Manufacturing method of alloy magnetic powder core non-annular magnetic component

Abstract

The invention relates to a manufacturing method of a non-annular magnetic component with an alloy magnetic powder core in the field of magnetic components. The manufacturing method comprises the following steps of 1, powder preparation, 2, passivation coating, 3, mold pressing, 4, sintering curing and 5, glue soaking treatment. In order to press and form the non-annular magnetic component with a smaller structure, combined dies are arranged, each group of dies correspond to different parts of the non-annular magnetic component, and accurate matching and positioning mechanisms are arranged among the groups of dies, so that the integrity of the non-annular magnetic component in the pressing process is ensured; multiple sets of dies are matched for pressing according to a preset program, the method can be suitable for the magnetic component which is smaller in overall structure, special-shaped and provided with multiple supporting legs, the minimum thickness of the non-annular magnetic component can reach 0.8 mm through tests, it is guaranteed that thinner and smaller connecting areas can be pressed and formed through matched pressing of the multiple sets of dies, the multiple sets of dies are matched for pressing, stress is uniform, and the production efficiency is improved. And the fracture phenomenon is not easy to occur.

Description

Technical Field

[0001] The invention relates to the field of magnetic components, and in particular to a method for manufacturing an alloy magnetic powder core non-annular magnetic component. Background Art

[0002] Manganese-zinc ferrite power material components are components made of manganese-zinc ferrite magnetic materials composed of ferrite and a small amount of manganese and zinc elements, such as inductors, transformers, etc. Manganese-zinc ferrite components are widely used in power electronics, communications, computers, automotive electronics and other fields. They are indispensable key components in electronic equipment. Due to the low density of manganese-zinc ferrite magnetic materials and weak overall brittleness, they are easy to press and form, and do not require high mold pressure and mold rigidity.

[0003] The continuous upgrading of manganese-zinc ferrite power materials (such as PC30, PC40, PC44, PC47, PC90, PC95 to PC97, etc.) is mainly aimed at improving efficiency and reducing power consumption. This upgrade is achieved by optimizing the material's magnetic permeability, operating frequency and other properties to meet the needs of electronic equipment for higher performance and lower energy consumption. However, with the continuous development of material technology, the performance improvement of manganese-zinc ferrite power materials is gradually approaching the physical limit, that is, the so-called "material improvement has reached a bottleneck." At this time, in order to further improve efficiency and reduce power consumption, a possible solution is to increase the effective area of ​​the material, but this means that the size of the components needs to be increased, which is contrary to the miniaturization and lightweight direction pursued by the electronics industry, forming a contradiction.

[0004] As a new type of magnetic material, alloy magnetic powder core has the characteristics of small size and high power. Compared with manganese-zinc ferrite power materials, alloy magnetic powder core has significant advantages. Alloy magnetic powder core has the advantages of reducing conducted interference and radiated interference, strong anti-interference ability, noise reduction, self-shielding, self-air gap, and not easy to reach saturation, which can just meet the needs of the electronics industry for high-performance and miniaturized components. Its high saturation magnetic induction intensity, low loss and other characteristics make alloy magnetic powder core have significant advantages in high-frequency and high-power applications.

[0005] However, the promotion and application of alloy magnetic powder cores also faces many challenges. First of all, due to its high density and difficulty in pressing and molding, a larger alloy magnetic powder core needs to be pressed with a greater pressure. When the pressure is not properly controlled, the pressing mold will be crushed. Therefore, the minimum thickness of the product produced in the production process of alloy magnetic powder cores in the prior art is 3.5 mm, and only annular magnetic components can be produced, and non-annular magnetic components cannot be produced. When pressing smaller non-annular magnetic components, due to the strong brittleness of the alloy magnetic powder core, the leg connection area of ​​the non-annular magnetic component is prone to break during the pressing process, resulting in high production equipment requirements, high costs, and low yields. At present, no company in the entire industry has been able to completely solve the technical problems of the entire chain from powder preparation, mold design, pressing and molding to sintering in the production of alloy magnetic powder core non-annular magnetic components. Summary of the invention

[0006] The purpose of the present invention is to solve the above defects and provide a method for manufacturing alloy magnetic powder core non-annular magnetic components, which can be used to produce non-annular magnetic components and is suitable for the production of smaller non-annular magnetic components. It solves the technical problem that in the prior art process, due to the influence of process and material properties, only larger and annular alloy magnetic powder core magnetic components can be produced.

[0007] The object of the present invention is achieved in the following ways:

[0008] A method for manufacturing a non-annular magnetic component of an alloy magnetic powder core, the manufacturing method comprising the following steps:

[0009] The first step is powder preparation. Any two or more metals among iron, silicon, aluminum, nickel, molybdenum, chromium and cobalt are first smelted according to a preset ratio, and then made into alloy powder by atomization method. The alloy powder is then annealed and then made into alloy magnetic powder core powder. Annealing can not only increase hardness and improve its plasticity, but also reduce surface oxides to improve mechanical properties, and at the same time remove oil and impurities on the surface.

[0010] The second step is passivation coating, preparing a passivation solution for passivation, pouring the passivation solution into the alloy magnetic powder core powder, and stirring the alloy magnetic powder core powder and the passivation solution to fully and evenly mix them, so that the alloy magnetic powder core powder and the passivation solution react chemically, and a dense passivation film is formed on the surface of the alloy magnetic powder core powder, and then the passivated alloy magnetic powder core powder is mixed with a binder and a release agent and stirred evenly, and the alloy magnetic powder core powder is further coated with a binder and a release agent to increase the mechanical strength and tensile strength of the alloy magnetic powder core powder, and further strengthen the insulation between the alloy magnetic powder core powder particles;

[0011] The third step is mold pressing, which is divided into the following steps in order of operation:

[0012] a. Prepare a combined mold. According to the shape design drawings of the non-annular magnetic components, the combined mold is composed of multiple groups of molds. Each group of molds corresponds to different parts of the non-annular magnetic components. Precise matching and positioning mechanisms are set between the groups of molds to ensure the integrity of the non-annular magnetic components during the pressing process;

[0013] b. Loading and pressing, the passivated and coated alloy magnetic powder core powder is evenly filled in the corresponding loading area of ​​each group of molds in the combined mold. Before pressing, the starting time and pressure curve of the pressing equipment are set according to the shape and size characteristics of the non-annular magnetic components, and then the pressing equipment is started. The equipment will start working according to the preset program. As the pressing process proceeds, each group of molds is started in sequence according to the preset starting time. Each group of molds starts to apply pressure at an appropriate time point to press different parts of the non-annular magnetic components. Since the starting time of each group of molds is different, they can press different parts of the non-annular magnetic components in sequence or simultaneously. After each group of molds completes the pressing, the set holding time is maintained to make the alloy magnetic powder core powder fully stable under pressure;

[0014] c. Overall molding: After all the molds have been pressed and maintained, the various parts of the non-annular magnetic component will be fully and tightly combined in the mold to form a complete non-annular magnetic component. The entire non-annular magnetic component has the required shape. After the non-annular magnetic component has been maintained and fully solidified, demolding is then performed, and the molded product will automatically be removed from the mold;

[0015] The fourth step is sintering and solidification, placing the pressed non-annular magnetic components into a sintering furnace for sintering and solidification;

[0016] The fifth step is the foaming treatment. Put the sintered and solidified non-annular magnetic components into glue for foaming treatment. The foaming process requires that the non-annular magnetic components are completely immersed in glue. Bubbles will be generated during the foaming process. The foaming is completed until no bubbles are generated. Then take them out and dry them before putting them in the oven for baking. The finished product can be taken out after baking is completed.

[0017] After the fifth step, the sixth step, surface coating treatment, can be selected according to the needs. Coating is carried out according to different requirements. The color is coated through the coating process. The coating material is required to meet the requirements of high temperature resistance, high voltage resistance, insulation and flame retardancy, and high voltage resistance of 1200-3800V. Specifically, RLHY-20S3 high temperature resistant insulating coating can be used, which can form a ceramic coating with a high volume resistivity on the surface of the coated object, which can withstand a voltage of up to 20,000 volts. At the same time, it has good temperature resistance and can work for a long time below 1800℃. The coating also has the properties of corrosion resistance, acid and alkali resistance, waterproof, moisture resistance, and wear resistance, and is very suitable for motors and electrical equipment running at high temperatures.

[0018] Furthermore, in the fourth step, sintering and curing are carried out in stages, including a preheating stage, a main sintering stage and a cooling stage in sequence. Preheating stage: before formal sintering, the non-annular magnetic components are preheated. The control temperature of the preheating stage is lower than that of the main sintering stage, which is used to remove moisture and gas in the material, reduce thermal stress concentration during the sintering process, and improve the sintering quality; main sintering stage: after preheating, the non-annular magnetic components are placed at a set sintering temperature for main sintering. The main sintering stage is the main stage for material sintering and curing; cooling stage: after sintering, the non-annular magnetic components need to be cooled to avoid excessive residual stress inside the material. The control temperature of the cooling stage is lower than that of the preheating stage.

[0019] Furthermore, after the second passivation coating, a drying process is required. The alloy magnetic powder core powder is taken out from the passivation solution, and is thoroughly cleaned to remove the residual passivation solution, and then dried to make the passivation film on the surface of the alloy magnetic powder core powder more stable and pure.

[0020] Furthermore, the drying treatment adopts a room temperature drying method, which is suitable for a passivation liquid using a diluent. The diluent is easy to volatilize at room temperature. The alloy magnetic powder core powder after passivation coating is spread flat in a room temperature environment, and the liquid on the surface of the alloy magnetic powder core powder will evaporate naturally at room temperature. After a certain period of drying, the alloy magnetic powder core powder is completely dry.

[0021] Furthermore, the drying treatment adopts a heating evaporation method to quickly heat the alloy magnetic powder core powder after passivation coating, so that the liquid on its surface will completely evaporate after heating, and finally stop heating to wait for the alloy magnetic powder core powder to return to room temperature. Rapid heating can prevent the alloy magnetic powder core powder from being oxidized.

[0022] Furthermore, the passivation solution used in the second step is composed of a phosphate solution or a chromate solution.

[0023] Furthermore, in the second step, the binder is an organic binder, and the organic binder is polyamide, polyurethane or epoxy resin.

[0024] Furthermore, in the second step, the binder is an inorganic binder, and the inorganic binder is silicate or glass powder.

[0025] Furthermore, the combined mold in the third step includes an upper punch, a lower punch and a mother mold, the alloy magnetic powder core powder is evenly filled in the mother mold, and the upper punch and the lower punch each include more than two modules.

[0026] The beneficial effects of the present invention are as follows: non-annular magnetic components are manufactured using alloy magnetic powder core powder. The non-annular magnetic components manufactured by the manufacturing method of the present invention can replace manganese-zinc ferrite power non-annular products. Since the alloy magnetic powder core powder is denser and more brittle than manganese-zinc ferrite, a greater pressure needs to be applied during the pressing process. In addition, the non-annular magnetic components are of a special-shaped structure, and the connection area is thinner and narrower. In order to press-form non-annular magnetic components with smaller structures, a combination mold is provided, which is composed of a plurality of groups of molds. Each group of molds corresponds to a different part of the non-annular magnetic component. Precise matching and positioning mechanisms are provided between the groups of molds to ensure the integrity of the non-annular magnetic components during the pressing process. Each group of molds is started in sequence according to a preset start time. Each group of molds starts to apply pressure at an appropriate time point to press different parts of the non-annular magnetic component. Since the start time of each group of molds is different, they can press the non-annular magnetic components in sequence or simultaneously. Different parts of the parts are pressed. After each set of molds is pressed, the set holding time is maintained to make the alloy magnetic powder core powder fully stable under pressure. Multiple sets of molds are pressed in cooperation with each other according to a preset program, which can be suitable for magnetic components with smaller overall structure, special shape, and multiple legs. The pressing can be completed without applying too much pressure, thereby reducing the scrap rate of the mold. After testing, the minimum thickness of the non-annular magnetic component can be 0.8mm, and multiple sets of molds are pressed together to ensure that thinner and smaller connection areas can be pressed and formed. Multiple sets of molds are pressed together to bear uniform force and are not prone to breakage. The structure is stable after forming and can be demolded normally. The non-annular magnetic component manufactured by the manufacturing method of the present invention can replace the manganese-zinc ferrite power non-annular product. Under the premise of the same small size, the alloy magnetic powder core non-annular magnetic component is compared with the manganese-zinc ferrite power non-annular product. The alloy magnetic powder core non-annular magnetic component has greater power, can reduce conducted interference and radiation interference, and is in line with the development trend of the electronics industry. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a schematic diagram of the three-dimensional structure of the alloy magnetic powder core non-annular magnetic component of the present invention;

[0028] Figure 2It is a schematic diagram of the three-dimensional structure of a ring-shaped magnetic component;

[0029] Figure 3 It is a flow chart of the method for manufacturing the alloy magnetic powder core non-annular magnetic component of the present invention;

[0030] In the figure, 1-alloy magnetic powder core non-annular magnetic component, 2-leg, 3-main body, 4-annular magnetic component. DETAILED DESCRIPTION

[0031] The present invention is further described in detail below in conjunction with the accompanying drawings and specific embodiments.

[0032] In this embodiment, refer to Figure 1-Figure 3 The specific manufacturing method of the alloy magnetic powder core non-annular magnetic component 1 includes the following steps:

[0033] The first step is powder preparation;

[0034] The second step is passivation coating;

[0035] The third step is mold pressing, a. prepare the combined mold, b. load the material and press, c. overall forming;

[0036] The fourth step is sintering and curing;

[0037] Step 5: Foam treatment.

[0038] Each step is described in detail below:

[0039] The first step is powder preparation. Any two or more metals among iron, silicon, aluminum, nickel, molybdenum, chromium and cobalt are first smelted according to a preset ratio, and then an alloy powder is made by atomization. The alloy powder is then annealed to prepare an alloy magnetic powder core powder. This embodiment provides the following four specific ingredients according to the mass fraction ratio:

[0040] The first type, 49% iron + 51% nickel;

[0041] The second type is 94% iron + 6% silicon;

[0042] The third type is 85% iron + 10% silicon + 5% nickel;

[0043] The fourth type, 51% iron + 39% aluminum + 10% silicon.

[0044] The second step is passivation coating. The alloy magnetic powder core powder is thoroughly cleaned and dried to remove oil and impurities on the surface, and a passivation solution for passivation is prepared. The passivation solution of this embodiment adopts a weak acid passivation solution, which is composed of a phosphate solution or a chromate solution. The pH value of the weak acid passivation solution is 2-5. The weak acid passivation solution is poured into the alloy magnetic powder core powder. After continuous stirring, the alloy magnetic powder core powder and the passivation solution are fully and evenly mixed, so that the alloy magnetic powder core powder and the passivation solution react chemically, and a dense passivation film is formed on the surface of the alloy magnetic powder core powder. Then, the passivated alloy magnetic powder core powder is mixed with a binder and a release agent and stirred evenly. The binder of this embodiment adopts an organic binder, specifically an epoxy resin. The alloy magnetic powder core powder is further coated by the binder and the release agent to increase the mechanical strength and tensile strength of the alloy magnetic powder core powder, and further strengthen the insulation between the particles of the alloy magnetic powder core powder.

[0045] In addition, after the passivation coating, drying treatment is required. The alloy magnetic powder core powder is taken out from the passivation liquid, thoroughly cleaned to remove the residual passivation liquid, and then dried to make the passivation film on the surface of the alloy magnetic powder core powder more stable and pure.

[0046] The third step is mold pressing, which is divided into the following steps in order of operation:

[0047] a. Prepare the combined mold and make the combined mold according to the shape design drawing of the non-annular magnetic component. The combined mold is composed of multiple groups of molds. Each group of molds corresponds to different parts of the non-annular magnetic component. Precise matching and positioning mechanisms are set between the groups of molds to ensure the integrity of the non-annular magnetic component during the pressing process.

[0048] b. Loading and pressing. The passivated and coated alloy magnetic powder core powder is evenly filled in the corresponding loading area of ​​each group of molds in the combined mold. Before pressing, the starting time and pressure curve of the pressing equipment are set according to the shape and size characteristics of the non-annular magnetic components. Then the pressing equipment is started. The equipment will start working according to the preset program. As the pressing process proceeds, each group of molds starts in sequence according to the preset starting time. Each group of molds starts to apply pressure at an appropriate time point to press different parts of the non-annular magnetic components, such as Figure 1As shown, the non-annular magnetic component includes three legs 2, which extend along one end of the main body 3 and extend in the same direction. The thickness of the two legs 2 at the two ends is the smallest, and the connection area between the two legs 2 at the two ends and the main body 3 is most likely to break. Since the start time of each group of molds is different, they can press different parts of the non-annular magnetic component in sequence or simultaneously. After each group of molds is pressed, the set holding time is maintained to make the alloy magnetic powder core powder fully stable under pressure. It is necessary to maintain a certain pressure and allow the non-annular magnetic component to cool in the combined mold for a period of time.

[0049] c. Overall molding: After all the molds have been pressed and maintained, the various parts of the non-annular magnetic component will be fully and tightly combined in the mold to form a complete non-annular magnetic component. The entire non-annular magnetic component has the required shape. After the non-annular magnetic component has been maintained and fully solidified, it is demolding, and the molded product will automatically be ejected from the mold.

[0050] The combined mold in the third step includes an upper punch, a lower punch and a mother mold. The alloy magnetic powder core powder is evenly filled in the mother mold. The upper punch and the lower punch each contain more than two modules. The corresponding modules can be called an upper punch, an upper second punch, an upper third punch, a lower punch, a lower second punch and a lower third punch respectively. The upper punch, the upper second punch, the upper third punch, the lower punch, the lower second punch and the lower third punch can be operated sequentially or simultaneously according to the program to press different parts of the non-annular magnetic components sequentially or simultaneously.

[0051] The fourth step is sintering and curing. The pressed non-annular magnetic components are placed in a sintering furnace for sintering and curing. The sintering and curing is carried out in stages, including the preheating stage, the main sintering stage and the cooling stage. The sintering and curing process undergoes a qualitative change after a high-temperature chemical reaction, which makes the non-annular magnetic components produce electromagnetic properties. At the same time, the sintering process also removes impurities. After high-temperature curing, the strength of the non-annular magnetic components is greatly increased.

[0052] Preheating stage: Before formal sintering, non-annular magnetic components are preheated. The control temperature in the preheating stage is lower than that in the main sintering stage. It is used to remove moisture and gas in the material, reduce thermal stress concentration during sintering, and improve sintering quality.

[0053] Main sintering stage: After preheating, the non-annular magnetic components are placed at the set sintering temperature for main sintering. The main sintering stage is the main stage of material sintering and solidification. The main sintering stage can also be divided into two stages. For example, in the first sintering stage, the sintering temperature is controlled at 200-750 degrees Celsius. After the first sintering stage is completed, the second sintering stage is carried out immediately, and the sintering temperature is controlled at 250-750 degrees Celsius.

[0054] Cooling stage: After sintering, the non-annular magnetic components need to be cooled to avoid excessive residual stress inside the material. The control temperature in the cooling stage is lower than that in the preheating stage. This embodiment uses rapid cooling or high-pressure gas quenching to perform the cooling stage.

[0055] The fifth step is the foaming treatment. The non-annular magnetic components after sintering and curing are placed in glue for foaming treatment. The foaming treatment can improve the insulation, moisture resistance, shock resistance and mechanical strength of the non-annular magnetic components. The glue used in the foaming process can be epoxy resin, polyurethane or silicone rubber. Before the foaming process, the surface of the non-annular magnetic components needs to be thoroughly cleaned to remove impurities such as oil and dust to ensure that the glue can adhere well to the surface of the non-annular magnetic components. The foaming process requires that all non-annular magnetic components are immersed in glue. Bubbles will be generated during the foaming process. The foaming is completed after no bubbles are generated. Then it is fished out and dried before being placed in the oven for baking. The finished product can be taken out after baking.

[0056] The non-annular magnetic components manufactured by the manufacturing method of the present embodiment can replace the manganese-zinc ferrite power non-annular products. The manganese-zinc ferrite magnetic material has a small density, weak overall brittleness, and is easy to press into shape. The manganese-zinc ferrite magnetic material can be made into non-annular products and has low mold requirements. However, due to the influence of its material properties, it is no longer possible to improve efficiency and reduce power consumption, and it must be replaced by material. Therefore, the alloy magnetic powder core non-annular magnetic component 1 of the present embodiment can directly replace the manganese-zinc ferrite power non-annular product.

[0057] Since the alloy magnetic powder core powder has a higher density and brittleness than manganese-zinc ferrite, a greater pressure needs to be applied during the pressing process, and the alloy magnetic powder core non-annular magnetic component 1 is a special-shaped structure, such as Figure 1 As shown in the figure, the connection area is thinner and narrower, in order to press and form a smaller non-annular magnetic component. Figure 2 The annular magnetic component 4 is shown. The annular magnetic component 4 is a standard annular structure, and the force is evenly applied. There is no need to worry about the support leg 2 breaking during a single pressing process.

[0058] In the manufacturing method of the present embodiment, a combination mold is provided, which is composed of a plurality of groups of molds. Each group of molds corresponds to a different part of the non-annular magnetic component. Precise matching and positioning mechanisms are provided between the groups of molds to ensure the integrity of the non-annular magnetic component during the pressing process. Each group of molds is started in a preset start time sequence. Each group of molds begins to apply pressure at an appropriate time point to press different parts of the non-annular magnetic component. Since the start time of each group of molds is different, they can press different parts of the non-annular magnetic component in sequence or simultaneously. After each group of molds is pressed, the set holding time is maintained to make the alloy magnetic powder core powder fully stable under pressure. By pressing with a plurality of groups of molds according to a preset program, the overall structure can be more compact. , special-shaped, and multi-legged magnetic components 2 can be pressed without applying too much pressure, reducing the scrap rate of the mold. After testing, the minimum thickness of the non-annular magnetic component can be 0.8mm, and multiple sets of molds are used to cooperate in pressing to ensure that thinner and smaller connection areas can be pressed into shape. The pressure of multiple sets of molds is evenly distributed, and it is not easy to break. The structure is stable after forming and can be demolded normally. The non-annular magnetic component manufactured by the manufacturing method of the present invention can replace the manganese-zinc ferrite power non-annular product. Under the premise of the same small size, the alloy magnetic powder core non-annular magnetic component 1 is compared with the manganese-zinc ferrite power non-annular product. The alloy magnetic powder core non-annular magnetic component 1 has greater power, can reduce conducted interference and radiation interference, and is in line with the development trend of the electronics industry.

[0059] The above contents are further detailed descriptions of the present invention in combination with specific preferred embodiments, and it cannot be determined that the specific implementation of the present invention is limited to these descriptions. For ordinary technicians in the technical field to which the present invention belongs, several simple deductions or substitutions can be made without departing from the concept of the present invention, which should be regarded as the protection scope of the present invention.

Claims

1. A method for manufacturing a non-annular magnetic component of an alloy magnetic powder core, characterized in that: The manufacturing method comprises the following steps: The first step is powder preparation, which involves smelting any two or more metals of iron, silicon, aluminum, nickel, molybdenum, chromium and cobalt in a preset ratio, and then making alloy powder by atomization, and then annealing the alloy powder to make alloy magnetic powder core powder; The second step is passivation coating, preparing a passivation solution for passivation, pouring the passivation solution into the alloy magnetic powder core powder, and stirring the alloy magnetic powder core powder and the passivation solution to fully and evenly mix them, so that the alloy magnetic powder core powder and the passivation solution react chemically, and a dense passivation film is formed on the surface of the alloy magnetic powder core powder, and then the passivated alloy magnetic powder core powder is mixed with a binder and a release agent and stirred evenly, and the alloy magnetic powder core powder is further coated with a binder and a release agent to increase the mechanical strength and tensile strength of the alloy magnetic powder core powder, and further strengthen the insulation between the alloy magnetic powder core powder particles; The third step is mold pressing, which is divided into the following steps in order of operation: a. Prepare a combined mold. According to the shape design drawings of the non-annular magnetic components, the combined mold is composed of multiple groups of molds. Each group of molds corresponds to different parts of the non-annular magnetic components. Precise matching and positioning mechanisms are set between the groups of molds to ensure the integrity of the non-annular magnetic components during the pressing process; b. Loading and pressing, the passivated and coated alloy magnetic powder core powder is evenly filled in the corresponding loading area of ​​each group of molds in the combined mold. Before pressing, the starting time and pressure curve of the pressing equipment are set according to the shape and size characteristics of the non-annular magnetic components, and then the pressing equipment is started. The equipment will start working according to the preset program. As the pressing process proceeds, each group of molds is started in sequence according to the preset starting time. Each group of molds starts to apply pressure at an appropriate time point to press different parts of the non-annular magnetic components. Since the starting time of each group of molds is different, they can press different parts of the non-annular magnetic components in sequence or simultaneously. After each group of molds completes the pressing, the set holding time is maintained to make the alloy magnetic powder core powder fully stable under pressure; c. Overall molding: After all the molds have been pressed and maintained, the various parts of the non-annular magnetic component will be fully and tightly combined in the mold to form a complete non-annular magnetic component. The entire non-annular magnetic component has the required shape. After the non-annular magnetic component has been maintained and fully solidified, demolding is then performed, and the molded product will automatically be removed from the mold; The fourth step is sintering and solidification, placing the pressed non-annular magnetic components into a sintering furnace for sintering and solidification; The fifth step is the foaming treatment. Put the sintered and solidified non-annular magnetic components into glue for foaming treatment. The foaming process requires that the non-annular magnetic components are completely immersed in glue. Bubbles will be generated during the foaming process. The foaming is completed until no bubbles are generated. Then take them out and dry them before putting them in the oven for baking. The finished product can be taken out after baking is completed.

2. The method for manufacturing the alloy magnetic powder core non-annular magnetic component according to claim 1, characterized in that: In the fourth step, sintering and curing are carried out in stages, including a preheating stage, a main sintering stage and a cooling stage. The preheating stage: before formal sintering, the non-annular magnetic components are preheated. The control temperature in the preheating stage is lower than that in the main sintering stage, which is used to remove moisture and gas in the material, reduce the concentration of thermal stress during the sintering process, and improve the sintering quality; the main sintering stage: after preheating, the non-annular magnetic components are placed at a set sintering temperature for main sintering. The main sintering stage is the main stage for material sintering and curing; the cooling stage: before formal sintering, the non-annular magnetic components are preheated. The control temperature in the preheating stage is lower than that in the main sintering stage, which is used to remove moisture and gas in the material, reduce the concentration of thermal stress during the sintering process, and improve the sintering quality. Stage: After sintering, non-annular magnetic components need to be cooled to avoid excessive residual stress inside the material. The control temperature in the cooling stage is lower than that in the preheating stage.

3. The method for manufacturing the alloy magnetic powder core non-annular magnetic component according to claim 1, characterized in that: After the second step of passivation coating, drying treatment is required. The alloy magnetic powder core powder is taken out from the passivation liquid, thoroughly cleaned to remove the residual passivation liquid, and then dried to make the passivation film on the surface of the alloy magnetic powder core powder more stable and pure.

4. The method for manufacturing the alloy magnetic powder core non-annular magnetic component according to claim 3, characterized in that: The drying treatment adopts a room temperature drying method, and the alloy magnetic powder core powder after passivation coating is spread flat at room temperature. The liquid on the surface of the alloy magnetic powder core powder will evaporate naturally at room temperature. After a certain period of drying, the alloy magnetic powder core powder is completely dry.

5. The method for manufacturing the alloy magnetic powder core non-annular magnetic component according to claim 3, characterized in that: The drying treatment adopts a heating evaporation method to quickly heat the alloy magnetic powder core powder after passivation coating, so that the liquid on its surface will be completely evaporated after heating, and finally the heating is stopped to wait for the alloy magnetic powder core powder to return to room temperature. Rapid heating can prevent the alloy magnetic powder core powder from being oxidized.

6. The method for manufacturing the alloy magnetic powder core non-annular magnetic component according to any one of claims 1 to 5, characterized in that: The passivation solution used in the second step is composed of a phosphate solution or a chromate solution.

7. The method for manufacturing the alloy magnetic powder core non-annular magnetic component according to any one of claims 1 to 5, characterized in that: In the second step, the binder is an organic binder, and the organic binder is polyamide, polyurethane or epoxy resin.

8. The method for manufacturing the alloy magnetic powder core non-annular magnetic component according to any one of claims 1 to 5, characterized in that: In the second step, the binder is an inorganic binder, and the inorganic binder is silicate or glass powder.

9. The method for manufacturing the alloy magnetic powder core non-annular magnetic component according to any one of claims 1 to 5, characterized in that: The combined mold in the third step includes an upper punch, a lower punch and a mother mold. The alloy magnetic powder core powder is evenly filled in the mother mold. The upper punch and the lower punch each include more than two modules.

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