Inductor impregnation method, system and high heat dissipation inductor

Abstract

The present invention provides an inductor impregnation method, system and high heat dissipation inductor, which relate to the field of impregnation technology. The method includes the following steps: immersing two-thirds of the volume of the inductor semi-finished product into thermally conductive silica gel; performing an impregnation treatment by controlling the rotation or swing of the inductor semi-finished product so that the thermally conductive silica gel flows to the remaining one-third of the volume of the inductor semi-finished product; after reaching a preset impregnation time, evacuating the thermally conductive silica gel and transferring the inductor semi-finished product to an oven, and controlling the inductor semi-finished product to rotate or swing during the transfer process; drying the thermally conductive silica gel attached to the inductor semi-finished product, and controlling the inductor semi-finished product to rotate or swing during the drying process, and finally obtaining the finished inductor product. The method of the present invention overcomes the shortcomings of conventional static impregnation and static drying, ensures that the thermally conductive silica gel is fully filled and has a uniform thickness, which is conducive to ensuring the heat dissipation effect, thereby effectively controlling the temperature rise of the high-power inductor.

Description

Technical Field

[0001] The present invention relates to the field of impregnation technology, and in particular to a high-power inductor impregnation method, system and high-heat dissipation inductor. Background Art

[0002] At present, the output power of RF power supplies and microwave power supplies used in semiconductor equipment generally reaches 5KW and above due to semiconductor process requirements. This directly affects the power borne by the inductor in the power circuit of the semiconductor equipment, thereby increasing the temperature rise of the inductor.

[0003] Reference Attachment Figure 6 To address the severe temperature rise issues in high-power inductors, and given the inability to further reduce core losses, existing technology involves improving the impregnation process, replacing conventional insulating varnish (varnish) with thermally conductive silicone. This increases the thermal conductivity between the inductor core and windings, and between windings, thereby reducing temperature rise. To maximize the thermal conductivity of the thermally conductive silicone, the silicone needs to be as thin as possible, which in turn requires a certain degree of fluidity and a limited viscosity.

[0004] However, refer to the attached Figure 2 The improved impregnation process still continues the conventional static impregnation and static drying practices. During the static process, the thermal conductive silicone will flow to the top or bottom of the inductor due to its low viscosity, resulting in insufficient filling between the core and the winding, and between the windings, as well as uneven thickness of the thermal conductive silicone coated on the surface of the core, ultimately reducing the temperature rise improvement effect of the inductor. Summary of the Invention

[0005] The purpose of the present invention is to provide an inductor impregnation method, system and high-heat dissipation inductor, which overcome the shortcomings of conventional static impregnation and static drying, ensure that the thermal conductive silicone is fully filled and the thickness is uniform, which is conducive to ensuring the heat dissipation effect, thereby effectively controlling the temperature rise of high-power inductors.

[0006] In a first aspect, the present invention provides an inductor impregnation method for processing an inductor, wherein the inductor includes a toroidal magnetic core and a winding wound on the toroidal magnetic core, and the inductor impregnation method includes the following steps:

[0007] S1. Obtain the semi-finished inductor;

[0008] S2. Keep the center plane of the semi-finished inductor perpendicular to the liquid surface of the thermally conductive silicone and the leads from the windings above the liquid surface. Immerse two-thirds of the volume of the semi-finished inductor in the thermally conductive silicone.

[0009] S3. The inductor semi-finished product is impregnated by rotating the semi-finished product in a fixed direction around the drive shaft or by swinging the semi-finished product back and forth within a specified swing range, so that the thermally conductive silicone attached to the semi-finished product flows to the remaining one-third of the volume of the semi-finished product;

[0010] S4. After the preset soaking time is reached, the thermally conductive silicone is removed and the semi-finished inductor is transferred to the oven. During the transfer process, the semi-finished inductor is controlled to rotate or swing in its original motion.

[0011] S5. The thermal conductive silicone attached to the semi-finished inductor is dried. During the drying process, the semi-finished inductor is controlled to rotate or swing while maintaining its original motion mode, thereby obtaining a finished inductor.

[0012] The inductor impregnation method provided by the present invention adopts a dynamic impregnation process to manufacture the inductor, and has the advantages of sufficient gap filling with thermal conductive silicone and uniform coating thickness, without accumulation on the top or bottom of the inductor.

[0013] In a second aspect, the present invention provides an inductor impregnation system for processing an inductor, wherein the inductor includes a toroidal magnetic core and a winding wound on the toroidal magnetic core, comprising:

[0014] An acquisition module, used for acquiring the semi-finished inductor;

[0015] A control module is used to control the center plane of the semi-finished inductor to be perpendicular to the liquid surface of the thermally conductive silicone and to keep the pins extending from the winding above the liquid surface of the thermally conductive silicone, so that two-thirds of the volume of the semi-finished inductor is immersed in the thermally conductive silicone;

[0016] The impregnation module is used to control the semi-finished inductor to rotate in a fixed direction around the driving shaft or to swing back and forth within a specified swing range to perform an impregnation treatment, so that the thermal conductive silicone attached to the semi-finished inductor flows to the remaining one-third of the volume of the semi-finished inductor;

[0017] The transfer module is used to remove the thermal conductive silicone and transfer the semi-finished inductor to the oven after the preset impregnation time is reached. During the transfer process, the semi-finished inductor is controlled to rotate or swing in its original motion mode;

[0018] The drying module is used to dry the thermal conductive silica gel attached to the semi-finished inductor. During the drying process, the semi-finished inductor is controlled to rotate or swing in its original motion mode, and finally the finished inductor is obtained.

[0019] In a third aspect, the present invention provides a high heat dissipation inductor obtained by the inductor impregnation method as described above.

[0020] From the above, it can be seen that the inductor impregnation method provided by the present invention and the dynamic rotation / swing impregnation process effectively utilize the sticky characteristics of thermally conductive silicone, so that a part of the bonding force between the thermally conductive silicone and the magnetic core or winding overcomes the gravity of the thermally conductive silicone itself to prevent the thermally conductive silicone from accumulating on the top or bottom of the magnetic core device; the other part provides the centripetal force required for the rotation / swing of the thermally conductive silicone, which can hinder the centrifugal movement of the thermally conductive silicone. Therefore, the inductor made by the dynamic impregnation process has the advantages of sufficient gap filling with thermally conductive silicone and uniform thickness coating, and there is no accumulation on the top or bottom of the inductor. The temperature rise of the inductor made by the present invention is 40°C lower than that of the device made by the conventional insulating paint impregnation process, and 20°C lower than that of the device made by static impregnation with thermally conductive silicone. It can be seen that the product of the present invention is more suitable for application in the power supply circuit of high-power semiconductor equipment.

[0021] Other features and advantages of the present invention will be described in the following description, and in part will become apparent from the description, or will be understood by practicing the embodiments of the present invention. The purposes and other advantages of the present invention can be realized and obtained by the structures particularly pointed out in the written description and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 A flow chart of the inductor impregnation method provided in an embodiment of the present invention.

[0023] Figure 2 This is a schematic diagram of the finished inductor after conventional static impregnation and static drying.

[0024] Figure 3 Schematic diagram of the dynamic impregnation process in an embodiment of the present invention.

[0025] Figure 4 Schematic diagram of the dynamic drying process in an embodiment of the present invention.

[0026] Figure 5 Schematic diagram of a finished inductor according to an embodiment of the present invention.

[0027] Figure 6 This is a comparison chart of temperature rise under different impregnation processes.

[0028] Figure 7 A schematic structural diagram of an inductor impregnation system provided in an embodiment of the present invention.

[0029] Description of labels:

[0030] 100, acquisition module; 200, control module; 300, impregnation module; 400, transfer module; 500, drying module; a, fixture; b, driving shaft. DETAILED DESCRIPTION

[0031] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, not all of the embodiments. The components of the embodiments of the present invention generally described and shown in the drawings herein can be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present invention provided in the drawings is not intended to limit the scope of the claimed invention, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without making creative work are within the scope of protection of the present invention.

[0032] It should be noted that similar reference numerals and letters represent similar items in the following drawings. Therefore, once an item is defined in one drawing, it does not need to be further defined or explained in subsequent drawings. At the same time, in the description of the present invention, the terms "first", "second", etc. are used only to distinguish the description and should not be understood as indicating or implying relative importance.

[0033] It should be noted that the attached Figure 2 and attached Figure 5 The black part in the middle indicates that it is coated with thermal conductive silicone.

[0034] Reference Attachment Figure 1 , Attachment Figure 3 , Attachment Figure 4 , Attachment Figure 5 and attached Figure 6 The present invention provides an inductor impregnation method for processing a high-power inductor, wherein the high-power inductor includes a toroidal magnetic core and a winding wound on the toroidal magnetic core. The inductor impregnation method includes the following steps:

[0035] S1. Obtain the semi-finished inductor;

[0036] S2. Ensure the center plane of the semi-finished inductor (the center plane is the cross section through the center of the inductor) is perpendicular to the surface of the thermally conductive silicone. Keep the leads from the windings above the surface of the silicone. Immerse two-thirds of the inductor's volume in the silicone to prevent the leads from being directly immersed in the silicone and contaminating them.

[0037] S3. Control the semi-finished inductor to rotate in a fixed direction around the drive shaft (for example, 360° clockwise or 360° counterclockwise around the drive motor shaft. Figure 3 and attached Figure 4The drive shaft rotates clockwise (as indicated by the marking) or swings back and forth within a specified swing range to perform the impregnation treatment, so that the thermal conductive silicone attached to the semi-finished inductor flows to the remaining one-third of the volume of the semi-finished inductor. Rotation or swinging helps to ensure that the thermal conductive silicone is fully filled between the magnetic core and the windings, and between the windings.

[0038] S4. After the preset impregnation time has elapsed, the thermally conductive silicone is removed and the semi-finished inductor is transferred to the oven. During the transfer process, the semi-finished inductor is rotated or swung while maintaining its original motion. This rotation or swung motion utilizes the centripetal force provided by the motion to prevent the thermally conductive silicone from flowing due to gravity and accumulating in a localized area of ​​the semi-finished inductor. This ensures a uniform thickness of the thermally conductive silicone adhered to the surface, ultimately ensuring effective heat dissipation of the semi-finished inductor.

[0039] S5. The thermal conductive silicone attached to the semi-finished inductor is dried. During the drying process, the semi-finished inductor is controlled to rotate or swing while maintaining its original motion mode, thereby obtaining a finished inductor.

[0040] A semi-finished inductor refers to a high-power inductor that has been wound but not yet impregnated. It includes a toroidal core and a winding wound on the toroidal core. It is the object to be processed in the subsequent impregnation process, which is mainly for thermal conductivity enhancement. Thermal conductive silicone refers to a liquid or semi-liquid material with thermal conductivity, which can be made of an organic silicone polymer as a basis and added with thermal conductive fillers, such as aluminum oxide, boron nitride and other fillers. It is mainly used to fill the internal gaps of the inductor and form a surface coating to enhance heat dissipation. Controlling the center plane of the semi-finished inductor to be perpendicular to the liquid surface of the thermal conductive silicone and keeping the pins leading from the winding above the liquid surface of the thermal conductive silicone means adjusting the semi-finished inductor relative to the liquid surface of the thermal conductive silicone by a fixture or positioning device. The posture of the liquid surface ensures that its center plane is perpendicular to the liquid surface, and at the same time, the electrical connection terminals of the inductor are kept above the liquid surface. This is mainly to avoid the pins being contaminated by the thermal conductive silicone in the early stage of impregnation and to ensure the subsequent electrical connection performance; immersing two-thirds of the volume of the inductor semi-finished product into the thermal conductive silicone means that the impregnation is carried out in steps. First, most of the inductor body is immersed in the thermal conductive silicone. This is mainly to preliminarily fill the lower area of ​​the inductor; controlling the rotation of the inductor semi-finished product for impregnation treatment means that the inductor semi-finished product is rotated / swayed around its axis or specific center during the impregnation process. It can be achieved by continuous rotation or reciprocating swinging. It is mainly to use centrifugal force or dynamic force to promote heat conduction. The silicone penetrates into the internal gaps of the inductor; so that the thermally conductive silicone attached to the semi-finished inductor flows to the remaining one-third of the volume of the semi-finished inductor, which means that the force during rotation or swinging is used to drive the thermally conductive silicone attached to the semi-finished inductor to flow to the remaining part of the semi-finished inductor (that is, the remaining one-third of the volume not directly immersed in the thermally conductive silicone), thereby achieving overall impregnation; after reaching the preset impregnation time, it means that the impregnation process continues for a certain time, which can be pre-set or calculated based on the characteristics of the thermally conductive silicone, the inductor structure and the desired filling effect. It is mainly to ensure that the thermally conductive silicone has enough time to penetrate and fill; evacuating the thermally conductive silicone and transferring the semi-finished inductor to the oven means that the inductor is placed in the oven. The inductor is taken out of the thermally conductive silicone and moved to the heating equipment used to cure the thermally conductive silicone, mainly for the subsequent curing process; the transfer process controls the inductor semi-finished product to keep rotating or swinging, which means that the inductor is kept in motion from the time it is taken out of the thermally conductive silicone until it enters the oven for curing. This is mainly to use the centripetal force or centrifugal force generated by the rotation / swing to counteract gravity and prevent the liquid thermally conductive silicone from flowing downward and accumulating; by drying the thermally conductive silicone attached to the inductor semi-finished product, it means that the inductor is heated in an oven so that the thermally conductive silicone attached and filled on the inductor is cured to form a stable structure. This is mainly to complete the impregnation process and obtain an inductor finished product with enhanced heat dissipation capability.

[0041] The core innovation of this application lies in the introduction of rotation / swing control of the semi-finished inductor during the impregnation treatment, transfer to the oven, and drying process, thereby effectively solving the problems of insufficient filling and uneven surface coating thickness in the static state due to the low viscosity of the thermal conductive silicone, thereby achieving the purpose of improving the heat dissipation effect of the inductor.

[0042] Specifically, this method first obtains a semi-finished inductor to be processed. Then, a first stage of step-by-step impregnation is performed. By controlling the position of the semi-finished inductor so that its center plane is perpendicular to the surface of the thermally conductive silicone liquid, the pins are kept above the liquid surface, and approximately two-thirds of the inductor body is immersed in the thermally conductive silicone. This position control and step-by-step immersion prepares for the subsequent rotational impregnation and effectively protects the pins from contamination. Next, through rotation or oscillation, the thermally conductive silicone adhering to two-thirds of the inductor's volume is driven to flow toward the remaining one-third of the inductor's volume, achieving full impregnation. The dynamic forces generated by the rotation / oscillation encourage the thermally conductive silicone to more effectively penetrate the tiny gaps between the magnetic core and windings, and between the windings, ensuring full filling of the inductor. After the predetermined impregnation time has elapsed, the inductor is removed from the thermally conductive silicone and transferred to an oven for curing. The key is to maintain the rotation or oscillation of the semi-finished inductor during the transfer process from the liquid surface to the oven, as well as during the oven drying process. The rotation / oscillation generates centripetal or centrifugal forces to counteract or offset the effects of gravity, effectively preventing uncured thermal silicone from flowing downward due to gravity and accumulating at locations such as the inductor's base. This ensures a uniform thickness of thermal silicone adhered to the inductor's surface. Finally, the semi-finished inductor is dried in an oven to cure the thermal silicone, resulting in the final inductor. By introducing this dynamic rotation / oscillation process at a critical stage, this process overcomes the shortcomings of traditional static processes, ensuring sufficient filling of the inductor with thermal silicone and uniform coating of its surface, significantly improving the inductor's heat dissipation performance.

[0043] As a preferred embodiment, the solution of the present application is specifically implemented as follows: an automated fixture a system can be used to grab the inductor semi-finished product. The fixture a system integrates a rotation drive unit and a lifting and moving unit. First, the fixture a grabs the inductor semi-finished product and moves it above the thermal conductive silicone tank. Then, the lifting and moving unit controls the fixture a to descend, and at the same time adjusts the posture of the fixture a so that the center plane of the inductor semi-finished product is perpendicular to the silicone liquid surface, and ensures that the pins are above the liquid surface, and immerses about two-thirds of the inductor body in the silicone. Then, the rotation drive unit is started to make the inductor semi-finished product start to rotate and drive the silicone attached to the inductor body to the remaining one-third. The rotation can be set to continuous uniform rotation. After the preset impregnation time is reached, the lifting and moving unit controls the fixture a to rise and remove the inductor from the silicone tank. During the process of the fixture a rising and moving horizontally to the oven entrance, the rotation drive unit continues to work to keep the inductor semi-finished product rotating. After entering the oven, the semi-finished inductor is kept rotating while the oven starts the heating program to dry and solidify the inductor until the thermal conductive silicone is completely solidified.

[0044] Through the above solution, the present application effectively solves the problems of insufficient internal filling and uneven surface coating thickness caused by standing still when high-power inductors are impregnated with thermally conductive silicone. It ensures that the thermally conductive silicone is fully filled between the magnetic core and the windings, and between the windings, and forms a uniform thermally conductive silicone coating on the surface of the inductor, ultimately significantly improving the heat dissipation effect of the high-power inductor and reducing the temperature rise.

[0045] In some embodiments, the specific steps in step S3 include:

[0046] The impregnation treatment is performed only by controlling the semi-finished inductor to swing back and forth within a specified swing range to prevent the thermal conductive silicone attached to the semi-finished inductor from flowing to the pins and causing contamination of the pins.

[0047] A specified swing range refers to a preset, limited angular interval, which can be achieved using mechanical limiters or angle sensors in conjunction with a control system. Reciprocating swing refers to repeated back-and-forth motion within a specified swing range, which can be achieved using a forward-reversible motor drive in conjunction with a motion control unit.

[0048] Based on the above technical solution, this solution controls the inductor semi-finished product to oscillate back and forth within a specified oscillating range during the impregnation step. This oscillating motion, unlike continuous circular rotation, limits the movement of the inductor semi-finished product to a preset angular range. As the inductor semi-finished product reciprocates within this oscillating range, the thermally conductive silicone adhered to its surface tends to flow downward due to gravity. However, because the direction of movement periodically changes, the silicone's flow tendency also changes, and it no longer flows continuously in the specific direction where the pins are located. This oscillation ensures that the thermally conductive silicone fully contacts and fills the surface of the inductor semi-finished product, particularly between the magnetic core and windings, and between the windings. Furthermore, by limiting the range of motion and changing the flow direction, it effectively prevents the thermally conductive silicone from accumulating or flowing toward the pins of the inductor semi-finished product. In this way, while achieving sufficient impregnation and internal filling, it effectively prevents the pins from being contaminated by the thermally conductive silicone, ensuring the smooth progress of subsequent processes.

[0049] Specifically, in one embodiment, a fixture can be used to fix the inductor semi-finished product, and the fixture is connected to a rotating shaft driven by a motor. The motor can be a servo motor or a stepper motor, and is precisely controlled by a connected control unit. The control unit receives preset parameters of a specified swing range and outputs instructions to control the motor to perform forward and reverse periodic rotation within this angle range, thereby achieving a back-and-forth swing of the inductor semi-finished product within the specified swing range. For example, the swing range can be set to an angle interval, and the motor can be controlled to rotate from the starting angle of the interval to the end angle, and then rotate in the opposite direction back to the starting angle, and repeat this process. In order to improve the control accuracy, an angle encoder can be installed on the rotating shaft to feed back the actual angle to the control unit for closed-loop control.

[0050] By adopting the above technical solution, compared with circular rotation, the flow direction of the thermal conductive silicone attached to the surface of the semi-finished inductor can be effectively controlled to prevent it from flowing to the pin area, thereby preventing the pins from being contaminated by the thermal conductive silicone, ensuring the cleanliness of the pins, and facilitating subsequent welding and other processes.

[0051] It should be noted that if the movement of the semi-finished inductor product is controlled in a swinging manner during the impregnation process, the movement of the semi-finished inductor product is also controlled in a swinging manner during the transfer process and the drying process.

[0052] In certain embodiments, reference is made to the accompanying Figure 3 and attached Figure 4 , specify the swing range as the specified coordinate system The specified coordinate system is a rectangular coordinate system with the center of the drive shaft as the origin and the horizontal axis parallel to the horizontal plane (that is, the attached Figure 3 and attached Figure 4The specified swing range can prevent the semi-finished inductor from being too high after rotation / swing, which may cause the thermal conductive silicone attached to the semi-finished inductor to drip onto the pins and cause contamination of the pins.

[0053] Based on the above technical means, this application further optimizes the impregnation process by limiting the specific angular range within which the semi-finished inductor can oscillate back and forth during the impregnation step, thereby more effectively preventing contamination of the pins with thermally conductive silicone. Specifically, after immersing two-thirds of the semi-finished inductor in the thermally conductive silicone according to the aforementioned scheme and maintaining the pins above the liquid surface, the impregnation process is performed by controlling the semi-finished inductor to oscillate back and forth within an angular range of [-150°, -30°] in a specified coordinate system. The specified coordinate system is a rectangular coordinate system constructed with the center of the drive axis b as its origin and its horizontal axis parallel to the horizontal plane. Within this coordinate system, limiting the oscillation range to [-150°, -30°] means that the semi-finished inductor oscillates only within the third and fourth quadrants of the rectangular coordinate system. By limiting the oscillation range to this specific angular range, this solution prevents the semi-finished inductor from being positioned too high after rotation / oscillation, thereby preventing thermally conductive silicone adhering to the semi-finished inductor from dripping onto the pins below due to gravity, ultimately preventing pin contamination. This precise angle limitation, building on the oscillation proposed in the previous solution, further improves the reliability of the impregnation process, ensures pin cleanliness, and facilitates subsequent electrical connections and product performance. By combining the oscillation motion with a specific low-angle range, this solution not only utilizes the oscillation to promote uniform silicone distribution, but also cleverly avoids the silicone dripping problem that may be caused by high-angle oscillation, thereby improving the overall impregnation quality and product qualification rate.

[0054] In some embodiments, the specific steps in step S3 include:

[0055] The impregnation time of the semi-finished inductor is controlled according to the following formula:

[0056] ;

[0057] ;

[0058] ;

[0059] in, is the soaking time, is the dynamic viscosity of thermal conductive silicone rubber, are the preset fitting parameters, It depends on the density of the thermally conductive silicone and the geometry of the inductor (such as size and surface characteristics), which can be obtained by fitting after experimental measurement; is the movement speed of the semi-finished inductor, The average thickness of the silicone coating on the surface of the finished inductor (the average thickness is designed by the user). is the density of thermal conductive silicone.

[0060] The impregnation time refers to the length of time the semi-finished inductor is rotated / swung in the thermally conductive silicone, which determines the time it takes for the thermally conductive silicone to fill the inductor structure and form a coating on the surface; the dynamic viscosity of the thermally conductive silicone refers to the resistance characteristics of the thermally conductive silicone during the flow process, which affects the fluidity and filling capacity of the thermally conductive silicone and can be measured by a viscometer or other equipment; the preset fitting parameter k is an empirical parameter used to link the theoretical model with complex factors in the actual process (such as surface tension, wettability, inductor structure details, etc.). Its value is not fixed and requires a series of experiments to measure the actual impregnation time under different conditions (different viscosities, movement speeds, and desired thicknesses), and then pass the fitting parameter k to the actual impregnation time. Calculated by data fitting methods (such as the least squares method), this parameter reflects the process characteristics of a specific thermally conductive silicone and a specific inductor geometry, and can be obtained through numerical simulation or physical experiments; the movement speed of the inductor semi-finished product refers to the angular velocity or linear velocity of the inductor semi-finished product rotating / swinging around the drive axis b during the impregnation process. The centrifugal force generated is a key factor affecting the distribution of the thermally conductive silicone, and can be accurately set and adjusted through the motor control system; the average thickness of the silicone coating on the surface of the inductor finished product refers to the average geometric thickness of the thermally conductive silicone layer attached to the surface of the inductor finished product after impregnation and drying. This is a key indicator affecting the heat dissipation performance of the inductor. Its value is determined by the product design requirements and can be obtained through measurement or calculation.

[0061] This solution introduces a quantitative control method based on physical parameters and empirical fitting to determine the impregnation duration during the impregnation process during the rotation of the semi-finished inductor. Specifically, by establishing a functional relationship between the impregnation time t and the dynamic viscosity η of the thermally conductive silicone, a preset fitting parameter k, the movement speed ω of the semi-finished inductor, and the desired average thickness h of the silicone coating on the surface of the finished inductor, precise control of the impregnation process is achieved. This method fully considers the key factors that influence the filling and coating formation of the thermally conductive silicone: the flow characteristics of the thermally conductive silicone itself are characterized by the dynamic viscosity η; the influence of the inductor structure and material properties on the adhesion and distribution of the silicone is reflected by the fitting parameter k; the centrifugal force effect generated by rotation is reflected by the movement speed ω; and the final product performance requirements are set by the desired average thickness h of the silicone layer. By incorporating these parameters into the calculation model, the optimal impregnation time can be dynamically calculated based on actual conditions and design objectives. This quantitative control method overcomes the shortcomings of traditional reliance on experience or fixed durations, making the impregnation process more controllable and stable. Compared to the basic solution that relies solely on rotation / oscillation-assisted filling, this solution can more effectively manage the filling level of the thermal conductive silicone inside the inductor and the thickness of the external coating by precisely controlling the impregnation duration. This avoids insufficient filling due to insufficient impregnation or excessive silicone loss or excessive coating due to excessive impregnation. This further improves the stability and consistency of the impregnation effect based on rotation / oscillation-assisted filling, ensuring that the final inductor has a uniform thermal conductive silicone coating that meets the design thickness.

[0062] The physical meaning of the above relationship:

[0063] : The higher the viscosity, the greater the resistance to flow of the silicone, and therefore the thickness is greater.

[0064] : The higher the movement speed, the greater the centrifugal force, which throws out more silicone, thus reducing the thickness.

[0065] : The longer the time, the more silicone is thrown out and the thickness decreases, but the impact is weaker than the movement speed.

[0066] Furthermore, by setting the parameter k in the impregnation time control formula to an expression related to the thermally conductive silicone density ρ, this application provides a more direct and physically meaningful method for determining parameter k. This approach reduces reliance on complex experimental fitting and improves the accuracy and stability of parameter k determination. The improved accuracy and stability of parameter k make the impregnation time t calculated using the formula more accurate. Accurate impregnation time control helps ensure uniform coating thickness of the thermally conductive silicone on the semi-finished inductor and sufficient internal filling.

[0067] Example 1: If a thermally conductive silica gel with a dynamic viscosity of 200-500 mPa·s is used, the impregnation process is carried out as follows:

[0068] (1) Fix the semi-finished inductor before impregnation on the motor bearing with the pins facing upwards;

[0069] (2) About two-thirds of the inductor is immersed in thermally conductive silicone;

[0070] (3) Adjust the motor speed to 50-100 rpm, start the motor rotation, and start timing at the same time;

[0071] (4) After 3 minutes, remove the thermal conductive silicone rubber and the motor will continue to rotate.

[0072] (5) Place the rotating inductor in the oven, set the drying time to 3 hours, and turn on the oven;

[0073] (6) After drying, stop the motor, remove the inductor, and the impregnation process is completed.

[0074] Example 2: If a thermally conductive silica gel with a dynamic viscosity of 500-1000 mPa·s is used, the impregnation process is carried out as follows:

[0075] (1) Fix the semi-finished inductor before impregnation on the motor bearing with the pins facing upwards;

[0076] (2) About two-thirds of the inductor is immersed in thermally conductive silicone;

[0077] (3) Adjust the motor speed to 150-200 rpm, start the motor rotation, and start timing at the same time;

[0078] (4) After 2 minutes, remove the thermal conductive silicone rubber and the motor will continue to rotate.

[0079] (5) Place the rotating inductor in the oven, set the drying time to 3 hours, and turn on the oven;

[0080] (6) After drying, stop the motor, remove the inductor, and the impregnation process is completed.

[0081] Example 3: If a thermally conductive silica gel with a dynamic viscosity of 1000-1500 mPa·s is used, the impregnation process is carried out as follows:

[0082] (1) Fix the semi-finished inductor before impregnation on the motor bearing with the pins facing upwards;

[0083] (2) About two-thirds of the inductor is immersed in thermal conductive silicone;

[0084] (3) Adjust the motor speed to 250-300 rpm, start the motor rotation, and start timing at the same time;

[0085] (4) After 1 minute, remove the thermal conductive silicone rubber and the motor will continue to rotate.

[0086] (5) Place the rotating inductor in the oven, set the drying time to 3 hours, and turn on the oven;

[0087] (6) After drying, stop the motor, remove the inductor, and the impregnation process is completed.

[0088] Reference Attachment Figure 7 The present invention provides an inductor impregnation system for processing high-power inductors, wherein the high-power inductors include a toroidal magnetic core and a winding wound on the toroidal magnetic core, including:

[0089] An acquisition module 100 is used to acquire a semi-finished inductor;

[0090] The control module 200 is used to control the center plane of the semi-finished inductor to be perpendicular to the liquid surface of the thermally conductive silicone and to keep the pins extending from the windings above the liquid surface of the thermally conductive silicone, so that two-thirds of the volume of the semi-finished inductor is immersed in the thermally conductive silicone;

[0091] The impregnation module 300 is used to control the semi-finished inductor to rotate in a fixed direction around a driving shaft or to swing back and forth within a specified swing range to perform an impregnation treatment, so that the thermally conductive silicone attached to the semi-finished inductor flows to the remaining one-third of the volume of the semi-finished inductor;

[0092] The transfer module 400 is used to remove the thermally conductive silicone and transfer the semi-finished inductor to the oven after the preset impregnation time is reached. During the transfer process, the semi-finished inductor is controlled to rotate or swing in the original motion mode.

[0093] The drying module 500 is used to dry the thermally conductive silica gel attached to the semi-finished inductor. During the drying process, the semi-finished inductor is controlled to rotate or swing in its original motion mode, thereby obtaining a finished inductor.

[0094] In certain embodiments, the impregnation module 300 is configured to perform an impregnation process by controlling the semi-finished inductor to rotate in a fixed direction about a driving shaft or to swing back and forth within a specified swing range, so that the thermally conductive silicone adhered to the semi-finished inductor flows to the remaining one-third of the volume of the semi-finished inductor.

[0095] The impregnation treatment is performed only by controlling the semi-finished inductor to swing back and forth within a specified swing range.

[0096] In certain embodiments, the impregnation module 300 is configured to perform an impregnation process by controlling the semi-finished inductor to rotate in a fixed direction about a driving shaft or to swing back and forth within a specified swing range, so that the thermally conductive silicone adhered to the semi-finished inductor flows to the remaining one-third of the volume of the semi-finished inductor.

[0097] The impregnation time of the semi-finished inductor is controlled according to the following formula:

[0098] ;

[0099] in, is the soaking time, is the dynamic viscosity of thermal conductive silicone rubber, are the preset fitting parameters, is the movement speed of the semi-finished inductor, It is the average thickness of the silicone coating on the surface of the finished inductor.

[0100] Reference Attachment Figure 5 and attached Figure 6 The present invention provides a high heat dissipation inductor obtained by the inductor impregnation method in the above embodiment.

[0101] Inductors manufactured using the dynamic impregnation process offer the advantages of fully filling gaps with thermally conductive silicone, applying a uniform thickness, and eliminating buildup at the top or bottom of the inductor. The temperature rise of inductors produced using this method is 40°C lower than that of devices impregnated with conventional insulating varnish, and 20°C lower than that of devices impregnated with static thermally conductive silicone. This makes the product of this invention particularly suitable for use in the power supply circuits of high-power semiconductor devices.

[0102] In this document, relational terms such as first and second, etc. are used merely to distinguish one entity or operation from another entity or operation, but do not necessarily require or imply any actual relationship or order between these entities or operations.

[0103] The foregoing description is merely an embodiment of the present invention and is not intended to limit the scope of protection of the present invention. Those skilled in the art will readily appreciate that the present invention is susceptible to various modifications and variations. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention shall be included within the scope of protection of the present invention.

Claims

1. An inductor impregnation method for processing an inductor, wherein the inductor comprises a toroidal magnetic core and a winding wound on the toroidal magnetic core, characterized in that: The inductor impregnation method comprises the following steps: S1. Obtain the semi-finished inductor; S2. Keep the center plane of the semi-finished inductor perpendicular to the liquid surface of the thermally conductive silicone and the leads from the windings above the liquid surface. Immerse two-thirds of the volume of the semi-finished inductor in the thermally conductive silicone. S3. The inductor semi-finished product is impregnated by rotating the semi-finished product in a fixed direction around the drive shaft or by swinging the semi-finished product back and forth within a specified swing range, so that the thermally conductive silicone attached to the semi-finished product flows to the remaining one-third of the volume of the semi-finished product; S4. After the preset soaking time is reached, the thermally conductive silicone is removed and the semi-finished inductor is transferred to the oven. During the transfer process, the semi-finished inductor is controlled to rotate or swing in its original motion. S5. The thermal conductive silicone attached to the semi-finished inductor is dried. During the drying process, the semi-finished inductor is controlled to rotate or swing while maintaining its original motion mode, thereby obtaining a finished inductor.

2. The inductor impregnation method according to claim 1, characterized in that: The specific steps in step S3 include: The impregnation treatment is performed only by controlling the semi-finished inductor to swing back and forth within a specified swing range.

3. The inductor impregnation method according to claim 2, characterized in that: The specified swing range is the specified coordinate system The specified coordinate system is a rectangular coordinate system with the center of the driving shaft as the origin and the horizontal axis parallel to the horizontal plane.

4. The inductor impregnation method according to claim 1, characterized in that: The specific steps in step S3 include: The impregnation time of the semi-finished inductor is controlled according to the following formula: ； in, is the impregnation time, is the dynamic viscosity of thermal conductive silicone rubber, are the preset fitting parameters, is the movement speed of the semi-finished inductor, It is the average thickness of the silicone coating on the surface of the finished inductor.

5. The inductor impregnation method according to claim 4, characterized in that: ;in, is the density of thermal conductive silicone.

6. An inductor impregnation system for processing an inductor, wherein the inductor comprises a toroidal magnetic core and a winding wound on the toroidal magnetic core, characterized in that: include: An acquisition module, used for acquiring the semi-finished inductor; A control module is used to control the center plane of the semi-finished inductor to be perpendicular to the liquid surface of the thermally conductive silicone and to keep the pins extending from the winding above the liquid surface of the thermally conductive silicone, so that two-thirds of the volume of the semi-finished inductor is immersed in the thermally conductive silicone; The impregnation module is used to control the semi-finished inductor to rotate in a fixed direction around the driving shaft or to swing back and forth within a specified swing range to perform an impregnation treatment, so that the thermal conductive silicone attached to the semi-finished inductor flows to the remaining one-third of the volume of the semi-finished inductor; The transfer module is used to remove the thermal conductive silicone and transfer the semi-finished inductor to the oven after the preset impregnation time is reached. During the transfer process, the semi-finished inductor is controlled to rotate or swing in its original motion mode; The drying module is used to dry the thermal conductive silica gel attached to the semi-finished inductor. During the drying process, the semi-finished inductor is controlled to rotate or swing in its original motion mode, and finally the finished inductor is obtained.

7. The inductor impregnation system according to claim 6, characterized in that: The impregnation module is used to control the semi-finished inductor to rotate in a fixed direction around the drive shaft or to swing back and forth within a specified swing range to perform the impregnation treatment, so that the thermal conductive silicone attached to the semi-finished inductor flows to the remaining one-third of the volume of the semi-finished inductor. The impregnation treatment is performed only by controlling the semi-finished inductor to swing back and forth within a specified swing range.

8. The inductor impregnation system according to claim 6, characterized in that: The impregnation module is used to control the semi-finished inductor to rotate in a fixed direction around the drive shaft or to swing back and forth within a specified swing range to perform the impregnation treatment, so that the thermal conductive silicone attached to the semi-finished inductor flows to the remaining one-third of the volume of the semi-finished inductor. The impregnation time of the semi-finished inductor is controlled according to the following formula: ； in, is the impregnation time, is the dynamic viscosity of thermal conductive silicone rubber, are the preset fitting parameters, is the movement speed of the semi-finished inductor, It is the average thickness of the silicone coating on the surface of the finished inductor.

9. A high heat dissipation inductor, characterized in that: The inductor is obtained by being processed by the inductor impregnation method according to any one of claims 1 to 5.

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