Inductor and preparation method thereof

Abstract

The invention provides an inductor and a preparation method thereof, and the preparation method comprises the steps: punching a plurality of accommodation holes which are uniformly arranged at intervals in any raw material sheet, so as to obtain a first magnetic sheet with the accommodation holes; punching a plurality of middle columns from any raw material sheet; any raw material sheet is selected as a first shielding sheet, the first magnetic sheet and the first shielding sheet are overlapped, the containing hole is filled with the coil, and then the coil is filled with the middle column; punching a plurality of groups of electrode holes in any raw material sheet to obtain a second shielding sheet with electrode holes, and laminating the second shielding sheet on one side of the first magnetic sheet to obtain a laminated body; pins of the coil are exposed in the corresponding electrode holes; performing low hot press molding and cutting on the laminated body to obtain a plurality of initial inductors with electrodes; and carrying out insulation treatment and electroplating treatment on the primary inductor to finally obtain the inductor. Compared with the prior art, the inductor preparation method not only can improve the preparation efficiency of the inductor, but also can reduce the deformation quantity of the coil and reduce the direct-current resistance, so that the electromagnetic compatibility of electronic equipment is remarkably improved.

Description

Technical Field

[0001] The present invention relates to an inductor and a preparation method thereof, belonging to the technical field of inductors. Background Art

[0002] Most existing one-piece molded inductors are formed by high-temperature and high-pressure pressing, and have the characteristics of good magnetic tightness and excellent performance. However, the disadvantage is that the high pressure will cause large coil deformation, large DC resistance and eddy current loss of the inductor, which in turn affects the inductor efficiency and reduces the energy storage capacity of the inductor.

[0003] In addition, most of the inductor preparation methods currently used cannot obtain a large amount of inductance at one time in a single preparation process, but require repeated operation steps, which is not conducive to improving production capacity.

[0004] In view of this, it is indeed necessary to improve the existing inductor and its manufacturing method to solve the above problems. Summary of the Invention

[0005] The object of the present invention is to provide a method for preparing an inductor to improve the preparation efficiency of the inductor and reduce the coil deformation, thereby reducing the DC resistance of the inductor and significantly improving the electromagnetic compatibility of electronic equipment.

[0006] To achieve the above object, the present invention provides a method for preparing an inductor, comprising:

[0007] Step S1, evenly spreading the powder material, pressing and cutting it to obtain a plurality of raw material sheets;

[0008] Step S2, selecting any raw material sheet and punching a plurality of evenly arranged and spaced receiving holes on the raw material sheet to obtain a first magnetic sheet with receiving holes;

[0009] Step S3, selecting any raw material sheet and punching out a plurality of center columns from the raw material sheet;

[0010] Step S4, selecting any raw material sheet as the first shielding sheet, overlapping the first magnetic sheet with the first shielding sheet, filling the pre-wound coil into the receiving hole, and then filling the center column into the coil;

[0011] Step S5: Select any raw material sheet and punch multiple sets of electrode holes in the raw material sheet to obtain a second shielding sheet with electrode holes. The second shielding sheet is superimposed on a side of the first magnetic sheet facing away from the first shielding sheet to obtain a laminated body. The coil is provided with pins, and the pins are exposed in the corresponding electrode holes.

[0012] Step S6, performing low-pressure hot pressing and cutting on the laminated body in step S5 to obtain a plurality of preliminary inductors with electrodes;

[0013] Step S7: performing insulation and electroplating on the preliminary inductor to finally obtain an inductor.

[0014] Optionally, in step S1, the powder material is iron powder containing glue, the concentration of the glue is ≥5%, the iron powder is evenly sprayed to form an embryo, and the embryo is pressed after being scraped.

[0015] Optionally, in step S1, the number of the raw material sheets is at least four, and the specifications of the at least four raw material sheets are the same.

[0016] Optionally, in step S2, the accommodating hole is arranged in an O-shape and passes through the first magnetic sheet; in step S4, the middle column is received in the accommodating hole, and both ends of the middle column are flush with the accommodating hole.

[0017] Optionally, in step S4, the first shielding sheet shields one end opening of the accommodating hole, the coil is filled in from the other end opening of the accommodating hole, and the pins of the coil are exposed outside the accommodating hole.

[0018] Optionally, in step S5, the second shielding sheet shields the other end opening of the accommodating hole, and the coil is encapsulated between the first shielding sheet and the second shielding sheet.

[0019] Optionally, each of the accommodating holes corresponds to a group of the electrode holes, and the pins of the coil extend into the corresponding electrode holes, and the pins are configured as electrodes of the preliminary inductor.

[0020] Optionally, in step S6, the pressure of low-pressure hot pressing is set to 1.5T / cm 2 ±0.2T / cm 2 .

[0021] Optionally, in step S7, the insulation treatment includes roll-spraying an insulation layer on the surface of each of the preliminary inductors, and the electroplating treatment includes sequentially electroplating Cu, Ni, and Sn at the electrodes of each of the preliminary inductors.

[0022] Another object of the present invention is to provide an inductor manufactured using the above-mentioned manufacturing method.

[0023] To achieve the above object, the present invention provides an inductor, which is prepared using the above preparation method.

[0024] The beneficial effects of the present invention are as follows: the method for preparing the inductor of the present invention prepares a first magnetic sheet with a receiving hole, a plurality of middle pillars, a first shielding sheet, and a second shielding sheet with an electrode hole by preparing a plurality of raw material sheets and selecting any of the raw material sheets multiple times, so that the first magnetic sheet can be first overlapped with the first shielding sheet, and the pre-wound coil is filled into the receiving hole, and the middle pillar is filled into the coil; then the second shielding sheet is overlapped on the side of the first magnetic sheet away from the first shielding sheet to obtain a laminated body, with the pins of the coil exposed to the corresponding electrode holes; then the laminated body is subjected to low-temperature pressing and cutting to obtain a plurality of preliminary inductors with electrodes; finally, the preliminary inductors are subjected to insulation treatment and electroplating treatment to finally obtain the inductor. Compared with the prior art, the inductor preparation method of the present invention can not only improve the preparation efficiency of the inductor, but also reduce the coil deformation, thereby reducing the DC resistance of the inductor, so that the electromagnetic compatibility of the electronic device is significantly improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a flow chart of the method for preparing the inductor of the present invention.

[0026] Figure 2 It is a flow chart of an embodiment of a method for preparing an inductor of the present invention.

[0027] Figure 3 yes Figure 1 Schematic diagram of an embodiment of step S7 in FIG.

[0028] Figure 4 yes Figure 2 A schematic diagram of an embodiment of the first magnetic sheet in FIG.

[0029] Figure 5 yes Figure 2 Schematic diagram of the three-dimensional structure of the middle coil. DETAILED DESCRIPTION

[0030] In order to make the objectives, technical solutions and advantages of the present invention more clear, the present invention is described in detail below with reference to the accompanying drawings and specific embodiments.

[0031] See also Figure 1-Figure 3 As shown, the present invention discloses a method for manufacturing an inductor. This method can be used to manufacture multiple inductors 100 at a time, thereby improving the manufacturing efficiency of the inductors 100. Furthermore, during the manufacturing process, the inductors 100 can be formed under relatively low pressure, thereby reducing the coil deformation, resulting in a lower DC resistance of the inductor 100 and improving the inductor efficiency.

[0032] Now combined Figure 2 and Figure 3 The preparation method of the inductor of the present invention is described in detail. The preparation method includes the following steps:

[0033] Step S1, evenly spraying the powder material, pressing and cutting it to obtain a plurality of raw material sheets 1. Specifically, in step S1, the powder material is iron powder containing glue, and the concentration of the glue is ≥5%, so that the powder material can be pressed and formed under low pressure.

[0034] The iron powder is evenly sprayed to form an embryo, which is then scraped and pressed. This scraping process ensures that the embryo is evenly distributed and reaches a certain thickness. The embryo is then pressed and cut to obtain multiple raw material sheets 1 of a certain thickness. In this embodiment, the raw material sheets 1 are rectangular in shape. The thickness of the raw material sheets 1 can be adjusted according to the actual requirements of the inductor 100 and is not specifically limited thereto.

[0035] Optionally, in step S1, there are at least four raw material sheets 1, and the at least four raw material sheets 1 have the same specifications to facilitate the subsequent preparation steps. The size specifications of the raw material sheets 1 are determined according to specific circumstances and are not limited thereto.

[0036] Step S2: select any raw material sheet 1 and punch a plurality of receiving holes 21 evenly arranged and spaced apart on the raw material sheet 1 to obtain a first magnetic sheet 2 with receiving holes 21. Figure 4 The figure shows an embodiment of the first magnetic sheet 2. Optionally, in step S2, the receiving hole 21 is arranged in an O-shape and extends through the first magnetic sheet 2. The receiving hole 21 is used to accommodate the coil 3. It should be noted that the number of receiving holes 21 that can be punched on the first magnetic sheet 2 should be determined based on the size of the raw material sheet 1 and the required size of the inductor 100.

[0037] In step S3, any raw material sheet 1 is selected and multiple center pillars 11 are punched out from the raw material sheet 1. Step S3 is performed to obtain multiple independent center pillars 11, which are used to fill the center of the coil 3. In this embodiment, the center pillars 11 and the first magnetic sheet 2 are both obtained from the raw material sheet 1 of the same specifications, and the height of the center pillars 11 is the same as the depth of the receiving hole 21.

[0038] In step S4, any raw material sheet 1 is selected as the first shielding sheet (not shown), the first magnetic sheet 2 is overlapped with the first shielding sheet, and the pre-wound coil 3 is filled into the receiving hole 21, and then the center column 11 is filled into the coil 3. In step S4, the first shielding sheet blocks one end opening of the receiving hole 21, and the coil 3 is filled into the other end opening of the receiving hole 21. It can be seen that the center column 11 is also accommodated in the receiving hole 21, and both ends of the center column 11 are flush with the receiving hole 21. In other words, one end of the center column 11 is in contact with the first shielding sheet.

[0039] like Figure 5 As shown, in this embodiment, the coil 3 includes a ring-shaped coil body 31 and two pins 32 protruding from one end of the coil body 31. The coil body 31 is received in the receiving hole 21, and the center column 11 cooperates with and is inserted into the coil body 31. The two pins 32 of the coil 3 are exposed from the receiving hole 21.

[0040] In step S5, any raw material sheet 1 is selected and multiple groups of electrode holes 41 are punched out on the raw material sheet 1 to obtain a second shielding sheet 4 with electrode holes 41. The second shielding sheet 4 is superimposed on the side of the first magnetic sheet 2 facing away from the first shielding sheet to obtain a laminated body 5. The pins 32 of the coil 3 are exposed in the corresponding electrode holes 41. Specifically, the electrode holes 41 are arranged corresponding to the receiving holes 21, and each receiving hole 21 corresponds to a group of electrode holes 41. Preferably, each group of electrode holes 41 is provided with two, and the electrode holes 41 are rectangular holes. The two pins 32 of the coil 3 extend into the corresponding electrode holes 41.

[0041] Specifically, in step S5, the second shielding sheet 4 blocks the other end opening of the accommodating hole 21, and the coil 3 is enclosed between the first shielding sheet and the second shielding sheet 4. The present invention encloses the coil 3 using the first shielding sheet, the first magnetic sheet 2, and the second shielding sheet 4, and sets the ends of the center column 11 in contact with the first shielding sheet and the second shielding sheet 4, respectively. This ensures that the subsequently manufactured inductor 100 has better magnetic sealing and reduces insulation wear of the coil 3.

[0042] In step S6, the laminated body 5 from step S5 is subjected to low-pressure hot pressing and cut to obtain a plurality of preliminary inductors 7 with electrodes 6. The first shielding sheet, the first magnetic sheet 2, the second shielding sheet 4, and the center column 11 are pressed and formed into a single unit using low pressure, resulting in a relatively low deformation of the coil 3. The pins 32 are fixed in the electrode holes 41 and serve as the electrodes 6 of the preliminary inductors 7.

[0043] In step S6, the pressure of low-pressure hot pressing is set to 1.5T / cm 2 ±0.2T / cm 2, and its heating temperature can be set according to actual needs, and there is no restriction on this. In this embodiment, the first shielding sheet, the first magnetic sheet 2 and the second shielding sheet 4 are all rectangular, and the three are convenient for pressing and cutting after being overlapped and aligned. The one-time cutting of the present invention can obtain more preliminary inductors 7, and can achieve high-efficiency production. Optionally, after obtaining the preliminary inductor 7, the edges and corners of the preliminary inductor 7 and the cutting area can be polished to make the surface of the preliminary inductor 7 smooth and improve the quality of the inductor 100.

[0044] In step S7, the preliminary inductor 7 is subjected to insulation and electroplating treatments to ultimately obtain the inductor 100. In step S7, the insulation treatment includes roll-spraying an insulating layer 8 on the surface of each preliminary inductor 7 and stripping the paint from the electrodes 6 of each preliminary inductor 7 to expose the electrodes 6 for easy electroplating. The insulating layer 8 insulates all surfaces of the preliminary inductor 7, providing excellent insulation performance and covering the exterior, thereby improving the quality of the inductor 100.

[0045] The electroplating process involves sequentially electroplating Cu, Ni, and Sn on the electrodes 6 of each preliminary inductor 7 to improve solderability, solder resistance, and adhesion at the electrodes 6. Optionally, in step S7, the inductors 100 are tested and packaged. By performing a full inspection of the inductors 100, such as testing Ls, Rs, Dcr, and electrode and ground impedance, defective products with poor dimensions and performance can be eliminated and qualified products packaged.

[0046] In summary, the preparation method of the inductor of the present invention prepares a plurality of raw material sheets 1 and selects any raw material sheet 1 multiple times to respectively prepare a first magnetic sheet 2 with a receiving hole 21, a plurality of middle columns 11, a first shielding sheet and a second shielding sheet 4 with an electrode hole 41, so that the first magnetic sheet 2 can be first overlapped with the first shielding sheet, and the pre-wound coil 3 is filled into the receiving hole 21, and the middle column 11 is filled into the coil; then the second shielding sheet 4 is overlapped on the side of the first magnetic sheet 2 away from the first shielding sheet to obtain a laminated body 5, and the pins 32 of the coil 3 are exposed to the corresponding electrode holes 41; then the laminated body 5 is subjected to low-temperature pressing and cutting to obtain a plurality of preliminary inductors 7 with electrodes 6; finally, the preliminary inductor 7 is insulated and electroplated to finally obtain the inductor 100. Compared with the prior art, the inductor manufacturing method of the present invention can not only improve the manufacturing efficiency of the inductor 100, but also reduce the deformation of the coil 3, thereby reducing the DC resistance of the inductor 100, thereby significantly improving the electromagnetic compatibility of the electronic device.

[0047] The above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the preferred embodiments, it should be understood by those skilled in the art that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. A method for preparing an inductor, characterized in that: include: Step S1, evenly spreading the powder material, pressing and cutting it to obtain a plurality of raw material sheets; Step S2, selecting any raw material sheet and punching a plurality of evenly arranged and spaced receiving holes on the raw material sheet to obtain a first magnetic sheet with receiving holes; Step S3, selecting any raw material sheet and punching out a plurality of center columns from the raw material sheet; Step S4, selecting any raw material sheet as the first shielding sheet, overlapping the first magnetic sheet with the first shielding sheet, filling the pre-wound coil into the receiving hole, and then filling the center column into the coil; Step S5: Select any raw material sheet and punch multiple sets of electrode holes in the raw material sheet to obtain a second shielding sheet with electrode holes. The second shielding sheet is superimposed on a side of the first magnetic sheet facing away from the first shielding sheet to obtain a laminated body. The coil is provided with pins, and the pins are exposed in the corresponding electrode holes. Step S6, performing low-pressure hot pressing and cutting on the laminated body in step S5 to obtain a plurality of preliminary inductors with electrodes; Step S7: performing insulation and electroplating on the preliminary inductor to finally obtain an inductor.

2. The preparation method according to claim 1, wherein: In step S1, the powder material is iron powder containing glue, the concentration of the glue is ≥5%, the iron powder is evenly sprayed to form an embryo, and the embryo is pressed after being scraped.

3. The preparation method according to claim 1, wherein: In step S1 , the number of the raw material sheets is at least four, and the specifications of the at least four raw material sheets are the same.

4. The preparation method according to claim 1, wherein: In step S2, the receiving hole is configured in an O-shape and passes through the first magnetic sheet; in step S4, the center column is received in the receiving hole, and both ends of the center column are flush with the receiving hole.

5. The preparation method according to claim 4, characterized in that: In step S4 , the first shielding sheet shields one end opening of the accommodating hole, and the coil is filled in from the other end opening of the accommodating hole, with the pins of the coil exposed outside the accommodating hole.

6. The preparation method according to claim 5, characterized in that: In step S5, the second shielding piece shields the other end opening of the accommodating hole, and the coil is encapsulated between the first shielding piece and the second shielding piece.

7. The preparation method according to claim 6, characterized in that: Each of the accommodating holes corresponds to a group of the electrode holes, and the pins of the coil extend into the corresponding electrode holes, and the pins are configured as electrodes of the preliminary inductor.

8. The preparation method according to claim 1, wherein: In step S6, the pressure of low pressure molding is set to 1.5T / cm 2 ±0.2T / cm 2 .

9. The preparation method according to claim 1, wherein: In step S7 , the insulation treatment includes roller spraying an insulation layer on the surface of each of the preliminary inductors, and the electroplating treatment includes sequentially electroplating Cu, Ni, and Sn at the electrodes of each of the preliminary inductors.

10. An inductor, characterized in that: The preparation method according to any one of claims 1 to 9 is used for preparation.

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