comparative Example 1

[0083] This comparative example is a comparative example corresponding to Example 1. The technical indicators such as the inductance of the common mode inductor are the same as those of Example 1; the raw materials, inner and outer diameters, effective cross-sectional area and effective magnetic path length of the magnetic core, the number of coil turns, the selected enameled wire specifications, the winding method, etc. are the same as those of Example 1. The difference is that the cross section of the bare magnetic core in this comparative example is a rectangle of 7mm×5mm, and the cross section of the magnetic core with a protective box is a rectangle of 9mm×7mm.

[0084] In this comparative example, the same nanocrystalline soft magnetic alloy strip as in Example 1 was selected, the strip thickness was 20 μm, a square cross-section magnetic core with a size of 30 (outer diameter) * 16 (inner diameter) * 5 mm (height) was selected, the size of the magnetic core protection box was 32 mm (outer diameter) * 14 mm (inner diameter) * 7 mm (height), and the wall thickness was 0.8 mm; 10 magnetic cores with protection boxes were placed on a balance and weighed, and the weight of a single magnetic core was 17.0 g. Each magnetic core was wound with a single-turn coil, and its single-turn inductance AL was tested under 100 kHz / 0.3 V conditions using an impedance analyzer. The average AL values ​​measured are summarized in Table 1.

[0085] In this comparative example, the number of turns of the coil is 10, and the enameled wire selected is a round enameled wire with a wire diameter of 1.5 mm.

[0086] Step S1, as step S1 in embodiment 1;

[0087] Step S2, as step S2 in embodiment 1;

[0088] Step S3, as step S3 in embodiment 1.

[0089] Step S4, as in step S4 in embodiment 1, obtaining a semi-finished inductor;

[0090] The 10 semi-finished inductors prepared in this comparative example were placed on a balance and weighed to obtain the average weight of the semi-finished inductors, and the average weight of the enameled copper wire wound around a single inductor was calculated and summarized in Table 1.

[0091] Step S5, as step S5 in embodiment 1.

[0092] The inductor of the comparative example 1 was tested under the same test conditions and test methods as those of the embodiment 1. The specific test results are shown in Table 1 below.

[0093] Comparative Example 2

[0094] This comparative example is a comparative example corresponding to Example 1. The inductance and other technical indicators of the common mode inductor are the same as those of Example 1; the raw materials, inner and outer diameters, effective cross-sectional area and effective magnetic path length of the magnetic core, the number of coil turns, and the specifications of the selected enameled wire are the same as those of Example 1. The differences are: (1) the cross-section of the bare magnetic core in this comparative example is a rectangle of 7 mm × 5 mm, and the cross-section of the magnetic core with a protective box is a rectangle of 9 mm × 7 mm, which is the same as that of Comparative Example 1; (2) the winding adopts the traditional manual winding method.

[0095] In this comparative example, when preparing the inductor, the only difference from comparative example 1 is the winding method used when winding the coil. The two coils are wound by the traditional manual wire pulling method, and the remaining steps and parameters are the same as those in comparative example 1.

[0096] In this comparative example, the same nanocrystalline soft magnetic alloy strip as in Example 1 was selected, the strip thickness was 20 μm, a square cross-section magnetic core with a size of 30 (outer diameter) * 16 (inner diameter) * 5 mm (height) was selected, the size of the magnetic core protection box was 32 mm (outer diameter) * 14 mm (inner diameter) * 7 mm (height), and the wall thickness was 0.8 mm; 10 magnetic cores with protection boxes were placed on a balance and weighed, and the weight of a single magnetic core was 17.0 g. Each magnetic core was wound with a single-turn coil, and its single-turn inductance AL was tested under 100 kHz / 0.3 V conditions using an impedance analyzer. The average AL values ​​measured are summarized in Table 1.

[0097] In this comparative example, the number of turns of the coil is 10, and the enameled wire selected is a round enameled wire with a wire diameter of 1.5 mm.

[0098] The specific steps for preparing the inductor are as follows:

[0099] Step S1, placing one side of the magnetic core with the protective box in a fixing mechanism, and selecting an enameled wire 4 of a suitable length;

[0100] Step S2, passing one end of the enameled wire 4 through the middle circle of the protective shell, winding one turn of the coil along the protective box, hooking the enameled wire 4 on the opposite side back with a hook, and winding the second turn of the coil until 10 turns of the coil are wound on the protective box;

[0101] Step S3, cutting the excess enameled wire 4 by a cutting tool, wherein 15 mm ends are left at both ends of the coil;

[0102] Step S4, removing the prepared wound magnetic core from the fixing mechanism, placing the wound part of the magnetic core in the fixing mechanism (i.e. the other half of the magnetic core not wound is completely exposed outside the fixing mechanism), and repeating the above steps S1-S3 to obtain a semi-finished inductor;

[0103] The 10 prepared semi-finished inductors were placed on a balance and weighed to obtain the average weight of the semi-finished inductors, and the average weight of the enameled copper wire wound around a single inductor was calculated and summarized in Table 1.

[0104] Step S5, shaping, soldering, gluing, baking and trimming the obtained semi-finished inductor to obtain a finished inductor.

[0105] The performance test of the inductor prepared in the above comparative example 2 was carried out, and the test conditions and test methods were the same as those of Example 1. The specific test results are shown in Table 1 below.

[0106] Comparative Example 3

[0107] This comparative example is a comparative example corresponding to Example 2. The technical indicators such as the inductance of the common mode inductor are the same as those of Example 1. The raw materials, inner and outer diameters, effective cross-sectional area and effective magnetic path length of the magnetic core, the number of coil turns, and the specifications of the selected enameled wire are the same as those of Example 2. The difference is that the cross section of the bare magnetic core in this comparative example is a rectangle of 5 mm × 3.7 mm, and the cross section of the magnetic core with a protective box is a rectangle of 7 mm × 5.7 mm.

[0108] In this comparative example, the same nanocrystalline soft magnetic alloy strip as in Example 2 was selected, the strip thickness was 20 μm, a square cross-section magnetic core with a size of 20 (outer diameter) * 10 (inner diameter) * 3.7 mm (height) was selected, the size of the magnetic core protection box was 22 mm (outer diameter) * 8 mm (inner diameter) * 5.7 mm (height), and the wall thickness was 0.8 mm; 10 magnetic cores with protection boxes were placed on a balance and weighed, and the weight of a single magnetic core was 7.2 g. Each magnetic core was wound with a single-turn coil, and its single-turn inductance AL was tested under 100 kHz / 0.3 V conditions using an impedance analyzer. The average AL values ​​measured are summarized in Table 1.

[0109] The number of turns of the coil in this comparative example is 10, and the enameled wire selected is a round enameled wire with a wire diameter of 1.0 mm.

[0110] Step S1, as step S1 in embodiment 2;

[0111] Step S2, as step S2 in embodiment 2;

[0112] Step S3, as step S3 in embodiment 2.

[0113] Step S4, as in step S4 in embodiment 2, obtaining a semi-finished inductor;

[0114] The 10 semi-finished inductors prepared in this comparative example were placed on a balance and weighed to obtain the average weight of the semi-finished inductors, and the average weight of the enameled copper wire wound around a single inductor was calculated and summarized in Table 1.

[0115] Step S5, as step S5 in embodiment 1.

[0116] The inductor of the comparative example 3 was tested under the same test conditions and test methods as those of the embodiment 2. The specific test results are shown in Table 1 below.

[0117] Comparative Example 4

[0118] This comparative example is a comparative example corresponding to Example 2. The inductance and other technical indicators of the common mode inductor are the same as those of Example 2. The raw materials, inner and outer diameters, effective cross-sectional area and effective magnetic path length of the magnetic core, the number of coil turns, and the specifications of the selected enameled wire are the same as those of Example 2. The differences are: (1) the cross-section of the bare magnetic core in this comparative example is a rectangle of 5 mm × 3.7 mm, and the cross-section of the magnetic core with a protective box is a rectangle of 7 mm × 5.7 mm, which is the same as that of Comparative Example 3; (2) the winding adopts the traditional manual winding method.

[0119] The manual winding process is detailed in the inductor preparation steps in Comparative Example 2, which will not be repeated here.

[0120] The inductor prepared in the comparative example 4 was subjected to a performance test. The test conditions and test methods were the same as those in the embodiment 2. The specific test results are shown in Table 1 below.

[0121] Table 1 Inductance performance parameters prepared in Examples 1-2 and Comparative Examples 1-4

[0122]

[0123] Combining Examples 1-2 and Comparative Examples 1-4, it can be seen that, by winding the magnetic core into a toroidal magnetic core with a quasi-circular cross-section, less copper wire material is used compared to the existing magnetic core with a rectangular cross-section, and the prepared electronic device has the advantages of high energy density and small void ratio. At the same time, the resistance and weight of the electronic device are smaller, and the production cost is reduced. Combining Example 1 and Comparative Example 2, and Example 2 and Comparative Example 4, it can be seen that by winding the magnetic core into a toroidal magnetic core with a quasi-circular cross-section and using stress-free winding, the inductance change rate of the inductor prepared is significantly reduced compared to the inductance change rate of the inductor prepared by the traditional rectangular or square cross-section magnetic core and the conventional winding method, and the inductance performance is more excellent.

[0124] The above description is only a preferred embodiment of the present invention, and does not limit the implementation mode and protection scope of the present invention. For those skilled in the art, it should be aware that all solutions obtained by equivalent substitutions and obvious changes made using the contents of this specification and illustrations should be included in the protection scope of the present invention.

Claims

1. A method for preparing an amorphous nanocrystalline inductor with a quasi-circular cross-section, characterized in that: An amorphous nanocrystalline magnetic core with a quasi-circular cross-section is placed on a winding device, and the coil winding mechanism, magnetic core supporting mechanism, wire conveying mechanism and wire shearing mechanism in the winding device cooperate with each other to complete stress-free winding of the magnetic core, and then the target inductance is obtained through subsequent assembly, soldering, dispensing, baking and shaping processes.

2. The method for preparing an amorphous nanocrystalline inductor with a quasi-circular cross-section according to claim 1, characterized in that: The coil winding mechanism is provided with an extending connecting rod which can move forward and backward, and the front end of the extending connecting rod is provided with an enameled wire bending disk, which is used to bend the enameled wire into a coil according to a preset winding direction and a preset curvature radius, and wind it around the outer periphery of the magnetic core.

3. The method for preparing an amorphous nanocrystalline inductor with a quasi-circular cross-section according to claim 2, characterized in that: The preset curvature radius R1 is greater than or equal to the outer contour radius R0 of the cross section of the magnetic core.

4. The method for preparing an amorphous nanocrystalline inductor with a quasi-circular cross-section according to claim 2, characterized in that: The magnetic core supporting mechanism is arranged at the rear end of the enameled wire bending disk, and is used to support the magnetic core and can rotate along the magnetic circuit direction.

5. The method for preparing an amorphous nanocrystalline inductor with a quasi-circular cross-section according to claim 2, characterized in that: The wire conveying mechanism is used to load the enameled wire and convey the enameled wire according to the preset enameled wire length in each inductor; the wire feeding port of the wire conveying mechanism faces the enameled wire bending disk.

6. The method for preparing an amorphous nanocrystalline inductor with a quasi-circular cross section according to claim 5, characterized in that: The wire cutting mechanism is arranged close to the wire inlet end of the enameled wire bending disk and is used for cutting the enameled wire.

7. The method for preparing an amorphous nanocrystalline inductor with a quasi-circular cross section according to claim 4, characterized in that: The magnetic core supporting mechanism comprises: A base is slidably disposed on a slide rail; A magnetic core clamping device is arranged above the base through an elastic component, the magnetic core clamping device comprises a rotating component and a baffle, the rotating component is in contact with the lower end of the magnetic core, and the baffle is arranged on both sides of the lower end of the magnetic core; The driving device is arranged on the base and can drive the base to move in a direction away from or close to the magnetic core.

8. The method for preparing an amorphous nanocrystalline inductor with a quasi-circular cross-section according to claim 1, characterized in that: The winding step specifically includes: Step S1, placing the magnetic core on the magnetic core supporting mechanism, and loading the enameled wire onto the wire conveying mechanism; Step S2, starting the coil winding mechanism and the wire feeding mechanism, the coil winding mechanism drives the enameled wire bending disk to move toward the magnetic core to a winding position, and the enameled wire is bent and wound around the outer periphery of the magnetic core according to a preset curvature radius under the joint action of the wire feeding mechanism and the enameled wire bending disk; Step S3, when the number of turns of the enameled wire around the outer periphery of the magnetic core reaches a preset number of turns, the wire cutting mechanism cuts the enameled wire to obtain the semi-finished inductor.

9. The method for preparing an amorphous nanocrystalline inductor with a quasi-circular cross section according to claim 2, characterized in that: A vertical rotating shaft is provided at the front end of the extending connecting rod, and the enameled wire bending disk is sleeved on the vertical rotating shaft and rotatably connected to the vertical rotating shaft.

10. The method for preparing an amorphous nanocrystalline inductor with a quasi-circular cross section according to claim 5, characterized in that: An annular limiting groove is provided in the middle of the enameled wire bending disk, the size of which is matched with the outer diameter of the enameled wire, and the wire feeding port of the wire feeding mechanism faces the annular limiting groove.

11. The method for preparing an amorphous nanocrystalline inductor with a quasi-circular cross section according to claim 8, characterized in that: In the step S2, during the winding process of the enameled wire, the magnetic core is supported by the magnetic core support mechanism and driven to rotate along its central axis until the winding is completed.

12. The method for preparing an amorphous nanocrystalline inductor with a quasi-circular cross section according to claim 8, characterized in that: The winding steps S1-S3 can be repeated multiple times according to the number of coils in the inductor.

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