A method for preparing an integrally formed inductor alloy powder

Abstract

This invention discloses a method for preparing integrally molded inductor alloy powder, belonging to the technical field of integrally molded inductor processing. The method includes using iron-silicon-aluminum, iron-silicon-chromium, or iron-nickel alloy raw materials. First, the alloy raw materials are vacuum-melted and atomized to obtain alloy magnetic powder. Then, impurities are removed through airflow classification. Subsequently, the magnetic powder is atomized and sprayed with phosphate solution for insulating coating in a high-speed mixing and coating machine. After heating, drying, curing, cooling, and sieving, a uniformly insulated integrally molded inductor alloy powder is obtained. This invention achieves the spiral winding of alloy magnetic powder onto the inner wall of a rotating annular sleeve, combined with adsorption and scraping to form a uniform thin layer, solving the problem of uneven dispersion in traditional coating methods. This lays the foundation for uniform insulation coating. Simultaneously, excess insulation is recycled and reused through a draining process, reducing costs, avoiding coating defects, and balancing product quality with energy conservation and environmental protection, making it suitable for industrial mass production.

Description

Technical Field

[0001] This invention belongs to the technical field of integral molding inductor processing, and more specifically relates to a method for preparing integral molding inductor alloy powder. Background Technology

[0002] Molded inductors are advanced power inductor devices. They are formed by die-casting a coil and magnetic powder made of metal alloys such as iron-silicon and iron-nickel in a single process using high temperature and high pressure. This process completely embeds and tightly wraps the coil inside the magnetic material, forming a gapless, robust, and dense whole. The outside is often covered with insulating resin and uses SMD surface mount packaging. It has advantages such as fully enclosed magnetic circuit, low leakage flux, low EMI, high saturation current, low DC impedance, high current resistance, vibration resistance, miniaturization, and suitability for SMT automated production. It is widely used in high-frequency, high-power, and high-density circuit scenarios such as DC-DC power supplies, CPU / GPU power supplies, consumer electronics, automotive electronics, and industrial control.

[0003] The alloy powders commonly used in integral molded inductors are mainly iron-silicon-aluminum, iron-silicon-chromium, and iron-nickel alloy magnetic powders. The preparation mainly uses water atomization / gas atomization methods. First, the alloy is melted and then atomized into powder under high pressure. Then, it goes through processes such as classification, insulation coating (such as phosphate, SiO2), mixing, granulation, drying, and annealing. The core equipment includes medium frequency / vacuum melting furnace, high pressure atomization powder making equipment, air classifier, high speed mixing and coating machine, granulator, vacuum / atmosphere annealing furnace, powder forming machine, etc.

[0004] Currently, alloy powder insulation coating process is often achieved using a high-speed mixing and coating machine. Its working principle is as follows: metal magnetic powder is placed in the cylinder of the coating machine, and the metal magnetic powder is fluidized and dispersed in the cylinder by the high-speed rotation of the stirring blade. At the same time, insulating coating agents such as phosphate and SiO2 sol are sent into the cylinder by spraying or dripping. Under the action of stirring and shearing, the coating agent is attached to and spread on the surface of the metal powder particles. Then, it is heated and dried to form an insulating coating layer. However, the above-mentioned cylindrical stirring mixing and coating method has obvious drawbacks: since the stirring blades can only drive local powder to form strong turbulence, the powder in the area near the cylinder wall, the dead corner of the blade edge, the bottom accumulation area and the upper floating powder area is difficult to be fully turned and dispersed. When the stirring speed or spray flow rate is not matched, uneven coating is likely to occur, which will directly lead to poor consistency of the insulation layer thickness on the surface of the metal powder particles. During subsequent pressing and molding, the uneven density increases the probability of product cracking, and the eddy current loss of the inductor element after molding is significantly increased and the magnetic performance is degraded, which seriously affects the mass production stability and reliability of the integral molding inductor. Summary of the Invention

[0005] This invention addresses the problem of overly simplistic solutions in existing technologies by providing a significantly different approach. Belonging to the technical field of integral molding inductor processing, this invention primarily offers a method for preparing integral molding inductor alloy powder. This addresses the issue raised in the background section where current insulation coating processes mainly employ cylindrical stirring, which sometimes leads to leakage of magnetic powder particles and exposed copper, increasing the likelihood of product cracking during subsequent pressing and molding.

[0006] The technical solution adopted by the present invention to solve the above-mentioned technical problems is as follows: A method for preparing integrally molded inductor alloy powder includes the following steps: S1: Iron-silicon-aluminum, iron-silicon-chromium, or iron-nickel alloy raw materials are placed in a vacuum melting furnace for melting, and then atomized into powder using gas atomization or water atomization powder making equipment to obtain alloy magnetic powder. S2: The alloy magnetic powder is classified by an air classifier to remove coarse particles and ultrafine powder; S3: The graded alloy magnetic powder is placed into a high-speed mixing and coating machine, so that the alloy magnetic powder flows in a spiral and spreads on the inner wall of the annular adsorption mechanism to form an annular alloy magnetic powder layer. Then, phosphate solution insulating agent is sprayed onto the alloy magnetic powder layer and an insulating coating layer is formed on the surface of the magnetic powder particles. S4: The magnetic powder particles with the insulating coating are introduced into the heating and drying device, and then the coated magnetic powder is heated, dried and cured to make the insulating layer stably adhere to the particle surface. S5: After the cured magnetic powder is cooled, it is sieved using a sieve to obtain a uniformly insulated, integrally molded inductor alloy powder.

[0007] Preferably, the high-speed mixing and coating machine includes a cylinder and a cover, and the annular adsorption mechanism is located in the cavity formed by the cylinder and the cover. The annular adsorption mechanism includes a base with a frustum structure and an annular sleeve. The annular sleeve and the base are connected by bolts. A hollow top column is provided on the lower side of the base. The top column is rotatably connected to a circular hole at the bottom of the cylinder. Multiple separation strips are arranged at equal intervals around the inner wall of the annular sleeve. Multiple mounting grooves are arranged at equal intervals around the outer wall of the annular sleeve, and an electromagnet plate is embedded in each mounting groove. The annular sleeve is connected to a protective cover by bolts, and the inner wall of the anti-slip cover is in close contact with the electromagnet plate. An output mechanism is provided at the central axis position inside the annular sleeve. The output mechanism includes a support frame, a hanger, and a feed hopper containing alloy magnetic powder. The hanger is bolted to the lower side of the cover, and the feed hopper is bolted to the upper side of the cover. A lead screw and a nut seat on the lead screw are provided inside the support frame. An installation frame is provided on one side of the outer wall of the nut seat. A first nozzle is bolted to the installation frame. A corrugated pipe is provided at the interface position of the first nozzle. The upper end of the corrugated pipe is connected to the interface on the feed hopper. A second nozzle is bolted to the upper side of the outer shell of the first nozzle. With the cooperation of the first nozzle and the annular sleeve, the alloy magnetic powder can be laid on the inner wall of the annular sleeve in a spiral manner.

[0008] Preferably, the base and the annular sleeve are connected by bolts. An outlet is provided at the middle position of the bottom of the base, which communicates with the inside of the top column. A first bearing is provided at the position where the outer wall of the top column connects to the cylinder. The lower end of the top column passes through a circular hole at the bottom of the cylinder. Arc-shaped discharge ports are symmetrically provided on both sides of the outlet. A receiving groove is provided below each arc-shaped discharge port, and two receiving grooves can be spliced ​​together to form an annular groove.

[0009] Preferably, a first motor is mounted inside the cylinder via a bracket, and a drive gear is provided at the output end of the first motor. The drive gear is meshed with a toothed ring, and the toothed ring is disposed in an annular notch on the outer wall of the base.

[0010] Preferably, both sides of the outer wall of the cylinder are provided with arc-shaped openings, and the size of the arc-shaped openings is larger than the size of the receiving groove. The receiving groove can be pulled out from the corresponding arc-shaped opening. A collection tray is bolted to the bottom of the outer wall of the cylinder, and the collection tray is located below the top column.

[0011] Preferably, a second motor is bolted to the top of the support frame, the output end of the second motor is connected to the upper end of the lead screw, and a groove on the outer wall of the support frame engages with a thickness-limiting plate, the leading edge of the thickness-limiting plate slidingly contacting the outer side of the separation strip.

[0012] Preferably, a solenoid valve is provided at the upper end of the bellows.

[0013] Preferably, the lower end of the support frame is provided with a blocking switching mechanism, the blocking switching mechanism includes a connecting seat and a connecting plate, the connecting seat and the connecting plate are connected by bolts, a second bearing is provided in the gap between the outer edge of the upper interface of the connecting plate and the groove at the lower end of the support frame, the connecting seat and the outlet are connected by bolts, a first blocking element and a second blocking element are provided in the inner cavity formed by the connecting seat and the connecting plate, the upper ends of the first blocking element and the second blocking element jointly abut against an adjusting block, a disc motor is provided in the interface of the connecting plate, and the output end of the disc motor is connected to the adjusting block; The adjusting block includes a connecting part and two symmetrically distributed guide parts, each of which is provided with an inclined area and a flat area.

[0014] Preferably, the first plug includes a first plug, a first top contact is provided at an eccentric position on the upper side of the first plug, the upper end of the first top contact contacts and engages with the planar area of ​​the corresponding guide portion, and a first spring in a compressed state is provided at the lower interface position of the first plug, the lower end of the first spring is connected to the lower side of the inner wall of the connecting seat.

[0015] Preferably, the second plugging component includes two second plugs and a connecting plate between the two second plugs. A second top contact is provided on the upper side of the connecting plate, and the upper end of the second top contact contacts and engages with the planar area of ​​the corresponding guide portion. Two interface positions on the lower side of the connecting plate are each provided with a second spring in a compressed state, and the lower end of the second spring is connected to the lower side of the inner wall of the connecting seat.

[0016] Compared with the prior art, the beneficial effects of the present invention are as follows: (1) The present invention, through the base, top column, annular sleeve, separating strip, electromagnet plate, protective cover, receiving groove, first motor, drive gear, gear ring, support frame, thickness limiting plate, hanger, feed hopper, screw, nut seat, mounting frame, first nozzle, bellows, solenoid valve and second motor, realizes the powder spreading method of using alloy magnetic powder to spirally spray downward and rotate the annular sleeve. With the adsorption of the electromagnet plate and the scraping of the thickness limiting plate, a continuous thin layer of alloy magnetic powder with precise and consistent thickness, uniform distribution and flat surface can be formed on the inner wall of the annular sleeve. This effectively avoids the defects of traditional high-speed mixing and coating machine where the stirring blade can only drive local powder movement, and the cylinder wall area, blade edge dead corner, bottom accumulation area and upper floating powder area are difficult to fully stir and disperse. Furthermore, the alloy magnetic powder particles are fully spread and arranged in an orderly manner in a thin layer, avoiding problems such as local agglomeration, stacking, and inclusion of voids. This significantly improves the uniformity of magnetic powder dispersion and the effective coating area, ensuring that the subsequent insulating agent can be uniformly and stably attached to the surface of each magnetic powder particle. This greatly improves the consistency and density of the insulation layer thickness, thereby effectively improving problems such as density differences in compression molding and product cracking caused by uneven coating, reducing eddy current losses in integrally molded inductors, optimizing magnetic performance stability, and significantly improving product yield and mass production consistency.

[0017] (2) This invention, through the setup of a base, annular sleeve, electromagnet plate, protective cover, first motor, drive gear, gear ring, support frame, thickness limiting plate, hanger, lead screw, nut seat, mounting bracket, second nozzle, and second motor, achieves uniform coverage of the insulating agent on the surface of a pre-laid thin layer of magnetic powder in a spiral upward trajectory. Compared with the traditional method of directly spraying the insulating agent into the powder bucket, this spraying method allows the insulating agent to contact and bond with the magnetic powder particles in all directions and without dead angles. The magnetic powder layer itself has the advantages of uniform thickness and sufficient spreading, which can ensure that the insulating agent quickly and evenly coats the surface of each alloy magnetic powder particle, and avoid local insulation agent accumulation or incomplete coverage. This further improves the consistency and density of the insulation layer thickness and reduces product performance defects caused by uneven coating. Meanwhile, the connection between the connecting seat, connecting plate, first blocking component, second blocking component, adjusting block and disc motor can switch the opening and closing of the arc-shaped discharge port and the discharge port, so as to achieve orderly connection and seamless switching between the two processes of collecting excess insulating agent and discharging magnetic powder, thereby improving production efficiency and process controllability.

[0018] (3) The present invention achieves the collection of excess insulating agent by draining the magnetic powder layer after coating through the vertical arrangement structure of the ring sleeve. It can quickly and fully guide the free phosphate solution insulating agent that is not adsorbed on the surface of the alloy magnetic powder particles to the collection tray for centralized recycling along the base and outlet, thereby achieving efficient recycling and recycling of the insulating agent, greatly reducing raw material waste, reducing production costs, and improving process economy. Meanwhile, timely removal of excess insulating agent can avoid local liquid accumulation, over-wetting, particle agglomeration and adhesion in the magnetic powder layer, further ensuring uniform insulation layer thickness and dense structure. This prevents the subsequent drying, curing and pressing effects from being affected by excessive local thickness or solvent residue. It not only improves the coating quality and product performance stability, but also saves energy, protects the environment, reduces costs and increases efficiency, and is more suitable for the needs of continuous and stable industrial production.

[0019] The present invention will be explained in detail below with reference to the accompanying drawings and specific embodiments. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is an exploded view of the overall structure of the present invention; Figure 3 This is an exploded view of the internal structure of the cylinder of the present invention; Figure 4 This is a schematic diagram of the annular adsorption mechanism of the present invention. Figure 5 This is a schematic diagram of the annular sleeve structure of the present invention; Figure 6This is a schematic diagram of the base structure of the present invention; Figure 7 This is a schematic diagram of the derived mechanism structure of the present invention; Figure 8 This is an exploded view of the export mechanism of the present invention; Figure 9 This is a schematic diagram showing the connection between the support frame and the thickness-limiting plate of the present invention; Figure 10 This is a schematic diagram of the blockage switching mechanism of the present invention; Figure 11 This is an exploded view of the blockage switching mechanism of the present invention; Figure 12 This is a schematic diagram showing the connection between the adjusting block, the first blocking member, and the second blocking member of the present invention. Figure 13 This is a schematic diagram of the connector structure of the present invention; Figure 14 This is a schematic diagram of the adjusting block structure of the present invention; Figure 15 This is a schematic diagram of the first blocking component structure of the present invention; Figure 16 This is a schematic diagram of the second blocking component structure of the present invention.

[0021] In the diagram: 1. Cylinder; 11. Cover; 12. Arc-shaped opening; 13. Collection tray; 2. Annular adsorption mechanism; 21. Base; 211. Top column; 212. Outlet; 213. Arc-shaped discharge port; 22. Annular sleeve; 221. Mounting groove; 222. Separating bar; 23. Electromagnetic plate; 24. Protective cover; 25. First bearing; 26. Receiving groove; 27. First motor; 28. Drive gear; 29. ​​Gear ring; 3. Outlet mechanism; 31. Support frame; 311. Second bearing; 312. Thickness limiting plate; 32. Hanger; 33. Feed hopper; 34. Lead screw; 341. Nut 35. Mounting bracket; 36. First nozzle; 37. Bellows; 371. Solenoid valve; 38. Second nozzle; 39. Second motor; 4. Blocking switching mechanism; 41. Connecting seat; 42. Connecting plate; 43. First blocking component; 431. First plug; 432. First top contact; 433. First spring; 44. Second blocking component; 441. Second plug; 442. Connecting plate; 443. Second top contact; 444. Second spring; 45. Adjusting block; 451. Connecting part; 452. Guide part; 4521. Sloping area; 4522. Flat area; 46. Disc motor. Detailed Implementation

[0022] To facilitate understanding of the present invention, a more comprehensive description of the present invention will be given below with reference to the accompanying drawings, which illustrate several embodiments of the present invention. However, the present invention can be implemented in different forms and is not limited to the embodiments described in the text. Rather, these embodiments are provided to make the disclosure of the present invention more thorough and complete.

[0023] It should be noted that when an element is referred to as being "fixed to" another element, it can be directly on the other element or there may be an intervening element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this document are for illustrative purposes only.

[0024] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly associated with those skilled in the art to which this invention pertains. The terminology used herein in the specification of this invention is for the purpose of describing particular embodiments and is not intended to limit the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0025] For the implementation examples, please refer to the appendix. Figure 1-16 As shown, a method for preparing integrally molded inductor alloy powder includes the following steps: S1: Iron-silicon-aluminum, iron-silicon-chromium, or iron-nickel alloy raw materials are placed in a vacuum melting furnace for melting, and then atomized into powder using gas atomization or water atomization powder making equipment to obtain alloy magnetic powder. S2: The alloy magnetic powder is classified by an air classifier to remove coarse particles and ultrafine powder; S3: The graded alloy magnetic powder is placed into a high-speed mixing and coating machine, so that the alloy magnetic powder flows in a spiral and spreads on the inner wall of the annular adsorption mechanism 2 to form an annular alloy magnetic powder layer. Then, the phosphate solution insulating agent is sprayed onto the alloy magnetic powder layer and an insulating coating layer is formed on the surface of the magnetic powder particles. The high-speed mixing and coating machine includes a cylinder 1 and a cover 11, and an annular adsorption mechanism 2 is located in the cavity formed by the cylinder 1 and the cover 11. The annular adsorption mechanism 2 includes a frustum-shaped base 21 and an annular sleeve 22. The annular sleeve 22 and the base 21 are connected by bolts (the annular sleeve 22 is made of a transparent, non-magnetic, and non-conductive material, such as acrylic, PC, PVC, or plastic, which allows the magnetic field to penetrate with almost no attenuation and still attract the inductive alloy powder). A hollow top post 211 is provided on the lower side of the base 21. The top post 211 is rotatably connected to a circular hole at the bottom of the cylinder 1. The inner wall of the annular sleeve 22 has equally spaced rings. Multiple separation strips 222 are provided around the annular sleeve 22. Through the interaction between the separation strips 222 and the alloy particles themselves, the alloy magnetic particles adsorbed on the inner wall of the annular sleeve 22 can be reduced from rolling and shifting circumferentially along the inner wall of the annular sleeve 22 when the annular sleeve 22 rotates. This ensures the uniformity of the thickness of the alloy magnetic powder layer at different positions, so as to better spray the phosphate solution insulating agent. Multiple mounting grooves 221 are provided at equal intervals around the outer wall of the annular sleeve 22, and an electromagnet plate 23 is embedded in each mounting groove 221. The annular sleeve 22 is connected to a protective cover 24 by bolts, and the inner wall of the anti-slip cover is in close contact with the electromagnet plate 23. An outlet mechanism 3 is provided at the central axis position inside the annular sleeve 22. The outlet mechanism 3 includes a support frame 31, a hanger 32, and a feed hopper 33 containing alloy magnetic powder. The hanger 32 is bolted to the lower side of the cover 11, and the feed hopper 33 is bolted to the upper side of the cover 11. The support frame 31 is provided with a lead screw 34 and a nut seat 341 on the lead screw 34. An installation frame 35 is provided on one side of the outer wall of the nut seat 341. The installation frame 35 is bolted to a first nozzle 36. A corrugated pipe 37 is provided at the interface position on the first nozzle 36. The upper end of the corrugated pipe 37 is connected to the interface on the feed hopper 33. A second nozzle 38 is bolted to the upper side of the outer shell of the first nozzle 36. With the cooperation of the first nozzle 36 and the annular sleeve 22, the alloy magnetic powder can be laid on the inner wall of the annular sleeve 22 in a spiral manner. S4: The magnetic powder particles with the insulating coating are introduced into the heating and drying device, and then the coated magnetic powder is heated, dried and cured to make the insulating layer stably adhere to the particle surface. S5: After the cured magnetic powder is cooled, it is sieved using a sieve to obtain a uniformly insulated, integrally molded inductor alloy powder.

[0026] Please refer to the appendix carefully. Figure 2-6As shown, the base 21 and the annular sleeve 22 are connected by bolts. An outlet 212 is located at the center of the bottom of the base 21, communicating with the interior of the top column 211. A first bearing 25 is located at the connection point between the outer wall of the top column 211 and the cylinder 1. The lower end of the top column 211 passes through a circular hole at the bottom of the cylinder 1. Through the cooperation between the top column 211 and the first bearing 25, the base 21 can rotate stably within the cylinder 1. Arc-shaped discharge ports 213 are symmetrically arranged on both sides of the outlet 212. A receiving groove 26 is provided below each arc-shaped discharge port 213, and two receiving grooves 26 can be joined to form an annular groove. Due to the annular structure of the groove, the discharge can be received regardless of the angle to which the arc-shaped discharge port 213 rotates. The alloy magnetic powder is used. A first motor 27 is installed inside the cylinder 1 via a bracket. A drive gear 28 is provided at the output end of the first motor 27. The drive gear 28 is meshed with a toothed ring 29, which is located in an annular notch on the outer wall of the base 21. The first motor 27, the toothed ring 29, and the drive gear 28 provide driving force for the rotation of the base 21 and the annular sleeve 22. Arc-shaped openings 12 are provided on both sides of the outer wall of the cylinder 1. The size of the arc-shaped openings 12 is larger than the size of the receiving groove 26. The receiving groove 26 can be pulled out from the corresponding arc-shaped openings 12. A collection tray 13 is bolted to the bottom of the outer wall of the cylinder 1. The collection tray 13 is located below the top column 211. The collection tray 13 is used to collect excess insulating agent.

[0027] Please refer to the appendix carefully. Figure 8-16 As shown, the top of the support frame 31 is connected to a second motor 39 by bolts. The output end of the second motor 39 is connected to the upper end of the lead screw 34. The groove on the outer wall of the support frame 31 engages with a thickness limiting plate 312. The front edge of the thickness limiting plate 312 slides in contact with the outer side of the separation strip 222. The thickness limiting plate 312 prevents the alloy powder layer from becoming too thick locally, with a thickness greater than the width of the separation strip 222, which would be detrimental to contact with the insulating agent later. The upper end of the bellows 37 is provided with a solenoid valve 371. The solenoid valve 371 controls the opening and closing of the bellows 37. The lower end of the support frame 31 is provided with a blocking switching mechanism 4. The blocking switching mechanism 4 includes a connecting seat 41 and a connecting plate 42, which are connected by bolts. A second bearing 311 is provided in the gap between the outer edge of the upper interface of the connecting plate 42 and the groove at the lower end of the support frame 31 to ensure that the blocking switching mechanism 4 can rotate stably and synchronously with the base 21. The connecting seat 41 and the outlet 212 are connected by bolts. A first blocking element 43 and a second blocking element 44 are provided in the inner cavity formed by the connecting seat 41 and the connecting plate 42. The upper ends of the plug 44 are engaged with an adjusting block 45. A disc motor 46 is installed inside the interface of the connecting disc 42. The output end of the disc motor 46 is connected to the adjusting block 45. The adjusting block 45 includes a connecting part 451 and two symmetrically distributed guide parts 452. Each guide part 452 is provided with a sloped area 4521 and a flat area 4522. In the initial state, the two flat areas 4522 of the adjusting block 45 press against the upper ends of the first blocking member 43 and the second blocking member 44, respectively. At this time, the first blocking member 43 closes the outlet 212, and the second blocking member 44 closes the arc-shaped outlet 213. The cooperation between the disc motor 46 and the adjusting block 45 enables the control of the up-and-down movement of the first blocking component 43 and the second blocking component 44, thereby achieving the purpose of blocking. The first blocking component 43 includes a first plug 431, and a first top contact 432 is provided at an eccentric position on the upper side of the first plug 431. The upper end of the first top contact 432 contacts and engages with the planar area 4522 of the corresponding guide part 452. A first spring 433 in a compressed state is provided at the lower interface position of the first plug 431. The lower end of the first spring 433 is connected to the lower side of the inner wall of the connecting seat 41. Through the first spring 433... The first plug 431 is provided with an upward force. The second plug 44 includes two second plugs 441 and a connecting plate 442 between the two second plugs 441. A second top contact 443 is provided on the upper side of the connecting plate 442. The upper end of the second top contact 443 contacts and engages with the planar area 4522 of the corresponding guide part 452. Two second springs 444 in a compressed state are provided at the two interface positions on the lower side of the connecting plate 442. The lower end of the second spring 444 is connected to the lower side of the inner wall of the connecting seat 41. The second spring 444 provides an upward force for the second plug 441.

[0028] The specific operation is as follows: First, the first motor 27 is turned on, driving the drive gear 28 to rotate. Since the drive gear 28 and the gear ring 29 mesh, the gear ring 29 drives the base 21 and the ring sleeve 22 to move in a circular motion around the top column 211. Then, the electromagnet plate 23 is energized, generating traction force, opening the valve at the upper end of the bellows 37. The alloy magnetic powder in the feed hopper 33 enters the first nozzle 36 through the bellows 37 and is then sprayed out from the first nozzle 36. At the same time, the second motor 39 drives the lead screw 34 to rotate. Subsequently, the nut seat 341 on the lead screw 34 drives the first nozzle 36 to move downward linearly through the mounting bracket 35. Due to the downward linear movement of the first nozzle 36... After the motion trajectory of the moving track and the rotation trajectory of the annular sleeve 22 are superimposed and coordinated, the alloy magnetic powder sprayed by the first nozzle 36 can be laid on the inner wall of the annular sleeve 22 in a downward spiral. Under the adsorption provided by the electromagnet plate 23, the alloy magnetic powder will form an annular alloy magnetic powder layer on the inner wall of the annular sleeve 22 (with the middle of the separation strips 222 evenly spaced). Due to the rotation of the annular sleeve 22, the separation strips 222 on the inner wall of the annular sleeve 22 will contact the thickness limiting plate 312 one by one. Therefore, the thickness limiting plate 312 will scrape out the alloy magnetic powder that is thicker than the separation strips 222, ensuring that the thickness of the alloy is the same at each position, so that the insulating agent can better cover it. When the nut seat 341 drives the first nozzle 36 to its lowest position, the first nozzle 36 closes, completing the first layering of alloy magnetic powder particles on the annular sleeve 22. Subsequently, the second motor 39 drives the lead screw 34 to rotate, and the nut seat 341 drives the second nozzle 38 located on the first nozzle 36 to move linearly upward. The second nozzle 38 opens and sprays out phosphate solution insulating agent. At the same time, in conjunction with the rotation of the annular sleeve 22, the insulating agent sprayed by the second nozzle 38 is sprayed onto the alloy magnetic powder layer in an upward spiral. Because the powder layer is relatively thin, the insulating agent can quickly and evenly coat each alloy particle, avoiding the method of directly spraying the insulating agent into the container of alloy powder in the prior art. This ensures the consistency of the insulation layer thickness on the surface of the alloy particles and improves product quality. When the second nozzle 38 moves to the top, spraying stops. At the same time, the first motor 27 is turned off, the annular sleeve 22 stops rotating, and the disc motor 46 drives the adjusting block 45 to rotate counterclockwise. As a result, the first top contact 432 moves from the planar area 4522 in the corresponding guide part 452 to the inclined area 4521 (at this time, the second top contact 443 slides from one side of the planar area 4522 in the corresponding guide part 452 to the other side, so the second plug 441 will not move up). This provides space for the first plug 43 to move up. The first spring 433, which is in a compressed state, returns to its original position and pushes the first plug 431 up, opening the outlet 212. Since the alloy magnetic powder layer of the entire annular structure is in a vertical state, it can play a "draining" role. As a result, the excess insulating agent will flow into the outlet 212 along the base 21, and then flow into the collection tray 13 through the cavity in the top column 211 for collection and reuse. After collecting the excess insulating agent, the disc motor 46 drives the adjusting block 45 to rotate in the opposite direction. Simultaneously, the second top contact 443 moves from the flat area 4522 in the corresponding guide section 452 to the inclined area 4521 (at this time, the first top contact 432 returns from the inclined area 4521 in the corresponding guide section 452 to the flat area 4522, the first spring 433 is compressed, and the first plug 431 moves downward to block the outlet 212), providing space for the second plug 44 to move upward. The compressed second spring 444 returns to its original position, pushing the second plug 441 upward and opening the arc-shaped discharge port 213. Then the power supply on the electromagnet plate 23 is disconnected, the traction force disappears, and the alloy particles, due to their own gravity, flow out from the arc-shaped discharge port 213 along the inner wall of the base 21 and enter the receiving groove 26 for collection. Then the disc motor 46 drives the adjusting block 45 to reset, so that the two planar areas 4522 press on the first top contact 432 and the second top contact 443 respectively, closing the arc-shaped discharge port 213 and the outlet 212. Then, secondary coating can be performed. Repeat the above operation. After the receiving groove 26 is full, the receiving groove 26 can be taken out through the arc-shaped opening 12 for subsequent curing treatment.

[0029] The present invention has been described by way of example in conjunction with the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvement made by adopting the inventive concept and technical solution of the present invention, or the direct application of the inventive concept and technical solution of the present invention to other occasions without modification, shall be within the protection scope of the present invention.

Claims

1. A method for preparing integrally molded inductor alloy powder, characterized in that, Includes the following steps: S1: Iron-silicon-aluminum, iron-silicon-chromium, or iron-nickel alloy raw materials are placed in a vacuum melting furnace for melting, and then atomized into powder using gas atomization or water atomization powder making equipment to obtain alloy magnetic powder. S2: The alloy magnetic powder is classified by an air classifier to remove coarse particles and ultrafine powder; S3: The graded alloy magnetic powder is placed into a high-speed mixing and coating machine, so that the alloy magnetic powder flows in a spiral and is spread on the inner wall of the annular adsorption mechanism (2) to form an annular alloy magnetic powder layer. Then, the phosphate solution insulating agent is sprayed onto the alloy magnetic powder layer and an insulating coating layer is formed on the surface of the magnetic powder particles. S4: The magnetic powder particles with the insulating coating are introduced into the heating and drying device, and then the coated magnetic powder is heated, dried and cured to make the insulating layer stably adhere to the particle surface. S5: After the cured magnetic powder is cooled, it is sieved using a sieve to obtain a uniformly insulated, integrally molded inductor alloy powder.

2. The method for preparing an integrally molded inductor alloy powder according to claim 1, characterized in that, The high-speed mixing and coating machine includes a cylinder (1) and a cover (11), and the annular adsorption mechanism (2) is located in the cavity formed by the cylinder (1) and the cover (11). The annular adsorption mechanism (2) includes a base (21) with a frustum structure and an annular sleeve (22). The annular sleeve (22) and the base (21) are connected by bolts. The base (21) has a hollow top column (211) on its lower side. The top column (211) is rotatably connected to the round hole at the bottom of the cylinder (1). Multiple separation strips (222) are arranged around the inner wall of the annular sleeve (22) at equal intervals. Multiple mounting grooves (221) are arranged around the outer wall of the annular sleeve (22) at equal intervals. An electromagnet plate (23) is embedded in each mounting groove (221). The annular sleeve (22) is connected to a protective cover (24) by bolts. The inner wall of the anti-slip cover is in close contact with the electromagnet plate (23). An outlet mechanism (3) is provided at the central axis position inside the annular sleeve (22). The outlet mechanism (3) includes a support frame (31), a hanger (32), and a feed hopper (33) containing alloy magnetic powder. The hanger (32) is bolted to the lower side of the cover (11), and the feed hopper (33) is bolted to the upper side of the cover (11). A lead screw (34) and a nut seat (341) on the lead screw (34) are provided inside the support frame (31). The nut seat (341) is located outside the nut seat (341). A mounting bracket (35) is provided on one side of the wall. The mounting bracket (35) is connected to a first nozzle (36) by bolts. A corrugated pipe (37) is provided at the interface position on the first nozzle (36). The upper end of the corrugated pipe (37) is connected to the interface on the feed hopper (33). A second nozzle (38) is connected to the upper side of the outer shell of the first nozzle (36) by bolts. With the cooperation of the first nozzle (36) and the annular sleeve (22), the alloy magnetic powder can be laid on the inner wall of the annular sleeve (22) in a spiral winding form.

3. The method for preparing an integrally molded inductor alloy powder according to claim 2, characterized in that, The base (21) and the annular sleeve (22) are connected by bolts. The bottom of the base (21) is provided with an outlet (212) in the middle position. The outlet (212) is connected to the inside of the top column (211). The outer wall of the top column (211) is provided with a first bearing (25) at the connection position between it and the cylinder (1). The lower end of the top column (211) passes through the round hole at the bottom of the cylinder (1). The two sides of the outlet (212) are symmetrically provided with arc-shaped discharge ports (213). Each arc-shaped discharge port (213) is provided with a receiving groove (26) below it, and two receiving grooves (26) can be spliced ​​together to form an annular groove.

4. The method for preparing an integrally molded inductor alloy powder according to claim 3, characterized in that, The first motor (27) is installed inside the cylinder (1) by a bracket. The output end of the first motor (27) is provided with a drive gear (28). The drive gear (28) is meshed with a toothed ring (29), and the toothed ring (29) is located in the annular notch on the outer wall of the base (21).

5. The method for preparing an integrally molded inductor alloy powder according to claim 4, characterized in that, Both sides of the outer wall of the cylinder (1) are provided with arc-shaped openings (12), and the size of the arc-shaped openings (12) is larger than the size of the receiving groove (26). The receiving groove (26) can be pulled out from the corresponding arc-shaped opening (12). The bottom of the outer wall of the cylinder (1) is connected to a collection plate (13) by bolts. The collection plate (13) is located below the top column (211).

6. The method for preparing an integrally molded inductor alloy powder according to claim 2, characterized in that, The top of the support frame (31) is connected to a second motor (39) by bolts. The output end of the second motor (39) is connected to the upper end of the lead screw (34). The groove on the outer wall of the support frame (31) is engaged with a thickness-limiting plate (312). The front edge of the thickness-limiting plate (312) slides in contact with the outer side of the separation strip (222).

7. The method for preparing an integrally molded inductor alloy powder according to claim 2, characterized in that, A solenoid valve (371) is provided at the upper end of the bellows (37).

8. The method for preparing an integrally molded inductor alloy powder according to claim 6, characterized in that, The lower end of the support frame (31) is provided with a blocking switching mechanism (4). The blocking switching mechanism (4) includes a connecting seat (41) and a connecting plate (42). The connecting seat (41) and the connecting plate (42) are connected by bolts. A second bearing (311) is provided in the gap between the outer edge of the upper interface of the connecting plate (42) and the groove at the lower end of the support frame (31). The connecting seat (41) and the outlet (212) are connected by bolts. A first blocking component (43) and a second blocking component (44) are provided in the inner cavity formed by the connecting seat (41) and the connecting plate (42). The upper ends of the first blocking component (43) and the second blocking component (44) are in contact with an adjusting block (45). A disc motor (46) is provided in the interface of the connecting plate (42). The output end of the disc motor (46) is connected to the adjusting block (45). The adjustment block (45) includes a connecting part (451) and two symmetrically distributed guide parts (452), each of which is provided with a slope area (4521) and a flat area (4522).

9. The method for preparing an integrally molded inductor alloy powder according to claim 8, characterized in that, The first plug (43) includes a first plug (431), a first top contact (432) is provided at an eccentric position on the upper side of the first plug (431), the upper end of the first top contact (432) is in contact with the planar area (4522) of the corresponding guide part (452), and a first spring (433) in a compressed state is provided at the lower interface position of the first plug (431), the lower end of the first spring (433) is connected to the lower side of the inner wall of the connecting seat (41).

10. The method for preparing an integrally molded inductor alloy powder according to claim 8, characterized in that, The second plug (44) includes two second plugs (441) and a connecting plate (442) between the two second plugs (441). A second top contact (443) is provided on the upper side of the connecting plate (442). The upper end of the second top contact (443) contacts and engages with the planar area (4522) of the corresponding guide part (452). Two interface positions on the lower side of the connecting plate (442) are provided with a second spring (444) in a compressed state, and the lower end of the second spring (444) is connected to the lower side of the inner wall of the connecting seat (41).

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