Inductor product manufacturing process and inductor product

Abstract

The invention belongs to the technical field of inductor manufacturing, and discloses an inductor product manufacturing process and an inductor product. The manufacturing process of the inductor product comprises the following steps of: winding a copper wire in the middle of the magnetic core, performing tin immersion treatment, and filling magnetic powder glue in the middle of the magnetic core and covering the copper wire after an electrode is formed by the tin immersion treatment; obtaining the top wall size a of the magnetic core, the bottom wall size b of the magnetic core, the middle space height h of the magnetic core, the distance r between the outer side of the copper wire and the middle of the magnetic core, the curing shrinkage rate n of the magnetic powder adhesive and the curing included angle theta between the side wall of the magnetic powder adhesive and the inner bottom wall of the magnetic core after the magnetic powder adhesive is cured; and when theta is equal to the first preset angle, the space amount V for filling the magnetic powder glue is equal to (b2-pir2) * h * (1-n), and when theta meets the preset angle range, the product is judged to be qualified. According to the inductance element manufactured through the process, it is ensured that the use amount of the magnetic powder glue meets the requirement, so that the magnetic powder glue and the magnetic core have high adhesion, the overall strength of a product is effectively improved, meanwhile, the inductance value can be increased, and the possibility of magnetic leakage can be reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of inductor manufacturing, and in particular to an inductor product manufacturing process and an inductor product. Background Art

[0002] The performance of inductor products is directly related to the amount of magnetic powder glue filled in its space. Magnetic powder glue refers to a suspended glue liquid made by adding a certain weight proportion of magnetic filler to the adhesive. It can be coated on the surface of the coil to replace the product shell.

[0003] In the prior art, the manufacturing process of inductor products is to directly wind the coil inside the space of the magnetic core, perform tinning treatment, and then coat the outside of the coil with magnetic powder glue to seal the coil inside the magnetic core. The magnetic powder glue is then baked to shrink and solidify under the action of thermal stress expansion.

[0004] This process makes it difficult to determine the amount of magnetic powder glue used in the space inside the magnetic core. If there is less magnetic powder glue, although it can cover the entire coil, the adhesion between the magnetic powder glue and the magnetic core is weak, resulting in insufficient overall strength of the product, and it will also reduce the inductance value and increase the possibility of leakage. Summary of the invention

[0005] The purpose of the present invention is to provide an inductor product manufacturing process and an inductor product, which solves the problem in the prior art that it is difficult to determine the amount of magnetic powder glue used during the manufacturing of the inductor product, resulting in insufficient amount of magnetic powder glue, insufficient product strength, reduced inductance value, and increased possibility of magnetic leakage.

[0006] To achieve this object, the present invention adopts the following technical solutions:

[0007] In a first aspect, the present invention provides a process for manufacturing an inductor product, which comprises:

[0008] After the copper wire is wound in the middle of the magnetic core, it is treated with tin immersion. After the electrode is formed by the tin immersion treatment, the magnetic powder glue is filled in the middle of the magnetic core and covers the copper wire;

[0009] Obtain the top wall size a, bottom wall size b, core middle space height h, the distance r between the outer side of the copper wire and the middle of the core, magnetic powder glue curing shrinkage n, and the curing angle θ between the side wall of the magnetic powder glue and the inner bottom wall of the core after curing;

[0010] When θ is equal to the first preset angle, the space volume V filled with magnetic powder glue is (b 2 -πr 2 )*h*(1-n) and when θ meets the preset angle range, the product is judged to be qualified.

[0011] Optionally, a≤b, 0.3mm≤h≤4mm.

[0012] Optionally, the first preset angle is 90°.

[0013] Optionally, the preset angle range includes: θ≥30°.

[0014] Optionally, the preset angle range also includes: θ≤150°.

[0015] Optionally, when θ satisfies a preset angle range, judging that the product is qualified specifically includes:

[0016] When θ satisfies the preset angle range, the inductance improvement rate is greater than 10%.

[0017] Optionally, when θ satisfies a preset angle range, judging that the product is qualified specifically includes:

[0018] When θ satisfies the preset angle range, the magnetic leakage rate is less than 6%.

[0019] Optionally, when θ satisfies a preset angle range, judging that the product is qualified specifically includes:

[0020] When θ meets the preset angle range, the number of impact resistance is greater than 25.

[0021] In a second aspect, the present invention further provides an inductor product, which includes:

[0022] Magnetic core;

[0023] Copper wire, wound around the magnetic core;

[0024] Magnetic powder glue is filled inside the magnetic core and covers the copper wire. The space volume V filled with the magnetic powder glue is (b 2 -πr 2 )*h*(1-n), and the magnetic powder glue forms a curing angle θ within a preset angle range between the side wall after curing and the inner bottom wall of the magnetic core.

[0025] Optionally, the magnetic core comprises:

[0026] A magnetic column, the copper wire is wound around the magnetic column;

[0027] A first blade is disposed at one end of the magnetic column;

[0028] The second blade is arranged at the other end of the magnetic column and is arranged opposite to the first blade. The magnetic powder glue is filled between the first blade and the second blade. The curing angle θ is formed between the side wall of the magnetic powder glue and the side wall of the second blade.

[0029] Beneficial effects of the present invention:

[0030] In the first aspect, when the inductor product is manufactured by the above manufacturing process, when θ is set to be equal to the first preset angle, the space amount V filled with magnetic powder glue is calculated to be (b 2 -πr 2 )*h*(1-n) to reserve enough space to accommodate the magnetic powder glue. After the magnetic powder glue is filled and solidified, θ meets the preset angle range to ensure that the filling amount of the magnetic powder glue meets the requirements. The inductor components manufactured by this process ensure that the amount of magnetic powder glue meets the requirements and avoid the situation where the amount of magnetic powder glue is too small, so that the magnetic powder glue and the magnetic core have a higher adhesion, effectively improving the overall strength of the product, while also increasing the inductance value and reducing the possibility of magnetic leakage.

[0031] Secondly, when the inductor product is manufactured using the above process, sufficient space can be reserved for the filling of magnetic powder glue in advance, and after the magnetic powder glue is filled and solidified, the amount of magnetic powder glue used can be determined by θ to meet the requirements, thereby ensuring that the magnetic powder glue can form a stable connection with the magnetic core while covering the copper wire, thereby ensuring that the overall strength and inductance value of the inductor product meet the requirements, and the possibility of magnetic leakage can be effectively reduced, which is conducive to comprehensively improving the quality and performance of the inductor product. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 is a schematic diagram of a partial cross-sectional structure of an inductor product according to an embodiment of the present invention;

[0033] Figure 2 is a schematic diagram of a structure in which the top wall size of the inductor product in an embodiment of the present invention is smaller than the bottom wall size;

[0034] Figure 3 It is a schematic diagram of a local cross-sectional structure in which the top wall size of the inductor product is equal to the bottom wall size in an embodiment of the present invention.

[0035] In the figure:

[0036] 1. Magnetic core; 11. Magnetic column; 12. First blade; 13. Second blade; 2. Electrode; 3. Magnetic powder glue; 4. Copper wire. DETAILED DESCRIPTION

[0037] The present invention will be further described in detail below in conjunction with the accompanying drawings and embodiments. It is to be understood that the specific embodiments described herein are only used to explain the present invention, rather than to limit the present invention. It should also be noted that, for ease of description, only parts related to the present invention, rather than all structures, are shown in the accompanying drawings.

[0038] In the description of the present invention, unless otherwise clearly specified and limited, the terms "connected", "connected", and "fixed" should be understood in a broad sense, for example, it 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 an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0039] In the present invention, unless otherwise clearly specified and limited, a first feature being "above" or "below" a second feature may include that the first and second features are in direct contact, or may include that the first and second features are not in direct contact but are in contact through another feature between them. Moreover, a first feature being "above", "above" and "above" a second feature includes that the first feature is directly above and obliquely above the second feature, or simply indicates that the first feature is higher in level than the second feature. A first feature being "below", "below" and "below" a second feature includes that the first feature is directly below and obliquely below the second feature, or simply indicates that the first feature is lower in level than the second feature.

[0040] In the description of this embodiment, the terms "upper", "lower", "left", "right" and other directions or positional relationships are based on the directions or positional relationships shown in the drawings, and are only for the convenience of description and simplification of operation, rather than indicating or implying that the device or element referred to must have a specific direction, be constructed and operate in a specific direction, and therefore cannot be understood as limiting the present invention. In addition, the terms "first" and "second" are only used to distinguish in the description and have no special meaning.

[0041] The embodiment of the invention discloses an inductor product manufacturing process and an inductor product.

[0042] Reference Figures 1 to 3 , the manufacturing process of inductor products includes:

[0043] A copper wire 4 is wound around the middle of the magnetic core 1 and then tinned. After the electrode 2 is formed by the tinning, a magnetic powder glue 3 is filled into the middle of the magnetic core 1 and covers the copper wire 4.

[0044] Obtain the top wall size a of the magnetic core 1, the bottom wall size b, the space height h in the middle of the magnetic core 1, the distance r between the outer side of the copper wire 4 and the middle of the magnetic core 1, the curing shrinkage rate n of the magnetic powder glue 3, and the curing angle θ formed between the side wall of the magnetic powder glue 3 and the inner bottom wall of the magnetic core 1 after curing;

[0045] When θ is equal to the first preset angle, the space volume V filled with the magnetic powder glue 3 is (b 2 -πr 2 )*h*(1-n) and when θ meets the preset angle range, the product is judged to be qualified.

[0046] Specifically, the middle of the magnetic core 1 has a space in which a copper wire 4 can be wound. The copper wire 4 can be an enameled copper wire 4, and the wire segment is wound in the wire slot of the magnetic core 1 after removing the enameled film, and then a tin alloy electrode 2 is attached to the bottom surface of the magnetic core 1 by tin immersion. Finally, the magnetic powder glue 3 is filled in the space, and after baking, it is expanded by thermal stress and then shrinks inward to solidify.

[0047] The magnetic core 1 is prefabricated in advance, and its dimensions a, b and h can be directly measured and combined with the spacing r formed by the copper wire 4 wound in the wire slot. When θ is set to be equal to the first preset angle, the space V filled with the magnetic powder glue 3 is calculated to be (b 2 -πr 2 )*h*(1-n), the magnetic powder glue 3 can be fully filled in the space so that θ meets the preset angle range, thereby determining that the amount of the magnetic powder glue 3 meets the requirements, and the product can be determined to be qualified. The first preset angle can be determined according to the size of the actual magnetic core 1, and n can be obtained according to the type of the magnetic powder glue 3. In this embodiment, the magnetic powder glue 3 is epoxy resin glue containing magnetic powder.

[0048] When the inductor product is manufactured by the above manufacturing process, when θ is set to be equal to the first preset angle, the space volume V filled with the magnetic powder glue 3 is calculated to be (b 2 -πr 2 )*h*(1-n) to reserve enough space to accommodate the magnetic powder glue 3. After the magnetic powder glue 3 is filled and solidified, θ meets the preset angle range to ensure that the filling amount of the magnetic powder glue 3 meets the requirements. The inductor component manufactured by this process ensures that the amount of magnetic powder glue 3 meets the requirements and avoids the situation where the amount of magnetic powder glue 3 is too small, so that the magnetic powder glue 3 and the magnetic core 1 have a higher adhesion, effectively improving the overall strength of the product, while also being able to increase the inductance value and reduce the possibility of magnetic leakage.

[0049] Optionally, a≤b, 0.3mm≤h≤4mm, and the first preset angle is 90°.

[0050] Specifically, a can be less than b or equal to b, and h is between 0.3 mm and 4 mm, and the first preset angle is set to 90°. In this embodiment, the dimensions of the magnetic core 1 are set to a=3.7 mm, b=4.0 mm, h=1.4, r=1.1, n=0.5%, and V=(4*4-π*1.1*1.1)*1.4*99.5%. In other embodiments, when the dimensions of the magnetic core 1 change, the first preset angle can also be adjusted accordingly.

[0051] Optionally, the preset angle range includes: 30°≤θ, and θ≤150°. When θ satisfies the preset angle range, the inductance improvement rate is greater than 10%, the magnetic leakage rate is less than 6%, and the number of impact resistance is greater than 25.

[0052] Specifically, different amounts of magnetic powder glue 3 are filled in the spaces of multiple inductor products to form different curing angles θ, where θ is between 0° and 180°. The following lists the changes in various properties of the inductor products during the change of θ:

[0053] When θ=0°, the inductance increase rate Ls=0, the magnetic leakage rate is 100%, the buzzing sound is strong, and the number of impact resistance is only 10 times;

[0054] When θ=10°, the inductance increase rate Ls=7.8%, the magnetic leakage rate is 74%, the buzzing sound is strong, and the number of impact resistance is 18 times;

[0055] When θ=20°, the inductance increase rate Ls=9.3%, the magnetic leakage rate is 62%, the buzzing sound is strong, and the number of impact resistance is 25 times;

[0056] When θ=30°, the inductance increase rate Ls=10.1%, the magnetic leakage rate is 5.3%, there is no buzzing sound, and the number of impact resistance is 27 times;

[0057] When θ=60°, the inductance increase rate Ls=10.5%, the magnetic leakage rate is 0.41%, there is no buzzing sound, and the number of impact resistance is 38 times;

[0058] When θ=90°, the inductance increase rate Ls=11.6%, the magnetic leakage rate is 0%, there is no buzzing sound, and the number of impact resistance is 41 times;

[0059] When θ=120°, the inductance increase rate Ls=13.4%, the magnetic leakage rate is 0%, there is no buzzing sound, and the number of impact resistance is 39 times;

[0060] When θ=130°, the inductance increase rate Ls=13.3%, the magnetic leakage rate is 0%, there is no buzzing sound, and the number of impact resistance is 39 times;

[0061] When θ=150°, the inductance increase rate Ls=12.36%, the magnetic leakage rate is 0%, there is no buzzing sound, and the number of impact resistance is 39 times;

[0062] When θ=170°, the inductance increase rate Ls=12.36%, the magnetic leakage rate is 0%, there is no buzzing sound, and the number of impact resistance is 39 times;

[0063] When θ=180°, the inductance increase rate Ls=12.36%, the magnetic leakage rate is 0%, there is no buzzing sound, and the number of impact resistance is 39 times.

[0064] According to the above experimental data, as θ changes, the inductance, magnetic leakage rate and impact resistance times all change, and when meeting product requirements, θ needs to be greater than or equal to 30°, and when θ=90°, the product's impact resistance times reach a peak value, and in the preferred embodiment, θ can be less than or equal to 150°, so that the usage of magnetic powder glue 3 can meet the product performance, reduce the waste of magnetic powder glue 3, and save raw materials.

[0065] The inductor product is manufactured by the inductor product manufacturing process in the above embodiment, and includes a magnetic core 1, a copper wire 4 and a magnetic powder glue 3. The copper wire 4 is wound around the magnetic core 1; the magnetic powder glue 3 is filled inside the magnetic core 1 and covers the copper wire 4, and the space V filled with the magnetic powder glue 3 is equal to (b 2 -πr 2 )*h*(1-n), and the magnetic powder glue 3 forms a curing angle θ within a preset angle range between the cured side wall and the inner bottom wall of the magnetic core 1.

[0066] Specifically, the magnetic core 1 includes a magnetic column 11, a first blade 12 and a second blade 13. The copper wire 4 is wound around the magnetic column 11; the first blade 12 is arranged at one end of the magnetic column 11; the second blade 13 is arranged at the other end of the magnetic column 11 and is arranged opposite to the first blade 12. According to the curing shrinkage rate of the magnetic powder glue 3, the space formed between the first blade 12 and the second blade 13 satisfies V=(b 2 -πr 2 )*h*(1-n), so that the magnetic powder glue 3 can be fully filled between the first blade 12 and the second blade 13, and the magnetic powder glue 3 has an arc-shaped side wall after curing to form a fixed angle θ with the top wall of the second blade 13.

[0067] When the inductor product is manufactured using the above process, sufficient space can be reserved in advance for the filling of the magnetic powder glue 3. After the magnetic powder glue 3 is filled and solidified, θ can be used to determine whether the amount of the magnetic powder glue 3 meets the requirements, thereby ensuring that the magnetic powder glue 3 can form a stable connection with the magnetic core 1 while covering the copper wire 4, thereby ensuring that the overall strength and inductance value of the inductor product meet the requirements, and the possibility of magnetic leakage can be effectively reduced, which is conducive to comprehensively improving the quality and performance of the inductor product.

[0068] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the embodiments of the present invention. For those skilled in the art, various obvious changes, readjustments and substitutions can be made without departing from the protection scope of the present invention. It is not necessary and impossible to list all the embodiments here. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the claims of the present invention.

Claims

1. The manufacturing process of inductor products is characterized by: include: A copper wire (4) is wound around the middle of the magnetic core (1) and then subjected to a tinning treatment. After the tinning treatment forms an electrode (2), a magnetic powder glue (3) is filled into the middle of the magnetic core (1) and covers the copper wire (4); Obtain the top wall size a of the magnetic core (1), the bottom wall size b, the height h of the space in the middle of the magnetic core (1), the distance r between the outer side of the copper wire (4) and the middle of the magnetic core (1), the curing shrinkage rate n of the magnetic powder glue (3), and the curing angle θ between the side wall of the magnetic powder glue (3) and the inner bottom wall of the magnetic core (1) after curing; When θ is equal to the first preset angle, the space amount V filled with the magnetic powder glue (3) is (b 2 -πr 2 )*h*(1-n) and when θ meets the preset angle range, the product is judged to be qualified.

2. The inductor product manufacturing process according to claim 1, characterized in that: a≤b, 0.3mm≤h≤4mm.

3. The inductor product manufacturing process according to claim 1, characterized in that: The first preset angle is 90°.

4. The inductor product manufacturing process according to claim 1, characterized in that: The preset angle range includes: θ≥30°.

5. The inductor product manufacturing process according to claim 1, characterized in that: The preset angle range also includes: θ≤150°.

6. The inductor product manufacturing process according to any one of claims 1 to 5, characterized in that: When θ meets the preset angle range, the product is judged to be qualified, which specifically includes: When θ satisfies the preset angle range, the inductance improvement rate is greater than 10%.

7. The inductor product manufacturing process according to any one of claims 1 to 5, characterized in that: When θ meets the preset angle range, the product is judged to be qualified, which specifically includes: When θ satisfies the preset angle range, the magnetic leakage rate is less than 6%.

8. The inductor product manufacturing process according to any one of claims 1 to 5, characterized in that: When θ meets the preset angle range, the product is judged to be qualified, which specifically includes: When θ meets the preset angle range, the number of impact resistance is greater than 25.

9. Inductor products, characterized in that: The inductor products include: Magnetic core (1); A copper wire (4) wound around the magnetic core (1); Magnetic powder glue (3) is filled in the magnetic core (1) and covers the copper wire (4). The space volume V filled with the magnetic powder glue (3) is (b 2 -πr 2 )*h*(1-n), and the magnetic powder glue (3) forms a curing angle θ within a preset angle range between the cured side wall and the inner bottom wall of the magnetic core (1).

10. The inductor product according to claim 9, characterized in that: The magnetic core (1) comprises: A magnetic column (11), the copper wire (4) being wound around the magnetic column (11); A first blade (12) is arranged at one end of the magnetic column (11); The second blade (13) is arranged at the other end of the magnetic column (11) and is arranged opposite to the first blade (12); the magnetic powder glue (3) is filled between the first blade (12) and the second blade (13); and the curing angle θ is formed between the side wall of the magnetic powder glue (3) and the side wall of the second blade (13).

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