Forming manufacturing method of copper sheet inductor and obtained copper sheet inductor

Abstract

The invention belongs to the technical field of inductors, and provides a forming manufacturing method of a copper sheet inductor and the obtained copper sheet inductor.The manufacturing method comprises the steps that a magnet of the copper sheet inductor is divided into a first magnetic blank and a second magnetic blank to be pressed and formed, the first magnetic blank is provided with a groove matched with a copper sheet, and the second magnetic blank is provided with a groove matched with the copper sheet; and after the first magnetic blank, the copper sheet and the second magnetic blank are assembled, pressing is carried out again, and the copper sheet inductor is obtained. According to the arrangement position of the copper sheet in the inductor, the groove capable of containing the copper sheet is manufactured in the first magnetic blank, the copper sheet is positioned and fixed, and position deviation of the copper sheet in the pressing process can be avoided; a one-time powder filling pressing method adopted in the prior art is adjusted into a first pressing and second pressing combined mode, and the problem that a copper sheet inductor cracks due to the density difference between the upper portion and the lower portion of a copper sheet is effectively solved.

Description

Technical Field

[0001] The invention belongs to the field of inductors and relates to a forming and manufacturing method of a copper sheet inductor and the obtained copper sheet inductor. Background Art

[0002] As one of the basic components in the circuit, inductor is widely used in circuits such as filtering, energy storage, oscillation and matching networks. Its main function is to store magnetic field energy and generate back electromotive force when the current changes to maintain the stability of the current. With the continuous development of electronic technology, the performance requirements for inductors are also increasing, especially in high-frequency applications and miniaturization requirements.

[0003] Traditional coil winding inductors are made of wires, usually enameled wire or bare copper wire, wound a certain number of turns around a ferrite core or other type of magnetic core. The advantages of this structure are large inductance and low loss, but the disadvantages are large size, complex manufacturing process and high cost, which cannot meet the needs of modern electronic equipment. In this regard, copper sheet inductors as a new structure have gradually attracted attention.

[0004] Copper sheet inductors use copper sheets as conductive materials. Through specific processing methods, copper sheets are combined with magnetic cores to form components with inductive effect. Compared with coil winding inductors, copper sheets have higher conductivity and can significantly reduce the internal resistance of inductor components and reduce losses in high-frequency circuits. In addition, copper sheet inductors can also flexibly control the inductance value, quality factor and other parameters of inductor components by adjusting the shape, size and arrangement of copper sheets to meet the needs of different circuits. More importantly, copper sheets have high mechanical strength and good plasticity. Through precise processing technology, copper sheets can be tightly combined with magnetic cores to form compact and small-sized inductor components.

[0005] However, despite the many structural advantages of copper sheet inductors, in the actual manufacturing process, they are often faced with cracking problems caused by density differences and copper sheet positioning problems. Specifically, the preparation of copper sheet inductors in the prior art involves placing a copper sheet in a mold, then filling magnetic powder on the upper and lower sides of the copper sheet, and applying pressure to tightly combine the magnetic powder with the copper sheet to form a component with an inductive effect. However, due to the presence of the copper sheet, the powder materials above and below the copper sheet are divided into two parts. Such a one-time pressing operation will lead to a density difference problem after the powder materials above and below the copper sheet are pressed. The density difference will cause stress concentration to easily occur when the inductor component is subjected to force, resulting in the product being prone to cracking. Cracking will not only reduce the mechanical strength of the inductor component, but will also destroy its internal electromagnetic structure, resulting in a deterioration in the inductor characteristics. At the same time, during this pressing process, the copper sheet will also shift up and down during the pressing process, causing the copper sheet to be not centered or not in the predetermined position, thereby affecting the performance of the inductor component.

[0006] In summary, in order to solve the problems existing in the manufacturing process of copper sheet inductors and improve the performance, reliability and stability of copper sheet inductors, it is still necessary to develop new manufacturing solutions for copper sheet inductors. Summary of the invention

[0007] In view of the problems existing in the prior art, the purpose of the present invention is to provide a forming and manufacturing method of a copper sheet inductor and the obtained copper sheet inductor, wherein the manufacturing method comprises dividing the magnet of the copper sheet inductor into a first magnetic blank and a second magnetic blank and performing pressing and molding respectively, wherein the first magnetic blank has a groove matching the copper sheet, and after assembling the first magnetic blank with the copper sheet and the second magnetic blank, performing pressing again to obtain the copper sheet inductor. The present invention manufactures a groove for placing the copper sheet on the first magnetic blank according to the setting position of the copper sheet in the inductor, and positions and fixes the copper sheet, thereby avoiding the position deviation of the copper sheet during the pressing process; the present invention adjusts the one-time powder filling pressing method used in the prior art to a combination of the first pressing and the second pressing method, which effectively solves the cracking problem of the copper sheet inductor caused by the density difference between the upper and lower parts of the copper sheet.

[0008] To achieve this object, the present invention adopts the following technical solutions:

[0009] In a first aspect, the present invention provides a forming and manufacturing method for a copper sheet inductor, the forming and manufacturing method comprising:

[0010] Providing magnetic powder raw materials and copper sheets; performing a first pressing on the magnetic powder raw materials to obtain a first magnetic blank and a second magnetic blank respectively; the first magnetic blank and the second magnetic blank respectively have mutually matching butt joint surfaces; on one side of the butt joint surfaces, the first magnetic blank has a groove matching the copper sheet, and after the first magnetic blank and the second magnetic blank are butt jointed, the groove forms a receiving cavity for receiving the copper sheet;

[0011] The copper sheet is placed in the groove, and the copper sheet and the first magnetic blank are assembled into an intermediate; the second magnetic blank is docked with the first magnetic blank in the intermediate, and the second magnetic blank and the intermediate are assembled into a blank body; the blank body is subjected to a second pressing to obtain the copper sheet inductor.

[0012] The present invention analyzes the prior art scheme of using one-time powder filling and pressing to manufacture copper sheet inductors, and finds that the reason for the uneven density of the copper sheet inductors on the upper and lower sides of the copper sheet is caused by the uneven powder filling in the upper and lower parts of the copper sheet. According to the characteristics of this molding process, the present invention divides the copper sheet inductor into two parts, and takes the plane where the copper sheet is located as the center plane, and divides the copper sheet inductor into two upper and lower magnetic blanks, so that the lower magnetic blank (i.e., the first magnetic blank) has a groove formed after the accommodating cavity is separated, and the groove can just match and place the copper sheet, thereby realizing the positioning and fixation of the copper sheet, and effectively preventing the position of the copper sheet from shifting during the pressing process. Then the two magnetic blanks and the copper sheet are combined together, and then a unified second pressing is performed to obtain the overall copper sheet inductor. This improved molding and manufacturing process makes the density of the copper sheet inductor on the upper and lower parts of the copper sheet completely consistent, solves the problem of product cracking and copper sheet displacement caused by uneven product density, and ensures the high-quality production and manufacturing of the copper sheet inductor.

[0013] The following are preferred technical solutions of the present invention, but are not intended to be limitations of the technical solutions provided by the present invention. Through the following technical solutions, the technical objectives and beneficial effects of the present invention can be better achieved and realized.

[0014] As a preferred technical solution of the present invention, along the thickness direction of the copper sheet, the depth of the groove is less than or equal to the thickness of the copper sheet.

[0015] As a preferred technical solution of the present invention, the shape of the copper sheet includes any one of an arc shape, a U shape or an X shape.

[0016] As a preferred technical solution of the present invention, after the second pressing, the obtained copper sheet inductor is baked and solidified.

[0017] As a preferred technical solution of the present invention, after the baking and curing, the obtained copper sheet inductor is subjected to shaping processing, and the shaping processing includes chamfering the edges of the copper sheet inductor.

[0018] As a preferred technical solution of the present invention, after the baking and curing or the shaping process, the obtained copper sheet inductor is surface coated to form a protective layer.

[0019] As a preferred technical solution of the present invention, the surface coating method includes spraying, and the protective layer includes paint and / or resin.

[0020] As a preferred technical solution of the present invention, two openings are formed at both ends of the groove on the bottom surface of the first magnetic blank and / or the second magnetic blank, so that the two ends of the copper sheet are exposed from the accommodating cavity and pins are formed at the openings.

[0021] As a preferred technical solution of the present invention, after the surface is coated, the protective layer at the position of the pin is removed by laser stripping and / or grinding to expose the pin.

[0022] As a preferred technical solution of the present invention, electroplating is performed on the exposed pins to form a solder layer, and the copper sheet inductor is externally connected and installed through the solder layer.

[0023] In a second aspect, the present invention provides a copper sheet inductor obtained by the molding manufacturing method described in the first aspect.

[0024] Compared with the prior art solutions, the present invention has at least the following beneficial effects:

[0025] The present invention divides the copper sheet inductor into two parts, and divides the copper sheet inductor into two upper and lower magnetic blanks with the plane where the copper sheet is located as the center plane, so that the lower magnetic blank (i.e., the first magnetic blank) has a groove formed after the accommodating cavity is divided, and the groove can just match and place the copper sheet, thereby realizing the positioning and fixation of the copper sheet, and effectively preventing the position of the copper sheet from shifting during the pressing process. Then the two magnetic blanks and the copper sheet are combined together, and then a unified second pressing is performed to obtain the overall copper sheet inductor. This improved molding and manufacturing process makes the density of the copper sheet inductor on the upper and lower sides of the copper sheet completely consistent, solves the problem of product cracking and copper sheet displacement caused by uneven product density, and ensures high-quality production and manufacturing of the copper sheet inductor. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 It is a schematic diagram of the first pressing in the forming and manufacturing method of the copper sheet inductor of Example 1.

[0027] Figure 2 It is a schematic diagram of the second pressing in the forming manufacturing method of the copper sheet inductor of Example 1.

[0028] Figure 3 It is a schematic diagram of the structure of the first magnetic blank obtained in Example 1.

[0029] Figure 4 It is a schematic diagram of the assembly of the first magnetic blank, the second magnetic blank and the copper sheet of Example 1.

[0030] Figure 5 Schematic diagram of the bottom of the copper sheet inductor obtained in Example 1 before electroplating.

[0031] In the figure: 1-first magnetic blank, 2-second magnetic blank, 3-copper sheet, 4-groove, 5-pin. DETAILED DESCRIPTION

[0032] The technical solution of the present invention is further illustrated below through specific implementation methods.

[0033] It should be clear to those skilled in the art that the embodiments are only intended to help understand the present invention and should not be considered as specific limitations of the present invention.

[0034] In a specific embodiment, the present invention provides a method for forming and manufacturing a copper sheet 3 inductor, such as Figure 1 and Figure 2 As shown, the molding manufacturing method includes:

[0035] Provide magnetic powder raw materials and copper sheets 3; perform a first pressing on the magnetic powder raw materials to obtain a first magnetic blank 1 and a second magnetic blank 2 respectively; the first magnetic blank 1 and the second magnetic blank 2 respectively have mutually matching butt joint surfaces; Figure 3 As shown, on one side of the docking surface, the first magnetic blank 1 has a groove 4 matching the copper sheet 3, and after the first magnetic blank 1 is docked with the second magnetic blank 2, the groove 4 forms a receiving cavity for receiving the copper sheet 3;

[0036] The copper sheet 3 is placed in the groove 4, so that the copper sheet 3 and the first magnetic blank 1 are assembled into an intermediate; the second magnetic blank 2 is docked with the first magnetic blank 1 in the intermediate, so that the second magnetic blank 2 and the intermediate are assembled into a blank body. Figure 4 The blank is pressed for the second time to obtain the copper sheet 3 inductor, as shown in FIG. Figure 5 shown.

[0037] In one embodiment, along the thickness direction of the copper sheet 3 , the depth of the groove 4 is less than or equal to the thickness of the copper sheet 3 .

[0038] That is, the second magnetic blank in the present invention may also have a groove. In this case, the groove of the first magnetic blank must ensure that the copper sheet can be placed and fixed therein, and the grooves of the first magnetic blank and the second magnetic blank are combined together to form a accommodating cavity for accommodating the copper sheet.

[0039] In one embodiment, the shape of the copper sheet 3 includes any one of an arc shape, a U shape or an X shape.

[0040] In one embodiment, after the second pressing, the obtained copper sheet 3 inductor is baked and cured.

[0041] In one embodiment, after the baking and curing, the obtained copper sheet 3 inductor is subjected to shaping processing, and the shaping processing includes chamfering the edges of the copper sheet 3 inductor.

[0042] In one embodiment, after the baking and curing or the shaping, the surface of the obtained copper sheet 3 inductor is coated to form a protective layer.

[0043] In one embodiment, the surface coating method comprises spraying, and the protective layer comprises paint and / or resin.

[0044] In one embodiment, both ends of the groove 4 form two openings on the bottom surface of the first magnetic blank 1 and / or the second magnetic blank 2, so that both ends of the copper sheet 3 are exposed from the accommodating cavity, and pins 5 are formed at the openings.

[0045] In one embodiment, after the surface coating, the protective layer at the position of the pins 5 is removed by laser stripping and / or grinding to expose the pins 5.

[0046] In one embodiment, electroplating is performed on the exposed pins 5 to form a soldering layer, and the copper sheet 3 inductor is externally connected and installed through the soldering layer.

[0047] In a second aspect, the present invention provides a copper sheet 3 inductor obtained by the molding manufacturing method described in the above embodiment.

[0048] Example 1

[0049] This embodiment provides a molding manufacturing method for a copper sheet 3 inductor, as Figure 1 and Figure 2 shown, the molding manufacturing method includes:

[0050] Providing magnetic powder raw materials and a copper sheet 3; the shape of the copper sheet 3 is a U-shape;

[0051] Performing a first pressing on the magnetic powder raw materials to obtain a first magnetic blank 1 and a second magnetic blank 2 respectively; the first magnetic blank 1 and the second magnetic blank 2 respectively have mating butting surfaces; on one side of the butting surface, the first magnetic blank 1 has a groove 4 matching the copper sheet 3, and the depth of the groove 4 is half of the thickness of the copper sheet 3; after the first magnetic blank 1 and the second magnetic blank 2 are butted, the groove 4 forms an accommodating cavity for accommodating the copper sheet 3;

[0052] Placing the copper sheet 3 in the groove 4 to assemble the copper sheet 3 and the first magnetic blank 1 into an intermediate body; butting the second magnetic blank 2 with the first magnetic blank 1 in the intermediate body to assemble the second magnetic blank 2 and the intermediate body into a blank body; wherein, both ends of the groove 4 form two openings on the bottom surface of the first magnetic blank 1 and / or the second magnetic blank 2, so that both ends of the copper sheet 3 are exposed from the accommodating cavity, and pins 5 are formed at the openings; performing a second pressing on the blank body to obtain the copper sheet 3 inductor.

[0053] After the second pressing, the obtained copper sheet 3 inductor is baked and cured; after the baking and curing, the obtained copper sheet 3 inductor is shaped, and the shaping includes chamfering the edges of the copper sheet 3 inductor; after the shaping, the obtained copper sheet 3 inductor is surface coated to form a protective layer; the surface coating method includes spraying paint; using laser stripping to remove the paint at the position of the pin 5 to expose the pin 5; electroplating the exposed pin 5 to form a copper-nickel layer, and the copper sheet 3 inductor is used as an inductor device for external connection and installation through the copper-nickel layer.

[0054] When performing the first pressing and the second pressing, the pressing device used should have matching upper molds, upper concave molds, concave molds and lower molds, so as to manufacture the first magnetic blank 1 and the second magnetic blank 2 of a specific structure, or to press and form the blank body composed of the first magnetic blank 1, the second magnetic blank 2 and the copper sheet 3. For example, it can be understood that when performing the first pressing, the mold used should follow the shape of the first magnetic blank and the second magnetic blank to obtain corresponding and matching structures on the docking surface. These structures refer to the structures that can make the first magnetic blank have a groove for placing and fixing the copper sheet, and the structures that can form a suitable accommodating cavity to accommodate the copper sheet after the second magnetic blank is docked and combined with the first magnetic blank.

[0055] The copper sheet 3 inductor obtained in Example 1 is as follows Figures 3 to 5 As shown, the copper sheet 3 inductor includes a magnet formed by a combination of a first magnetic blank 1 and a second magnetic blank 2, wherein the magnet has a receiving cavity, in which a copper sheet 3 in the shape of a Chinese numeral 9 is arranged; two openings are provided at both ends of the receiving cavity on the bottom surface of the magnet, and both ends of the copper sheet 3 are respectively exposed from the openings to form pins 5, and there is no protective layer on the pins 5 but a copper-nickel layer for electrically connecting the copper sheet 3 inductor as a device, and except for the position of the pins 5, the outer surface of the magnet is covered with a protective layer.

[0056] Comparative Example 1

[0057] This comparative example provides a method for forming and manufacturing a copper sheet 3 inductor, and the forming and manufacturing method comprises:

[0058] Provide magnetic powder raw materials and copper sheet 3; place the copper sheet 3 in a mold cavity, fill the mold cavity with the magnetic powder raw materials, and press to obtain the copper sheet 3 inductor.

[0059] By comparing Example 1 with Comparative Example 1, it can be found that the copper sheet inductor obtained in Example 1 is divided into two parts, and the copper sheet inductor is divided into upper and lower magnetic blanks with the plane where the copper sheet is located as the center plane, so that the lower magnetic blank (i.e., the first magnetic blank) has a groove formed after the accommodating cavity is separated, and the groove can just match and place the copper sheet, so as to realize the positioning and fixation of the copper sheet, and effectively prevent the position shift of the copper sheet during the pressing process. Then the two magnetic blanks and the copper sheet are combined together, and then a unified second pressing is performed to obtain the overall copper sheet inductor. This improved molding and manufacturing process makes the density of the copper sheet inductor on the upper and lower sides of the copper sheet completely consistent, solves the problem of product cracking and copper sheet displacement caused by uneven product density, and ensures the high-quality production and manufacturing of the copper sheet inductor.

[0060] The preferred embodiments of the present invention are described in detail above. However, the present invention is not limited to the specific details in the above embodiments. Within the technical concept of the present invention, a variety of simple modifications can be made to the technical solution of the present invention, and these simple modifications all belong to the protection scope of the present invention.

[0061] It should also be noted that the various specific technical features described in the above specific embodiments can be combined in any suitable manner without contradiction. In order to avoid unnecessary repetition, the present invention will not further describe various possible combinations.

[0062] In addition, various embodiments of the present invention may be arbitrarily combined, and as long as they do not violate the concept of the present invention, they should also be regarded as the contents disclosed by the present invention.

Claims

1. A method for forming and manufacturing a copper sheet inductor, characterized in that: The molding manufacturing method comprises: Providing magnetic powder raw materials and copper sheets; performing a first pressing on the magnetic powder raw materials to obtain a first magnetic blank and a second magnetic blank respectively; the first magnetic blank and the second magnetic blank respectively have mutually matching butt joint surfaces; on one side of the butt joint surfaces, the first magnetic blank has a groove matching the copper sheet, and after the first magnetic blank and the second magnetic blank are butt jointed, the groove forms a receiving cavity for receiving the copper sheet; The copper sheet is placed in the groove, and the copper sheet and the first magnetic blank are assembled into an intermediate; the second magnetic blank is docked with the first magnetic blank in the intermediate, and the second magnetic blank and the intermediate are assembled into a blank body; the blank body is subjected to a second pressing to obtain the copper sheet inductor.

2. The forming and manufacturing method of the copper sheet inductor according to claim 1, characterized in that: Along the thickness direction of the copper sheet, the depth of the groove is less than or equal to the thickness of the copper sheet.

3. The forming and manufacturing method of the copper sheet inductor according to claim 1 or 2, characterized in that: The shape of the copper sheet includes any one of an arc shape, a U shape or a cross shape.

4. The method for forming and manufacturing a copper sheet inductor according to any one of claims 1 to 3, characterized in that: After the second pressing, the obtained copper sheet inductor is baked and solidified.

5. The method for forming and manufacturing a copper sheet inductor according to claim 4, characterized in that: After the baking and curing, the obtained copper sheet inductor is subjected to shaping processing, and the shaping processing includes chamfering the edges of the copper sheet inductor.

6. The method for forming and manufacturing a copper sheet inductor according to claim 5, characterized in that: After the baking and curing or the shaping, the obtained copper sheet inductor is coated on the surface to form a protective layer; Preferably, the surface coating method comprises spraying, and the protective layer comprises paint and / or resin.

7. The method for forming and manufacturing a copper sheet inductor according to claim 6, characterized in that: Two openings are formed at the two ends of the groove on the bottom surface of the first magnetic blank and / or the second magnetic blank, so that the two ends of the copper sheet are exposed from the accommodating cavity and pins are formed at the openings.

8. The method for forming and manufacturing a copper sheet inductor according to claim 7, characterized in that: After the surface is coated, the protective layer at the position of the pins is removed by laser stripping and / or grinding to expose the pins.

9. The method for forming and manufacturing a copper sheet inductor according to claim 8, characterized in that: Electroplating is performed on the exposed pins to form a solder layer, and the copper sheet inductor is externally mounted and connected through the solder layer.

10. A copper sheet inductor obtained by the molding manufacturing method according to any one of claims 1 to 9.

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