Ultra-Thin Power Inductor Casting to Protect Coil Integrity
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Solution Overview
Problem
Conventional dry pressing integral molding of small-size and ultra-thin power inductors leads to deformation of the coil, damage to the insulating paint, high production costs, and low production efficiency, making it difficult to manufacture products with high performance and reliability.
Innovation Solution
A method involving integral pouring followed by cutting, combined with warm-water pressing and curing treatment, is used to prepare small-size and ultra-thin power inductors, reducing molding pressure and improving production efficiency, suitable for mass production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If dry pressing integral molding is used to manufacture small-size power inductors, then the inductor structure can be formed, but the molding pressure causes deformation of the internal coil and damage to the insulating paint
Solution Approach 1:
The manufacturing process is divided into two independent stages: first forming the magnetic powder core structure, then separately arranging the coil and pouring encapsulant. This segmentation eliminates the need for high-pressure molding that damages coils, while still achieving integrated inductor formation.
Solution Approach 2:
The magnetic powder core is pre-formed into a box structure before coil placement. This preliminary action allows the coil to be arranged in a pre-formed structure without requiring high-pressure molding, thus preventing coil deformation and insulating paint damage.
2Ease of manufacture
If dry pressing integral molding is used, then the inductor can be manufactured, but the high molding pressure and equipment requirements limit production efficiency and increase production cost
Solution Approach 1:
The process separates core formation from coil assembly and encapsulation, allowing each step to be optimized independently. The pouring process replaces high-pressure molding, enabling faster production cycles and higher efficiency without compromising product quality.
Solution Approach 2:
The high-pressure mechanical molding process is replaced with a pouring process that uses fluid encapsulant to fill the magnetic powder core structure. This substitution eliminates the need for high-tonnage pressing equipment, reducing capital investment and increasing production speed.
3Productivity
If conventional dry pressing integral molding is used, then production can proceed, but ultra-thin inductors with height less than or equal to 0.6 mm are difficult to manufacture
Solution Approach 1:
The manufacturing process is segmented to form the magnetic powder core first, then arrange the coil, and finally pour the encapsulant. This allows precise control of each layer's thickness, making it possible to manufacture ultra-thin inductors with heights ≤0.6mm without the distortion caused by high-pressure molding.
Solution Approach 2:
The process changes from high-pressure mechanical compression to low-pressure pouring and curing. This parameter change enables precise control of ultra-thin dimensions while maintaining structural integrity, as the pouring process applies uniform pressure without the localized stress concentration that plagues thin-component molding.
4Reliability
If the pouring method of first pressing a magnetic powder to mold a box and then arranging a coil separately is used, then coil deformation is avoided, but the process is complicated and production efficiency is low
Solution Approach 1:
The magnetic powder core formation and coil arrangement are merged into a single integrated process where the coil is placed in the pre-formed magnetic powder box and the encapsulant is poured in one continuous operation. This merging eliminates the complicated separate steps of the conventional pouring method while maintaining coil integrity.
Solution Approach 2:
The magnetic powder core is pre-formed into a box structure with precise dimensions before coil placement. This preliminary action simplifies the subsequent steps, allowing the coil to be easily arranged and the encapsulant to be poured without complex tooling or multiple operations, thereby improving production efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method effectively prevents coil damage, reduces molding pressure, and enhances production efficiency, enabling the production of high-performance inductors with uniform pressure application and suitable for mass production.
Implementation Method 1
sticking hollow coils onto a thermosensitive adhesive film
Implementation Method 2
injecting a magnetic slurry and drying to obtain a pouring body
Implementation Method 3
subjecting the first structure to warm-water pressing and curing treatment
Data Source
Figure 1~3
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AI summary
Provided in the present application are a power inductor and a preparation method therefor. The preparation method comprises the process steps of slurry preparation, slurry casting, coil winding, coil arrangement, slurry pouring, warm-water pressing, curing treatment, UV adhesive film lamination, cutting, etc. A small-size power inductor can be simply and efficiently prepared, the preparation method is particularly suitable for ultrathin inductors, the phenomena of a short circuit, an open circuit, etc., appearing due to the damage to copper wires that is caused by using dry-pressing integral forming technology are avoided, and the problem of a single box body being easily damaged during casting is solved, thereby facilitating industrial applications.