WO2023246108A1 - 一种浇注式功率电感及其制备方法 - Google Patents

一种浇注式功率电感及其制备方法 Download PDF

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Publication number
WO2023246108A1
WO2023246108A1 PCT/CN2023/074387 CN2023074387W WO2023246108A1 WO 2023246108 A1 WO2023246108 A1 WO 2023246108A1 CN 2023074387 W CN2023074387 W CN 2023074387W WO 2023246108 A1 WO2023246108 A1 WO 2023246108A1
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Prior art keywords
powder
preparation
curing
slurry
inductor
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Ceased
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PCT/CN2023/074387
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English (en)
French (fr)
Inventor
於扬栋
王雷杰
朱权
陈建宇
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Hengdian Group DMEGC Magnetics Co Ltd
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Hengdian Group DMEGC Magnetics Co Ltd
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Priority to US18/835,926 priority Critical patent/US20250385042A1/en
Priority to EP23825768.7A priority patent/EP4394817A4/en
Publication of WO2023246108A1 publication Critical patent/WO2023246108A1/zh
Anticipated expiration legal-status Critical
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00—Fixed inductances of the signal type
    • H01F17/04—Fixed inductances of the signal type with magnetic core
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/0206—Manufacturing of magnetic cores by mechanical means
    • H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F1/00—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties
    • H01F1/01—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials
    • H01F1/03—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity
    • H01F1/12—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials
    • H01F1/14—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys
    • H01F1/20—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder
    • H01F1/22—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together
    • H01F1/24—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
    • H01F1/26—Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated by macromolecular organic substances
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/02—Casings
    • H01F27/022—Encapsulation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H01F27/255—Magnetic cores made from particles
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2823—Wires
    • H01F27/2828—Construction of conductive connections, of leads
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/29—Terminals; Tapping arrangements for signal inductances
    • H01F27/292—Surface mounted devices
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F37/00—Fixed inductances not covered by group H01F17/00
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/005—Impregnating or encapsulating
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06—Coil winding
    • H01F41/08—Winding conductors onto closed formers or cores, e.g. threading conductors through toroidal cores
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/10—Connecting leads to windings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00—Fixed inductances of the signal type
    • H01F17/04—Fixed inductances of the signal type with magnetic core
    • H01F2017/048—Fixed inductances of the signal type with magnetic core with encapsulating core, e.g. made of resin and magnetic powder

Definitions

  • the insulating paint on the surface is damaged, causing open circuits and short circuits during the pressing process; in addition, the dry pressing molding process has higher requirements for molding equipment and molds, which is limited by the tonnage of the press and mold design, which limits the production efficiency of the product and the inductance. Production costs also remain high.
  • magnetic slurry casting molding is the focus of research.
  • this process mixes magnetic materials with glue to form a gel with a higher viscosity, resulting in a lower solid content of the magnetic powder compared to molding, resulting in a low inductance value. .
  • the casting inductor includes a box body and a conductor coil.
  • the box body is formed by pressing magnetic powder.
  • the conductor coil is arranged in the box body and the lead end of the conductor coil extends from the box body.
  • the box body is cast There is magnetic slurry, the magnetic slurry is flush with the opening edge of the box body, and the box body, conductor coil and magnetic slurry are integrally cast and formed.
  • the cast inductor provided by this patent is molded by casting, which eliminates the need to press the coil, avoids deformation of the coil, and can effectively avoid magnetic leakage.
  • this utility model patent uses magnetic powder to press-form the box body first, and then separately sets coils in the box body and performs casting. The process is complicated and cumbersome, and the production efficiency is low.
  • the box wall is thin and easily damaged during assembly, making it unsuitable for mass production of small-sized inductors.
  • CN 112397295A discloses a method for manufacturing an integrally formed inductor.
  • the manufacturing method includes: first pre-pressing the soft magnetic alloy material into a flat blank and a T-shaped blank, and then performing precise molding on the columnar protrusions of the T-shaped blank. Wind the enameled wire, then place the T-shaped body with the enameled wire in a " ⁇ " shape in the hot pressing mold, place the prefabricated flat body above the T-shaped body, and perform hot-pressing molding to obtain an integrated mold.
  • the inductor body is then spray-coated and electrodes are electroplated to obtain an integrated inductor.
  • the manufacturing method provided only solves the problem that due to the uneven prefabricated powder particles in the production of one-piece inductors, there is a large deviation in the amount of powder filled into each cavity of the mold during the molding stage, resulting in a larger size of the pressed inductor blank. , weight and performance deviations, and defective products contain enameled wire and other components, and the powder is difficult to recycle. It is still unavoidable to cause open circuits or short circuits due to the large deformation of the internal coil of the inductor during the molding process, or the damage to the insulating paint on the surface of the enameled wire.
  • Embodiments of the present application provide a cast power inductor and a preparation method thereof.
  • the cast power inductor achieves pressureless molding by pouring magnetic slurry, which prevents the coil from being short-circuited, broken, or deflected to the edge of the inductor due to excessive pressure; effectively improving the reliability of the inductor and the yield of the product.
  • embodiments of the present application provide a cast power inductor, which includes a T-shaped base, an air-core coil and a cast body;
  • the base includes a hem and a center column
  • the center column is fixedly arranged at the center of the hem
  • the casting body is used to wrap the base and the air-core coil.
  • a wire groove is provided on one side of the hem.
  • inventions of the present application provide a method for preparing a cast power inductor as provided in the first aspect.
  • the preparation method includes the following steps:
  • step (5) Post-processing: The inductor blank obtained in step (5) is sequentially cut, sprayed and electroplated to obtain the cast power inductor.
  • the auxiliary powder in step (1.1) includes any one or a combination of at least two of FeSiAl powder, FeSi powder or FeNi powder.
  • Typical but non-limiting combinations include FeSiAl powder, FeSi powder and FeNi powder. combination, a combination of FeSiAl powder and FeSi powder, a combination of FeSiAl powder and FeNi powder, or a combination of FeSi powder and FeNi powder.
  • compositions of the main powder and the auxiliary powder in the composite soft magnetic alloy powder described in step (1.1) of this application can be exactly the same, and the selection of materials depends on the specific application requirements.
  • FeSiAl material has high hardness, saturation magnetic induction intensity Bs, magnetic permeability and resistivity, and low cost; its disadvantages are that the magnetic properties are sensitive to composition fluctuations, are brittle, and have poor processing performance.
  • FeSi material has a higher saturation magnetic induction intensity than FeSiAl, has a higher ability to store energy, and is suitable for high current working conditions. Compared with iron-silicon-aluminum, FeNi has better DC superposition characteristics. Since the powder contains about 50% nickel, the material cost is higher.
  • the temperature of hot press molding in step (1) is 160-240°C, for example, it can be 160°C, 170°C, 180°C, 190°C, 200°C, 210°C, 220°C, 230°C or 240°C, However, it is not limited to the listed values, and other unlisted values within the numerical range are also applicable.
  • the baking temperature in step (1) is 180-260°C, for example, it can be 180°C, 190°C, 200°C, 210°C, 220°C, 230°C, 240°C, 250°C or 260°C, but Not limited to the listed values, other unlisted values within the range of values are also applicable.
  • the purpose of the hot press forming described in this application is to ensure that the T-shaped blank can obtain better strength and prevent the center column on the T-shaped base from breaking during the preparation process of the winding coil.
  • the distance between the combinations in step (3) is 0.5-2mm, for example, it can be 0.5mm, 0.8mm, 1mm, 1.2mm, 1.4mm, 1.6mm, 1.8mm or 2mm, but is not limited to the listed values. , other unlisted values within the value range are also applicable.
  • the adhesion of the heat-sensitive adhesive in the heat-sensitive adhesive film described in step (3) is 2000-3000gf/25mm, for example, it can be 2000gf/25mm, 2200gf/25mm, 2400gf/25mm, 2600gf/25mm, 2800gf/25mm or 3000gf/25mm, but not limited to the listed values, other unlisted values within the value range are also applicable.
  • the viscosity of the magnetic slurry in step (4) is 15000-25000mpa.s, for example, it can be 15000mpa.s, 17000mpa.s, 19000mpa.s, 21000mpa.s, 23000mpa.s or 25000mpa.s. However, it is not limited to the listed values, and other unlisted values within the numerical range are also applicable.
  • the amount of epoxy resin added in this application is to ensure a certain bonding strength between the cast body and the coil and T-shaped base assembly, while also ensuring that the cast body has a certain magnetic permeability after curing.
  • the epoxy resin is added in a small amount, the bonding strength between the cast body and the assembly is reduced, resulting in falling off. Adding too much epoxy resin will cause the magnetic permeability of the cast body to decrease, and the inductance value of the inductor will not meet the technical requirements.
  • the curing agent includes any one or a combination of at least two of ethylenediamine, diethylenetriamine, diethyltoluenediamine or dicyandiamide.
  • Typical but non-limiting combinations include ethylenediamine.
  • the organic solvent includes any one or a combination of at least two of ethyl acetate, n-propanol, isopropanol or ethanol.
  • Typical but non-limiting combinations include a combination of n-propanol and isopropanol.
  • the preparation method of the magnetic slurry in step (4) includes:
  • step (4.2) Add the composite soft magnetic alloy material to the organic mixture obtained in step (4.1), and stir for 4-12 hours to obtain a semi-finished soft magnetic alloy powder slurry;
  • step (4.3) Mix and stir the curing agent and the soft magnetic alloy powder slurry semi-finished product obtained in step (4.2) for 20-40 minutes, and then vacuum degassing to obtain the magnetic slurry.
  • the first powder includes any one or a combination of at least two of FeSiAl powder, FeSi powder, FeNi powder or amorphous powder;
  • the D50 of the first powder is 100-150 ⁇ m, for example, it can be 100 ⁇ m, 110 ⁇ m, 120 ⁇ m, 130 ⁇ m, 140 ⁇ m or 150 ⁇ m, but are not limited to the listed values, and other unlisted values within the numerical range are also applicable.
  • the second powder includes any one or a combination of at least two of FeSiAl powder, FeSi powder, FeNi powder or amorphous powder;
  • the D50 of the second powder is 20-50 ⁇ m, for example, it can be 20 ⁇ m, 25 ⁇ m, 30 ⁇ m, 35 ⁇ m, 40 ⁇ m, 45 ⁇ m or 50 ⁇ m, but is not limited to the listed values. Other unlisted values within the numerical range are the same. Be applicable.
  • the third powder includes any one or a combination of at least two of FeSiAl powder, FeSi powder, FeNi or amorphous powder;
  • the mass ratio of the first powder, the second powder and the third powder is 6:(1-3):(1-3), for example, it can be 6:1:1, 6:1: 3. 6:3:1, 6:2:3, 6:3:3 or 6:3:2, but not limited to the listed values. Other unlisted values within the value range are also applicable.
  • the amorphous powder material includes FeSiBCr.
  • the composite soft magnetic alloy material described in this application is made of a first powder (coarse powder), a second powder (medium powder) and a third powder (fine powder) with completely different particle sizes.
  • the coarse and The medium and fine powders need to be annealed at high temperatures respectively before mixing to eliminate internal stress and help reduce hysteresis loss.
  • the coarse powder in the composite soft magnetic alloy material provided by this application has a much larger particle size than the powder used in the traditional molding process.
  • the three kinds of coarse, medium and fine powders are mixed and matched, and the medium and fine powder particles fully fill the gaps between the coarse powder particles, thereby increasing the filling density of the slurry and achieving higher magnetic permeability of the cast body.
  • the slurry used in the cast body has a high epoxy resin content. In addition to improving the strength of the product, it can also better insulate the soft magnetic alloy powder, increase its resistivity, and reduce eddy current losses.
  • the height of the pouring mold in step (4) is 0.4-1.5mm greater than the height of the inductor, for example, it can be 0.4mm, 0.5mm, 0.6mm, 0.7mm, 0.8mm, 0.9mm, 1mm, 1.2mm, 1.4mm or 1.5mm, but not limited to the listed values, other unlisted values within the range of values are also applicable; preferably 0.6-1.2mm.
  • the height of the mold is required to be greater than the height of the inductor in order to reserve the space for the slurry to collect.
  • the amount of shrinkage and the amount that needs to be polished after the cast body is solidified.
  • the curing in step (5) includes sequential first-level curing, second-level curing and third-level curing.
  • the curing described in this application adopts a staged curing process. First, it is cured at low temperature for a long time, and then the temperature is gradually raised. The purpose is to ensure that the pouring body is dense during the curing process of the epoxy resin and avoid the formation of holes. Because thermosetting epoxy resin cures faster when cured at high temperatures, and curing is an exothermic reaction, which will accelerate the curing speed in a short time, which can easily lead to a "boiling" phenomenon. After curing, pores remain in the pouring body, causing pouring The bulk magnetic permeability and strength decrease.
  • the temperature of the first stage of curing is 80-100°C, for example, it can be 80°C, 84°C, 88°C, 92°C, 96°C or 100°C, but is not limited to the listed values, other values within the range The same applies to non-enumerated values.
  • the temperature of the second-stage curing is 120-140°C, for example, it can be 120°C, 124°C, 128°C, 132°C, 136°C or 140°C, but is not limited to the listed values, other values within the range The same applies to non-enumerated values.
  • the heat preservation time of the second-stage curing is 0.5-2h, for example, it can be 0.5h, 0.8h, 1h, 1.2h, 1.4h, 1.6h, 1.8h or 2h, but is not limited to the listed values. The same applies to other values within the numerical range that are not listed.
  • the third stage curing temperature is 150-200°C, for example, it can be 150°C, 155°C, 160°C, 165°C, 170°C, 175°C, 180°C, 185°C, 190°C, 195°C or 200°C, but not limited to the listed values, other unlisted values within the value range are also applicable.
  • the holding time of the third stage of curing is 1-3h, for example, it can be 1h, 1.2h, 1.4h, 1.6h, 1.8h, 2h, 2.2h, 2.4h, 2.6h, 2.8h or 3h, However, it is not limited to the listed values, and other unlisted values within the numerical range are also applicable.
  • step (5) of this application can not only accurately control the height of the inductor, but also ensure that the surface of the pouring body is flat.
  • step (6) of this application is performed using a dicing machine or wire cutting.
  • the UV adhesive film is pasted on the surface of the cast body polished in step (5), and then the surface with the UV adhesive film is placed on the workbench.
  • the UV adhesive film together with the polished inductor body is fixed through the vacuum suction cup on the workbench.
  • Set The starting mark and the moving distance of the workbench are determined to divide the polished inductor body into n ⁇ m inductor bodies.
  • the moving spacing of the workbench is determined according to the length and width of the inductor product.
  • step (1.2) Mix binder, curing agent, acetone and the composite soft magnetic alloy powder obtained in step (1.1) to obtain prefabricated powder;
  • step (4.2) Add the composite soft magnetic alloy material to the organic mixture obtained in step (4.1), and after stirring for 4-12 hours, a soft magnetic alloy powder slurry semi-finished product is obtained; wherein the composite soft magnetic alloy material is the first powder, A mixture of the second powder and the third powder; the D50 of the first powder is 100-150 ⁇ m, the D50 of the second powder is 20-50 ⁇ m, and the D50 of the third powder is 4-10 ⁇ m. ;
  • the second assembly obtained in step (4) is sequentially cured, demoulded and polished to obtain an inductor body; the curing process includes sequential first-stage curing, second-stage curing and third-stage curing. Stage curing; the temperature of the first stage curing is 80-100°C, and the holding time is 2-4h; so The temperature of the second-stage curing is 120-140°C, and the holding time is 0.5-2h; the temperature of the third-stage curing is 150-200°C, and the holding time is 1-3h;
  • step (5) Post-processing: The inductor blank obtained in step (5) is sequentially cut, sprayed and electroplated to obtain the cast power inductor.
  • the cast power inductor provided by the embodiment of the present application realizes pressure-free molding by pouring magnetic slurry, which prevents the coil from being short-circuited, broken, or deflected to the edge of the inductor due to excessive pressure; effectively improving the reliability of the inductor and the finished product Rate.
  • Figure 1 is a schematic structural diagram of a cast power inductor provided in Embodiment 1 of the present application;
  • Figure 3 is a schematic structural diagram of the inductor body provided in Embodiment 1 of the present application.
  • 1 is a T-shaped base
  • 2 is an air-core coil
  • 3 is a casting body
  • 4 is a center column
  • 13 is a wire trough.
  • the cast power inductor includes a T-shaped base 1, an air-core coil 2 and a cast body 3;
  • the T-shaped base 1 includes a bottom hem and a center column 4; the center column 4 is fixedly arranged at the center of the hem; the air-core coil 2 is tightly wound on the center column 4; and the casting body 3 is used for wrapping. T-shaped base 1 and air-core coil 2.
  • the preparation method of the cast power inductor includes the following steps:
  • Green body preparation Put the prefabricated powder into a T-shaped mold of preset size and perform hot-pressing molding, and then bake it at 220°C to obtain a T-shaped base; the hot-pressing molding temperature is 180°C , the pressure is 450MPa;
  • step (1.2) Mix binder, curing agent, acetone and the composite soft magnetic alloy powder obtained in step (1.1) to obtain prefabricated powder;
  • step (4.2) Add the composite soft magnetic alloy material to the organic mixture obtained in step (4.1), and after stirring for 10 hours, a soft magnetic alloy powder slurry semi-finished product is obtained; wherein the composite soft magnetic alloy material is the first powder, the second A mixture of powder and third powder; the D50 of the first powder is 146.8 ⁇ m, the D50 of the second powder is 49.6 ⁇ m, and the D50 of the third powder is 8.9 ⁇ m; the D50 of the first powder is 146.8 ⁇ m.
  • the mass ratio of the powder, the second powder and the third powder is 6:1:3;
  • step (4.3) Mix and stir ethylenediamine and the soft magnetic alloy powder slurry semi-finished product obtained in step (4.2) for 30 minutes, and then vacuum degassing to obtain the magnetic slurry;
  • the second assembly obtained in step (4) is sequentially cured, demoulded and polished to obtain the inductor body as shown in Figure 3; the curing process includes the first-level curing, the third-level curing, and the second-level curing.
  • Second-level curing and third-level curing the temperature of the first-level curing is 80°C, and the holding time is 4h; the second-stage curing temperature is 125°C, and the holding time is 1h; the third-stage curing temperature is 180°C, and the holding time is 1h;
  • step (5) Post-processing: The inductor blank obtained in step (5) is sequentially cut, sprayed and electroplated to obtain the cast power inductor.
  • the size of the cast power inductor prepared in this embodiment is 2.5 ⁇ 2.0 ⁇ 1.0mm.
  • This embodiment provides a cast power inductor, which is the same as the embodiment.
  • This embodiment provides a cast power inductor, which is the same as the embodiment.
  • This embodiment provides a cast power inductor, which is the same as the embodiment.

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  • Manufacturing & Machinery (AREA)
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Abstract

本文公布一种浇注式功率电感，所述浇注式功率电感包括底座、空心线圈以及浇注体；所述底座包括下摆以及中柱；所述中柱固定设置于下摆的中心位置；所述空心线圈紧密绕制在所述中柱上；所述浇注体用于包裹底座和空心线圈。所述浇注式功率电感的制备方法包括依次进行的坯体配制、绕制线圈、组合体排布、浆料浇注、固化处理以及后处理。本申请提供的浇注式功率电感通过浇注磁性浆料的方法实现无压成型，避免线圈由于压力过大导致短路、断路或者偏移到电感边缘；有效提高了电感的可靠性和产品的成品率。

Description

一种浇注式功率电感及其制备方法 技术领域
本申请实施例涉及电子元器件技术领域，例如一种功率电感，尤其涉及一种浇注式功率电感及其制备方法。
背景技术
随着科学技术的快速发展，对电子产品性能和可靠性的要求也越发严格，电感作为电子电路三大被动元件之一，在电路中起到滤波、振荡、过滤噪音、稳定电流及抑制电磁波干扰等，当今时代技术日新月异，电感使用的电流和频率的要求越来越高，传统的干压一体成型电感所需的成型压强较大，容易导致电感内部线圈产生较大的形变，或是铜线表面的绝缘漆破坏，压制过程中导致开路、短路现象发生；此外，干压成型工艺对成型设备和模具要求较高，受压机吨位和模具设计所致，限制了产品的生产效率，电感的生产成本也居高不下。
为此，磁性浆料浇筑成型作为研究的重点，但该工艺是将磁性材料混合胶水形成具有较高粘度的胶状，导致磁性粉末的固含量相比模压成型降低，从而使得电感感值不高。
CN 213752214U公开了一种浇注电感，所述浇注电感包括盒体和导体线圈，盒体由磁性粉料压制形成，导体线圈设置于盒体内且导体线圈的引线端从盒体内伸出，盒体内浇注有磁性浆料，磁性浆料与盒体的开口边缘平齐，盒体、导体线圈和磁性浆料整体浇注成型。该专利提供的浇注电感通过浇注成型，无须对线圈进行压合，避免线圈的变形，又可以有效避免漏磁。但是该实用新型专利采用先用磁粉压制成型盒体，在在盒体内分别设置线圈并进行浇注，工序复杂繁琐，生产效率低下。当生产微小型电感时，盒体壁较薄，组装过程中极容易破损，不适合大规模生产小尺寸电感。
CN 112397295A公开了一种一体成型电感的制造方法，所述制造方法包括：先将软磁合金材料预压成一个平板坯和T形坯体，然后在T形坯体的柱状凸起处进行精密绕制漆包线，再将绕有漆包线的T形坯体呈“丄”形置于热压模具内，并将预制的平板坯体置于T形坯体的上方，进行热压成型，得到一体成型的电感坯体，最后将电感坯体进行喷涂、电镀电极，便得到一体成型电感。该专利 提供的制造方法只是解决了一体成型电感生产中由于预制粉料颗粒的不均匀使得成型阶段填入模具各个型腔中粉料量存在较大偏差，造成压制出的电感坯件存在较大的尺寸、重量及性能偏差，以及不良品中已含漆包线等组件，粉料难以回收再利用的。依然无法避免因为模压过程中电感内部线圈产生较大的形变，或者漆包线表面的绝缘漆破坏出现开路、短路现象发生。
综上所述，本领域亟需提供一种电感及其制备方法，以解决相关技术中所需成型压强大、成型设备要求高以及由于成型压强过大导致铜线受损出现短路、断路等技术问题。
发明内容
以下是对本文详细描述的主题的概述。本概述并非是为了限制权利要求的保护范围。
本申请实施例提供一种浇注式功率电感及其制备方法。所述浇注式功率电感通过浇注磁性浆料的方法实现无压成型，避免线圈由于压力过大导致短路、断路或者偏移到电感边缘；有效提高了电感的可靠性和产品的成品率。
第一方面，本申请实施例提供了一种浇注式功率电感，所述浇注式功率电感包括T形底座、空心线圈以及浇注体；
所述底座包括下摆以及中柱；
所述中柱固定设置于下摆的中心位置；
所述空心线圈紧密绕制在所述中柱上；
所述浇注体用于包裹底座和空心线圈。
本申请提供的浇注式功率电感解决了相关技术所需成型压强大、成型设备要求高以及由于成型压强过大导致铜线受损出现短路、断路等技术问题
优选地，所述下摆的一侧设置有线槽。
优选地，所述空心线圈的两端引脚通过线槽设置于下摆的底部。
第二方面，本申请实施例提供了一种如第一方面所提供的浇注式功率电感的制备方法，所述制备方法包括如下步骤：
(1)坯体配制：将预制粉料装入一预设尺寸的T形模具并进行热压成型，而后进行烘烤，得到T形底座；
(2)绕制线圈：在步骤(1)所得T形底座的中柱上绕制漆包线，并将两 端引脚折弯后贴合到所述T形底座的下摆底部，得到组合体；
(3)组合体排布：将步骤(2)所得组合体等间距、呈n×m矩阵排列粘贴在热敏胶膜上；
(4)浆料浇注：在所述热敏胶膜上方安装浇注模具，并注入磁性浆料，得到第二组合体；
(5)固化处理：将步骤(4)所得第二组合体依次进行固化处理、脱模以及打磨后得到电感坯体；
(6)后处理：将步骤(5)所得电感坯体依次进行切割、喷涂以及电镀后得到所述浇注式功率电感。
本申请提供的浇注式功率电感的制备方法采用无压力进行一次成型，解决了相关技术所需成型压强大、成型设备要求高以及由于成型压强过大导致铜线受损出现短路、断路等技术问题。
优选地，步骤(1)所述预制粉料的制备方法包括：
(1.1)混合主体粉料和辅助粉料，得到复合软磁合金粉；
(1.2)混合粘结剂、固化剂、丙酮和步骤(1.1)所得复合软磁合金粉，得到预制粉料。
优选地，步骤(1.1)所述主体粉料包括FeSiAl粉末、FeSi粉末或FeNi粉末中的任意一种或至少两种的组合，典型但非限制性的组合包括FeSiAl粉末、FeSi粉末和FeNi粉末的组合，FeSiAl粉末和FeSi粉末的组合，FeSiAl粉末和FeNi粉末的组合，或FeSi粉末和FeNi粉末的组合。
优选地，步骤(1.1)所述主体粉料的D50为20-40μm，例如可以是20μm、25μm、30μm、35μm或40μm，但不限于所列举的数值，数值范围内其他未列举的数值同样适用。
优选地，步骤(1.1)所述辅助粉料包括FeSiAl粉末、FeSi粉末或FeNi粉末中的任意一种或至少两种的组合，典型但非限制性的组合包括FeSiAl粉末、FeSi粉末和FeNi粉末的组合，FeSiAl粉末和FeSi粉末的组合，FeSiAl粉末和FeNi粉末的组合，或FeSi粉末和FeNi粉末的组合。
优选地，步骤(1.1)所述辅助粉料的D50为2-10μm，例如可以是2μm、3μm、4μm、5μm、6μm、7μm、8μm、9μm或10μm，但不限于所列举的数值，数值范围内其他未列举的数值同样适用。
本申请步骤(1.1)所述复合软磁合金粉中主体粉料和辅助粉料的组成可以完全相同，材料的选择根据具体是应用需求而定。FeSiAl材料其硬度、饱和磁感应强度Bs、磁导率和电阻率都较高，成本低；缺点是磁性能对成分起伏敏感，脆性大，加工性能差。FeSi材料有比FeSiAl更高的饱和磁感应强度，具有更高的储存能量的能力，适合大电流工作条件。FeNi与铁硅铝相比，它具有更优的直流叠加特性，由于粉末中含有50％左右的镍，材料成本较高。
优选地，步骤(1)所述热压成型的温度为160-240℃，例如可以是160℃、170℃、180℃、190℃、200℃、210℃、220℃、230℃或240℃，但不限于所列举的数值，数值范围内其他未列举的数值同样适用。
优选地，步骤(1)所述热压成型的压力为300-600MPa，例如可以是300MPa、350MPa、400MPa、450MPa、500MPa、550MPa或600MPa，但不限于所列举的数值，数值范围内其他未列举的数值同样适用。
优选地，步骤(1)所述烘烤的温度为180-260℃，例如可以是180℃、190℃、200℃、210℃、220℃、230℃、240℃、250℃或260℃，但不限于所列举的数值，数值范围内其他未列举的数值同样适用。
本申请所述热压成型的目的是为了保证T形坯体能够获得较好的强度，防止绕制线圈的制备过程中T形底座上的中柱发生断裂现象。
优选地，步骤(3)所述组合体的间距为0.5-2mm，例如可以是0.5mm、0.8mm、1mm、1.2mm、1.4mm、1.6mm、1.8mm或2mm，但不限于所列举的数值，数值范围内其他未列举的数值同样适用。
所述组合体之间保留间距主要是为了能够让浇注体完整包裹起来，有效保证浇注体与组合体之间的粘合。
优选地，步骤(3)所述热敏胶膜中热敏胶的附着力为2000-3000gf/25mm，例如可以是2000gf/25mm、2200gf/25mm、2400gf/25mm、2600gf/25mm、2800gf/25mm或3000gf/25mm，但不限于所列举的数值，数值范围内其他未列举的数值同样适用。
本申请所述热敏胶的附着力的限定范围是为了保证线圈和T形底座能通过热敏胶紧密黏连。
优选地，步骤(4)所述磁性浆料的粘度为15000-25000mpa.s，例如可以是15000mpa.s、17000mpa.s、19000mpa.s、21000mpa.s、23000mpa.s或25000mpa.s， 但不限于所列举的数值，数值范围内其他未列举的数值同样适用。
本申请步骤(4)所述磁性浆料在频率为100kHz时，其磁导率为25-35。
优选地，步骤(4)所述磁性浆料的原料按重量份计，包括：100份复合软磁合金材料，2-8份环氧树脂，例如可以是2份、3份、4份、5份、6份、7份或8份，但不限于所列举的数值，数值范围内其他未列举的数值同样适用；0.5-2.5份固化剂，例如可以是0.5份、0.8份、1份、1.4份、1.8份、2.2份或2.5份，但不限于所列举的数值，数值范围内其他未列举的数值同样适用；2-6份有机溶剂，例如可以是2份3份、4份、5份或6份，但不限于所列举的数值，数值范围内其他未列举的数值同样适用。
本申请中环氧树脂的添加量是兼顾浇注体与线圈和T形底座组合体之间具有一定的粘结强度，同时还要保证浇注体固化后所具有一定的磁导率。所述环氧树脂添加量较少时，浇注体与组合体之间因粘结强度降低导致脱落。所述环氧树脂添加量过多，会导致浇注体的磁导率降低，电感的感值达不到技术要求。
优选地，所述固化剂包括乙二胺、二亚乙基三胺、二乙基甲苯二胺或双氰胺中的任意一种或至少两种的组合，典型但非限制性的组合包括乙二胺和二亚乙基三胺的组合，或二乙基甲苯二胺和双氰胺的组合。
优选地，所述有机溶剂包括乙酸乙酯、正丙醇、异丙醇或乙醇中的任意一种或至少两种的组合，典型但非限制性的组合包括正丙醇和异丙醇的组合，正丙醇和乙醇的组合，或乙酸乙酯和乙醇的组合。
优选地，步骤(4)所述磁性浆料的制备方法包括：
(4.1)将环氧树脂以及有机溶剂混合，搅拌混合1-3h后得到有机混合物；
(4.2)将复合软磁合金材料添加至步骤(4.1)所得有机混合物中，搅拌4-12h后，得到软磁合金粉浆料半成品；
(4.3)混合搅拌20-40min固化剂以及步骤(4.2)所得软磁合金粉浆料半成品，而后真空脱泡后得到所述磁性浆料。
优选地，步骤(4.2)所述复合软磁合金材料为第一粉料、第二粉料以及第三粉料的混合物。
优选地，所述第一粉料包括FeSiAl粉末、FeSi粉末、FeNi粉末或非晶粉末中的任意一种或至少两种的组合；
优选地，所述第一粉料的D50为100-150μm，例如可以是100μm、110μm、 120μm、130μm、140μm或150μm，但不限于所列举的数值，数值范围内其他未列举的数值同样适用。
优选地，所述第二粉料包括FeSiAl粉末、FeSi粉末、FeNi粉末或非晶粉末中的任意一种或至少两种的组合；
优选地，所述第二粉料的D50为20-50μm，例如可以是20μm、25μm、30μm、35μm、40μm、45μm或50μm，但不限于所列举的数值，数值范围内其他未列举的数值同样适用。
优选地，所述第三粉料包括FeSiAl粉末、FeSi粉末、FeNi或非晶粉末中的任意一种或至少两种的组合；
优选地，所述第三粉料的D50为4-10μm，例如可以是4μm、5μm、6μm、7μm、8μm、9μm或10μm，但不限于所列举的数值，数值范围内其他未列举的数值同样适用。
优选地，所述第一粉料、第二粉料以及第三粉料的质量比为6:(1-3):(1-3)，例如可以是6:1:1、6:1:3、6:3:1、6:2:3、6:3:3或6:3:2，但不限于所列举的数值，数值范围内其他未列举的数值同样适用。
优选地，所述非晶粉料包括FeSiBCr。
本申请所述复合软磁合金材料采用粒径完全不同的第一粉料(粗粉料)、第二粉料(中粉料)以及第三粉料(细粉料)混合而成，粗、中、细三种粉料混合前需要经各自高温退火，消除内应力，有利于降低磁滞损耗。
本申请提供的复合软磁合金材料中粗粉料相对传统模压工艺所用粉料粒度大很多。所述的粗、中、细三种粉料混合搭配，中、细粉料颗粒充分填充粗粉料颗粒的间隙，提高浆料的填充密度，实现浇注体获得较高磁导率。弥补无压状态下磁导率低的问题。此外，浇筑体所用浆料的环氧树脂含量高，除了提高产品强度外，还可以较好的绝缘软磁合金粉料，提高其电阻率，起到降低涡流损耗的作用。
优选地，步骤(4)所述浇注模具的高度大于所述电感高度的0.4-1.5mm，例如可以是0.4mm、0.5mm、0.6mm、0.7mm、0.8mm、0.9mm、1mm、1.2mm、1.4mm或1.5mm，但不限于所列举的数值，数值范围内其他未列举的数值同样适用；优选为0.6-1.2mm。
本申请所述浇注过程中要求模具高度大于电感高度，是为了预留浆料的收 缩余量和浇注体固化后还需打磨的余量。
优选地，步骤(5)所述固化包括依次进行的第一级固化、第二级固化以及第三级固化。
本申请所述固化采取分阶段固化工艺，首先低温长时间固化，再逐渐提升温度，其目的是为了确保环氧树脂固化过程中浇注体内致密，避免有孔洞产生。因为热固型环氧树脂在高温固化时固化速度加快，同时固化是放热反应，在短时间会更加促进固化速度，极易导致出现“沸腾”现象，固化后在浇注体内残留气孔，导致浇注体磁导率和强度降低。
优选地，所述第一级固化的温度为80-100℃，例如可以是80℃、84℃、88℃、92℃、96℃或100℃，但不限于所列举的数值，数值范围内其他未列举的数值同样适用。
优选地，所述第一级固化的保温时间为2-4h，例如可以是2h、2.2h、2.4h、2.6h、2.8h、3h、3.2h、3.4h、3.6h、3.8h或4h，但不限于所列举的数值，数值范围内其他未列举的数值同样适用。
优选地，所述第二级固化的温度为120-140℃，例如可以是120℃、124℃、128℃、132℃、136℃或140℃，但不限于所列举的数值，数值范围内其他未列举的数值同样适用。
优选地，所述第二级固化的保温时间为0.5-2h，例如可以是0.5h、0.8h、1h、1.2h、1.4h、1.6h、1.8h或2h，但不限于所列举的数值，数值范围内其他未列举的数值同样适用。
优选地，所述第三级固化的温度为150-200℃，例如可以是150℃、155℃、160℃、165℃、170℃、175℃、180℃、185℃、190℃、195℃或200℃，但不限于所列举的数值，数值范围内其他未列举的数值同样适用。
优选地，所述第三级固化的保温时间为1-3h，例如可以是1h、1.2h、1.4h、1.6h、1.8h、2h、2.2h、2.4h、2.6h、2.8h或3h，但不限于所列举的数值，数值范围内其他未列举的数值同样适用。
优选地，步骤(6)所述喷涂后还包括对喷涂材料后的烘烤处理。
本申请步骤(5)所述打磨不仅可以精确控制电感高度，还可以保证浇注体表明平整。
本申请步骤(6)所述切割采用划片机或线切割的方式进行切割。首先，将 UV胶膜粘贴在步骤(5)打磨的浇注体表面，再将贴有UV胶膜面放置在作业台上，通过作业台上的真空吸盘将UV胶膜连同打磨后的电感坯体固定，设定起始标记和作业台的移动间距将打磨后的电感坯体分割成n×m颗电感坯体，作业台的移动间距依据电感产品的长、宽尺寸而定。
作为本申请的优选技术方案，本申请第二方面提供的所述浇注式功率电感的制备方法包括如下步骤：
(1)坯体配制：将预制粉料装入一预设尺寸的T形模具并进行热压成型，而后在180-260℃下进行烘烤，得到T形底座；其中热压成型的温度为160-240℃，压力为300-600MPa；
(1.1)混合主体粉料和辅助粉料，得到复合软磁合金粉；其中主体粉料的D50为20-40μm，辅助粉料的D50为2-10μm；
(1.2)混合粘结剂、固化剂、丙酮以及步骤(1.1)所得复合软磁合金粉，得到预制粉料；
(2)绕制线圈：在步骤(1)所得T形底座的中柱上绕制漆包线，并将两端引脚折弯后贴合到所述T形底座的下摆底部，得到组合体；
(3)组合体排布：将步骤(2)所得组合体等间距、呈n×m矩阵排列粘贴在附着力为2000-3000gf/25mm的热敏胶膜上；其中组合体的间距为0.5-2mm；
(4)浆料浇注：在所述热敏胶膜上方安装浇注模具，并注入粘度为15000-25000mpa.s的磁性浆料，得到第二组合体；其中，所述浇注模具的高度大于所述电感高度的0.4-1.5mm；
(4.1)将环氧树脂以及有机溶剂混合，搅拌混合1-3h后得到有机混合物；
(4.2)将复合软磁合金材料添加至步骤(4.1)所得有机混合物中，搅拌4-12h后，得到软磁合金粉浆料半成品；其中，所述复合软磁合金材料为第一粉料、第二粉料以及第三粉料的混合物；所述第一粉料的D50为100-150μm，所述第二粉料的D50为20-50μm，所述第三粉料的D50为4-10μm；
(4.3)混合搅拌20-40min固化剂以及步骤(4.2)所得软磁合金粉浆料半成品，而后真空脱泡后得到所述磁性浆料；
(5)固化处理：将步骤(4)所得第二组合体依次进行固化处理、脱模以及打磨后得到电感坯体；其中固化处理包括依次进行的第一级固化、第二级固化以及第三级固化；所述第一级固化的温度为80-100℃，保温时间为2-4h；所 述第二级固化的温度为120-140℃，保温时间为0.5-2h；所述第三级固化的温度为150-200℃，保温时间为1-3h；
(6)后处理：将步骤(5)所得电感坯体依次进行切割、喷涂以及电镀后得到所述浇注式功率电感。
本申请所述的数值范围不仅包括上述例举的点值，还包括没有例举出的上述数值范围之间的任意的点值，限于篇幅及出于简明的考虑，本申请不再穷尽列举所述范围包括的具体点值。
相对于相关技术，本申请实施例具有以下有益效果：
本申请实施例提供的浇注式功率电感通过浇注磁性浆料的方法实现无压成型，避免线圈由于压力过大导致短路、断路或者偏移到电感边缘；有效提高了电感的可靠性和产品的成品率。
在阅读并理解了附图和详细描述后，可以明白其他方面。
附图说明
附图用来提供对本文技术方案的进一步理解，并且构成说明书的一部分，与本申请的实施例一起用于解释本文的技术方案，并不构成对本文技术方案的限制。
图1为本申请实施例1提供的浇注式功率电感的结构示意图；
图2为本申请实施例1提供的浇注式功率电感的侧面剖视图；
图3为本申请实施例1提供的电感坯体的结构示意图。
其中，1为T形底座，2为空心线圈，3为浇注体，4为中柱，13为线槽。
具体实施方式
下面通过具体实施方式来进一步说明本申请的技术方案。本领域技术人员应该明了，所述实施例仅仅是帮助理解本申请，不应视为对本申请的具体限制。
实施例1
本实施例提供了一种如图1所示的浇注式功率电感，所述浇注式功率电感包括T形底座1、空心线圈2以及浇注体3；
所述T形底座1包括下摆以及中柱4；所述中柱4固定设置于下摆的中心位置；所述空心线圈2紧密绕制在所述中柱4上；所述浇注体3用于包裹T形底座1和空心线圈2。
所述下摆的一侧设置有线槽13；所述空心线圈2的两端引脚通过线槽12设置于下摆的底部。
所述浇注式功率电感的侧面剖视图如图2所示。
所述浇注式功率电感的制备方法包括如下步骤：
(1)坯体配制：将预制粉料装入一预设尺寸的T形模具并进行热压成型，而后在220℃下进行烘烤，得到T形底座；其中热压成型的温度为180℃，压力为450MPa；
(1.1)混合主体粉料和辅助粉料，得到复合软磁合金粉；其中主体粉料的D50为39.84μm，辅助粉料的D50为9.58μm；
(1.2)混合粘结剂、固化剂、丙酮以及步骤(1.1)所得复合软磁合金粉，得到预制粉料；
(2)绕制线圈：在步骤(1)所得T形底座的中柱上绕制漆包线，并将两端引脚折弯后贴合到所述T形底座的下摆底部，得到组合体；
(3)组合体排布：将步骤(2)所得组合体等间距、呈n×m矩阵排列粘贴在附着力为2000-3000gf/25mm的热敏胶膜上；其中组合体的间距为2mm；
(4)浆料浇注：在所述热敏胶膜上方安装浇注模具，并注入粘度为20000mpa.s的磁性浆料，得到第二组合体；其中，所述浇注模具的高度大于所述电感高度的1.2mm；所述磁性浆料的原料按重量份计，包括：100份复合软磁合金材料，4份环氧树脂，1.12份乙二胺，3.60份乙酸乙酯；
(4.1)将环氧树脂以及乙酸乙酯混合，搅拌混合2h后得到有机混合物；
(4.2)将复合软磁合金材料添加至步骤(4.1)所得有机混合物中，搅拌10h后，得到软磁合金粉浆料半成品；其中，所述复合软磁合金材料为第一粉料、第二粉料以及第三粉料的混合物；所述第一粉料的D50为146.8μm，所述第二粉料的D50为49.6μm，所述第三粉料的D50为8.9μm；所述第一粉料、第二粉料以及第三粉料的质量比为6:1:3；
(4.3)混合搅拌30min乙二胺以及步骤(4.2)所得软磁合金粉浆料半成品，而后真空脱泡后得到所述磁性浆料；
(5)固化处理：将步骤(4)所得第二组合体依次进行固化处理、脱模以及打磨后得到如图3所示的电感坯体；其中固化处理包括依次进行的第一级固化、第二级固化以及第三级固化；所述第一级固化的温度为80℃，保温时间为 4h；所述第二级固化的温度为125℃，保温时间为1h；所述第三级固化的温度为180℃，保温时间为1h；
(6)后处理：将步骤(5)所得电感坯体依次进行切割、喷涂以及电镀后得到所述浇注式功率电感。
本实施例制备得到的浇注式功率电感的尺寸为2.5×2.0×1.0mm。
本实施例步骤(4)所得磁性浆料在频率f＝1MHz时，测试其磁导率为32.8。
实施例2
本实施例提供了一种浇注式功率电感，所述浇注式功率电感与实施例相同。
所述浇注式功率电感的制备方法与实施例1的区别仅在于：本实施例将步骤(4)中制备磁性浆料时原料的重量比更改为：100份复合软磁合金材料，2.4份环氧树脂，0.67份乙二胺，2.8份乙酸乙酯。所述磁性浆料在频率f＝1MHz时，测试其磁导率为34.87。
实施例3
本实施例提供了一种浇注式功率电感，所述浇注式功率电感与实施例相同。
所述浇注式功率电感的制备方法与实施例1的区别仅在于：本实施例将步骤(4)中制备磁性浆料时原料的重量比更改为：100份复合软磁合金材料，6.0份环氧树脂，1.68份乙二胺，4.6份乙酸乙酯。所述磁性浆料在频率f＝1MHz时，测试其磁导率为31.2。
本实施例提供的制备方法中还将步骤(5)所述固化处理中所述第一级固化的温度更改为100℃，保温时间更改为2h；所述第二级固化的温度更改为140℃，保温时间为1h；所述第三级固化的温度更改为200℃，保温时间为1h。
实施例4
本实施例提供了一种浇注式功率电感，所述浇注式功率电感与实施例相同。
所述浇注式功率电感的制备方法与实施例1的区别仅在于：本实施例将步骤(4.2)中所述第一粉料的D50更改为108.34μm，所述第二粉料的D50更改为28.86μm，所述第三粉料的D50更改为4.2μm；所述第一粉料、第二粉料以及第三粉料的质量比为6:2:2。
本实施例步骤(4)所得磁性浆料在频率f＝1MHz时，测试其磁导率为28.84。
实施例5
本实施例提供了一种浇注式功率电感，所述浇注式功率电感与实施例相同。
所述浇注式功率电感的制备方法与实施例1的区别仅在于：本实施例将步骤(4)所述第一粉料、第二粉料以及第三粉料的质量比更改为6:3:1。
本实施例步骤(4)所得磁性浆料在频率f＝1MHz时，测试其磁导率为30.82。
实施例6
本实施例提供了一种浇注式功率电感，所述浇注式功率电感与实施例相同。
所述浇注式功率电感的制备方法与实施例1的区别仅在于：本实施例将步骤(4.2)中所述第一粉料的D50更改为162.83μm，所述第二粉料的D50更改为54.69μm，所述第三粉料的D50更改为10.84μm。
本实施例步骤(4)所得磁性浆料在频率f＝1MHz时，测试其磁导率为38.45。
实施例7
本实施例提供了一种浇注式功率电感，所述浇注式功率电感与实施例相同。
所述浇注式功率电感的制备方法与实施例1的区别仅在于：本实施例将步骤(4)中制备磁性浆料时原料的重量比更改为：100份复合软磁合金材料，1.80份环氧树脂，0.5份乙二胺，6.5份乙酸乙酯。所述磁性浆料在频率f＝1MHz时，测试其磁导率为34.46。
实施例8
本实施例提供了一种浇注式功率电感，所述浇注式功率电感与实施例相同。
所述浇注式功率电感的制备方法与实施例1的区别仅在于：本实施例将步骤(4)中制备磁性浆料时原料的重量比更改为：100份复合软磁合金材料，8.40份环氧树脂，2.35份乙二胺，6份乙酸乙酯。所述磁性浆料在频率f＝1MHz时，测试其磁导率为24.6。
对实施例1-8提供的浇注式功率电感进行尺寸测定、电感性能以及直流电阻的检测，其结果如表1所示。
表1

本申请实施例6提供的浇注式功率电感的涡流损耗过大，温升电流较小，电感效率低；实施例7提供的浇注式功率电感中浇注体与组合体之间的粘合强度第，导致产品脱落；实施例8提供的浇注式功率电感的磁导率较低，导致电感感值达不到技术要求。
综上所述，本申请提供的浇注式功率电感通过浇注磁性浆料的方法实现无压成型，避免线圈由于压力过大导致短路、断路或者偏移到电感边缘；有效提高了电感的可靠性和产品的成品率。
申请人声明，以上所述仅为本申请的具体实施方式，但本申请的保护范围并不局限于此，所属技术领域的技术人员应该明了，任何属于本技术领域的技术人员在本申请揭露的技术范围内，可轻易想到的变化或替换，均落在本申请的保护范围和公开范围之内。

Claims (15)

  1. 一种浇注式功率电感，其包括T形底座、空心线圈以及浇注体；
    所述底座包括下摆以及中柱；
    所述中柱固定设置于下摆的中心位置；
    所述空心线圈紧密绕制在所述中柱上；
    所述浇注体用于包裹底座和空心线圈。
  2. 根据权利要求1所述的浇注式功率电感，其中，所述下摆的一侧设置有线槽。
  3. 根据权利要求2所述的浇注式功率电感，其中，所述空心线圈的两端引脚通过所述线槽设置于下摆的底部。
  4. 一种如权利要求1-3任一项所述浇注式功率电感的制备方法，其包括如下步骤：
    (1)坯体配制：将预制粉料装入一预设尺寸的T形模具并进行热压成型，而后进行烘烤，得到T形底座；
    (2)绕制线圈：在步骤(1)所得T形底座的中柱上绕制漆包线，并将两端引脚折弯后贴合到所述T形底座的下摆底部，得到组合体；
    (3)组合体排布：将步骤(2)所得组合体等间距、呈n×m矩阵排列粘贴在热敏胶膜上；
    (4)浆料浇注：在所述热敏胶膜上方安装浇注模具，并注入磁性浆料，得到第二组合体；
    (5)固化处理：将步骤(4)所得第二组合体依次进行固化处理、脱模以及打磨后得到电感坯体；
    (6)后处理：将步骤(5)所得电感坯体依次进行切割、喷涂以及电镀后得到所述浇注式功率电感。
  5. 根据权利要求4所述的制备方法，其中，步骤(1)所述预制粉料的制备方法包括：
    (1.1)混合主体粉料和辅助粉料，得到复合软磁合金粉；
    (1.2)混合粘结剂、固化剂、丙酮和步骤(1.1)所得复合软磁合金粉，得到预制粉料。
  6. 根据权利要求5所述的制备方法，其中，步骤(1.1)所述主体粉料包括FeSiAl粉末、FeSi粉末或FeNi粉末中的任意一种或至少两种的组合。
  7. 根据权利要求5或6所述的制备方法，其中，步骤(1.1)所述主体粉料的D50为20-40μm。
  8. 根据权利要求5-7任一项所述的制备方法，其中，步骤(1.1)所述辅助粉料包括FeSiAl粉末、FeSi粉末或FeNi粉末中的任意一种或至少两种的组合。
    优选地，步骤(1.1)所述辅助粉料的D50为2-10μm。
  9. 根据权利要求4-8任一项所述的制备方法，其中，步骤(1)所述热压成型的温度为160-240℃；
    优选地，步骤(1)所述热压成型的压力为300-600MPa；
    优选地，步骤(1)所述烘烤的温度为180-260℃。
  10. 根据权利要求4-9任一项所述的制备方法，其中，步骤(3)所述组合体的间距为0.5-2mm；
    优选地，步骤(3)所述热敏胶膜中热敏胶的附着力为2000-3000gf/25mm。
  11. 根据权利要求4-10任一项所述的制备方法，其中，步骤(4)所述磁性浆料的粘度为15000-25000mpa.s；
    优选地，步骤(4)所述磁性浆料的原料按重量份计，包括：100份复合软磁合金材料，2-8份环氧树脂，0.5-2.5份固化剂，2-6份有机溶剂；
    优选地，所述固化剂包括乙二胺、二亚乙基三胺、二乙基甲苯二胺或双氰胺中的任意一种或至少两种的组合；
    优选地，所述有机溶剂包括乙酸乙酯、正丙醇、异丙醇或乙醇中的任意一种或至少两种的组合。
  12. 根据权利要求11所述的制备方法，其中，步骤(4)所述磁性浆料的制备方法包括：
    (4.1)将环氧树脂以及有机溶剂混合，搅拌混合1-3h后得到有机混合物；
    (4.2)将复合软磁合金材料添加至步骤(4.1)所得有机混合物中，搅拌4-12h后，得到软磁合金粉浆料半成品；
    (4.3)混合搅拌20-40min固化剂以及步骤(4.2)所得软磁合金粉浆料半成品，而后真空脱泡后得到所述磁性浆料；
    优选地，步骤(4.2)所述复合软磁合金材料为第一粉料、第二粉料以及第三粉料的混合物；
    优选地，所述第一粉料包括FeSiAl粉末、FeSi粉末、FeNi或非晶粉末中的 任意一种或至少两种的组合；
    优选地，所述第一粉料的D50为100-150μm；
    优选地，所述第二粉料包括FeSiAl粉末、FeSi粉末、FeNi或非晶粉末中的任意一种或至少两种的组合；
    优选地，所述第二粉料的D50为20-50μm；
    优选地，所述第三粉料包括FeSiAl粉末、FeSi粉末、FeNi或非晶粉末中的任意一种或至少两种的组合；
    优选地，所述第三粉料的D50为4-10μm；
    优选地，所述第一粉料、第二粉料以及第三粉料的质量比为6:(1-3):(1-3)；
    优选地，所述非晶粉料包括FeSiBCr。
  13. 根据权利要求4-12任一项所述的制备方法，其中，步骤(4)所述浇注模具的高度大于所述电感高度的0.4-1.5mm，优选为0.6-1.2mm。
  14. 根据权利要求4-13任一项所述的制备方法，其中，步骤(5)所述固化包括依次进行的第一级固化、第二级固化以及第三级固化；
    优选地，所述第一级固化的温度为80-100℃；
    优选地，所述第一级固化的保温时间为2-4h；
    优选地，所述第二级固化的温度为120-140℃；
    优选地，所述第二级固化的保温时间为0.5-2h；
    优选地，所述第三级固化的温度为150-200℃；
    优选地，所述第三级固化的保温时间为1-3h。
  15. 根据权利要求4-14任一项所述的制备方法，其包括如下步骤：
    (1)坯体配制：将预制粉料装入一预设尺寸的T形模具并进行热压成型，而后在180-260℃下进行烘烤，得到T形底座；其中热压成型的温度为160-240℃，压力为300-600MPa；
    (1.1)混合主体粉料和辅助粉料，得到复合软磁合金粉；其中主体粉料的D50为20-40μm，辅助粉料的D50为2-10μm；
    (1.2)混合粘结剂、固化剂、丙酮以及步骤(1.1)所得复合软磁合金粉，得到预制粉料；
    (2)绕制线圈：在步骤(1)所得T形底座的中柱上绕制漆包线，并将两端引脚折弯后贴合到所述T形底座的下摆底部，得到组合体；
    (3)组合体排布：将步骤(2)所得组合体等间距、呈n×m矩阵排列粘贴在附着力为2000-3000gf/25mm的热敏胶膜上；其中组合体的间距为0.5-2mm；
    (4)浆料浇注：在所述热敏胶膜上方安装浇注模具，并注入粘度为15000-25000mpa.s的磁性浆料，得到第二组合体；其中，所述浇注模具的高度大于所述电感高度的0.4-1.5mm；
    (4.1)将环氧树脂以及有机溶剂混合，搅拌混合1-3h后得到有机混合物；
    (4.2)将复合软磁合金材料添加至步骤(4.1)所得有机混合物中，搅拌4-12h后，得到软磁合金粉浆料半成品；其中，所述复合软磁合金材料为第一粉料、第二粉料以及第三粉料的混合物；所述第一粉料的D50为100-150μm，所述第二粉料的D50为20-50μm，所述第三粉料的D50为4-10μm；
    (4.3)混合搅拌20-40min固化剂以及步骤(4.2)所得软磁合金粉浆料半成品，而后真空脱泡后得到所述磁性浆料；
    (5)固化处理：将步骤(4)所得第二组合体依次进行固化处理、脱模以及打磨后得到电感坯体；其中固化处理包括依次进行的第一级固化、第二级固化以及第三级固化；所述第一级固化的温度为80-100℃，保温时间为2-4h；所述第二级固化的温度为120-140℃，保温时间为0.5-2h；所述第三级固化的温度为150-200℃，保温时间为1-3h；
    (6)后处理：将步骤(5)所得电感坯体依次进行切割、喷涂以及电镀后得到所述浇注式功率电感。
PCT/CN2023/074387 2022-06-24 2023-02-03 一种浇注式功率电感及其制备方法 Ceased WO2023246108A1 (zh)

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