CN101901668A - Inducer and production method thereof - Google Patents
Inducer and production method thereof Download PDFInfo
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- CN101901668A CN101901668A CN2009101430769A CN200910143076A CN101901668A CN 101901668 A CN101901668 A CN 101901668A CN 2009101430769 A CN2009101430769 A CN 2009101430769A CN 200910143076 A CN200910143076 A CN 200910143076A CN 101901668 A CN101901668 A CN 101901668A
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- magnaglo
- magnetic
- inductor
- inductor according
- average grain
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 13
- 239000000411 inducer Substances 0.000 title abstract 3
- 239000006247 magnetic powder Substances 0.000 claims abstract description 10
- 238000000034 method Methods 0.000 claims description 45
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 40
- 239000000463 material Substances 0.000 claims description 40
- 239000000853 adhesive Substances 0.000 claims description 31
- 230000008569 process Effects 0.000 claims description 28
- 239000000203 mixture Substances 0.000 claims description 26
- 238000000465 moulding Methods 0.000 claims description 26
- 238000010438 heat treatment Methods 0.000 claims description 21
- 238000004804 winding Methods 0.000 claims description 18
- 229910000808 amorphous metal alloy Inorganic materials 0.000 claims description 12
- 229910052742 iron Inorganic materials 0.000 claims description 12
- 229910000676 Si alloy Inorganic materials 0.000 claims description 7
- 229910001092 metal group alloy Inorganic materials 0.000 claims description 7
- 229910045601 alloy Inorganic materials 0.000 claims description 4
- 239000000956 alloy Substances 0.000 claims description 4
- 239000000843 powder Substances 0.000 claims description 4
- 229920005989 resin Polymers 0.000 claims description 4
- 239000011347 resin Substances 0.000 claims description 4
- 229910000632 Alusil Inorganic materials 0.000 claims description 3
- 229910000640 Fe alloy Inorganic materials 0.000 claims description 3
- 229910001021 Ferroalloy Inorganic materials 0.000 claims description 3
- 229910001030 Iron–nickel alloy Inorganic materials 0.000 claims description 3
- 229920001187 thermosetting polymer Polymers 0.000 claims description 3
- 238000002474 experimental method Methods 0.000 description 16
- 230000035699 permeability Effects 0.000 description 14
- 238000010586 diagram Methods 0.000 description 11
- 230000000694 effects Effects 0.000 description 9
- 238000002360 preparation method Methods 0.000 description 8
- 238000005516 engineering process Methods 0.000 description 6
- 230000008859 change Effects 0.000 description 5
- 238000005452 bending Methods 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 230000002950 deficient Effects 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 239000000696 magnetic material Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 230000003647 oxidation Effects 0.000 description 2
- 238000007254 oxidation reaction Methods 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 238000007493 shaping process Methods 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000003990 capacitor Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000005684 electric field Effects 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 230000004907 flux Effects 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000000750 progressive effect Effects 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 238000012827 research and development Methods 0.000 description 1
- 230000000087 stabilizing effect Effects 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
Images
Classifications
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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
- 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
- H01F1/032—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 hard-magnetic materials
- H01F1/04—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 hard-magnetic materials metals or alloys
- H01F1/047—Alloys characterised by their composition
-
- 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
- H01F1/147—Alloys characterised by their composition
- H01F1/14766—Fe-Si based alloys
- H01F1/14791—Fe-Si-Al based alloys, e.g. Sendust
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F3/00—Cores, Yokes, or armatures
- H01F3/10—Composite arrangements of magnetic circuits
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F3/00—Cores, Yokes, or armatures
- H01F3/10—Composite arrangements of magnetic circuits
- H01F2003/106—Magnetic circuits using combinations of different magnetic materials
-
- 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
Abstract
The invention relates to an inducer and a production method thereof. The inducer comprises a magnetic body and a lead, wherein the magnetic body comprises first magnetic powder and second magnetic powder; the Vickers hardness of the first magnetic powder is greater than that of the second magnetic powder; the average grain diameter of the first magnetic powder is greater than that of the second magnetic powder; and the first magnetic powder is mixed with the second magnetic powder.
Description
Technical field
The present invention relates to a kind of magnetic element and preparation method thereof, particularly relate to a kind of inductor and preparation method thereof.
Background technology
The function of inductor is the electric current in the stabilizing circuit and reaches the effect of filtering noise information, effect is similar with capacitor, be to store, to discharge the stability that the electric energy in the circuit is regulated electric current equally, and be to come store electrical energy with the form of electric field (electric charge) compared to electric capacity, inductor then is to reach with the form in magnetic field.Inductor has the energy loss of lead and the energy loss of magnetic stamen (being commonly referred to as magnetic loss, core loss) on using.
The lead of a kind of inductor in the existing known techniques is embedded in the magnetic in being, and the method that forms this kind inductor is earlier lead to be placed mould, and the suitable iron powder of the particle size that will have adhesive agent is filled in the mould, with coated wire, then, utilize pressure forming that iron powder is pressed into magnetic again, afterwards, the heating adhesive agent is so that its curing.Because during as high frequency more than 10KHz of the inductor of magnetic, permeability can fall sharply with iron powder.Therefore, existing known inductor can't be as the application of high frequency.
This shows that above-mentioned existing inductor and preparation method thereof obviously still has inconvenience and defective, and demands urgently further being improved in product structure, manufacture method and use.In order to solve the problem of above-mentioned existence, relevant manufacturer there's no one who doesn't or isn't seeks solution painstakingly, but do not see always that for a long time suitable design finished by development, and common product and method do not have appropriate structure and method to address the above problem, and this obviously is the problem that the anxious desire of relevant dealer solves.Therefore how to found a kind of new inductor and preparation method thereof, real one of the current important research and development problem that belongs to, also becoming the current industry utmost point needs improved target.
Summary of the invention
The objective of the invention is to, overcome the defective that existing inductor exists, and a kind of new inductor is provided, technical problem to be solved is to make its magnetic contain the multiple Magnaglo of different hardness and different average grain diameters, to promote the permeability of inductor, be very suitable for practicality.
Another object of the present invention is to, overcome the defective of the manufacture method existence of existing inductor, and provide a kind of manufacture method of new inductor, technical problem to be solved is to make it adopt the multiple Magnaglo of different hardness and different average grain diameters to form magnetic, with the permeability of lifting inductor, thereby be suitable for practicality more.
The object of the invention to solve the technical problems realizes by the following technical solutions.A kind of inductor that proposes according to the present invention comprises a magnetic and a lead.Magnetic comprises one first Magnaglo and one second Magnaglo, wherein the Vickers hardness of first Magnaglo (Vicker ' sHardness) is greater than the Vickers hardness of second Magnaglo, and the average grain diameter of first Magnaglo is greater than the average grain diameter of second Magnaglo, and first Magnaglo mixes mutually with second Magnaglo.
The object of the invention to solve the technical problems also can be applied to the following technical measures to achieve further.
In one embodiment of this invention, the Vickers hardness of first Magnaglo is more than or equal to 150, and the Vickers hardness of second Magnaglo is less than or equal to 100.
In one embodiment of this invention, the Vickers hardness of first Magnaglo is more than or equal to 250, and the Vickers hardness of second Magnaglo is less than or equal to 80.
In one embodiment of this invention, the average grain diameter of first Magnaglo is essentially 10 microns to 40 microns.
In one embodiment of this invention, the average grain diameter of second Magnaglo is less than or equal to 10 microns.
In one embodiment of this invention, the average grain diameter of second Magnaglo is essentially and is less than or equal to 4 microns.
In one embodiment of this invention, the ratio of the average grain diameter of the average grain diameter of first Magnaglo and second Magnaglo is greater than 2.
In one embodiment of this invention, the ratio of the average grain diameter of the average grain diameter of first Magnaglo and second Magnaglo is 2.5 to 10.
In one embodiment of this invention, the material of first Magnaglo comprises metal alloy.
In one embodiment of this invention, the material of first Magnaglo comprises siderochrome silicon alloy, iron-nickel alloy, amorphous alloy, ferro-silicium or iron alusil alloy.
In one embodiment of this invention, the material of second Magnaglo comprises iron or ferroalloy.
In one embodiment of this invention, the material of first Magnaglo comprises amorphous alloy, and the material of second Magnaglo comprises iron.
In one embodiment of this invention, the ratio of the weight of the weight of first Magnaglo and second Magnaglo is 0.25 to 4.
In one embodiment of this invention, when the material of first Magnaglo comprises amorphous alloy, and the material of second Magnaglo is when comprising iron, and the ratio of the weight of the weight of first Magnaglo and second Magnaglo is 0.67 to 1.5.
In one embodiment of this invention, when the material of first Magnaglo comprises the siderochrome silicon alloy, and the material of second Magnaglo is when comprising iron, and the ratio of the weight of the weight of first Magnaglo and second Magnaglo is 1.5 to 4.
In one embodiment of this invention, inductor more comprises an adhesive agent, and it engages first Magnaglo and second Magnaglo, and the content of adhesive agent is 2 percentage by weights (the wt%)～3wt% of the total weight of magnetic.
In one embodiment of this invention, the material of adhesive agent is a thermosetting resin.
In one embodiment of this invention, lead have be embedded in one in the magnetic in bury portion or have a winding section that is wound on the magnetic.
In one embodiment of this invention, magnetic utilizes a moulding process (be processing procedure, this paper all is called technology) and forms, and the briquetting pressure of moulding process is 6 tons every square centimeter to 11 tons every square centimeter.
In one embodiment of this invention, magnetic imposes a heating process, and the temperature of heating process is below 300 ℃.
The object of the invention to solve the technical problems also realizes by the following technical solutions.The manufacture method of a kind of inductor that proposes according to the present invention is as described below.At first, provide a lead.Then, one mixture is provided, mixture comprises one first Magnaglo, one second Magnaglo and an adhesive agent, and wherein the Vickers hardness of first Magnaglo is greater than the Vickers hardness of second Magnaglo, and the average grain diameter of first Magnaglo is greater than the average grain diameter of second Magnaglo.Adhesive agent mixes mutually with this first Magnaglo and this second magnetic powder powder.Then, mixture is carried out a moulding process, to form a magnetic.Afterwards, solidify adhesive agent.
The object of the invention to solve the technical problems also can be applied to the following technical measures to achieve further.
In one embodiment of this invention, solidify adhesive agent in the mode of a heating, the temperature of heating is below 300 ℃.
In one embodiment of this invention, in moulding process, apply a briquetting pressure in mixture, briquetting pressure is 6 tons every square centimeter to 11 tons every square centimeter.
In one embodiment of this invention, mixture is carried out in the moulding process, the magnetic coated wire one in bury portion.
In one embodiment of this invention, after solidifying adhesive agent, a winding section of lead is wound on the magnetic.
By technique scheme, inductor of the present invention and preparation method thereof has following advantage and beneficial effect at least: the present invention adopts the different Magnaglo of average grain diameter to form magnetic, therefore, in moulding process, the Magnaglo that average grain diameter is little can be filled up in the space that the big Magnaglo of average grain diameter is asked, and make pressed density increase, and then promote the permeability of inductor.In addition, the present invention adopts the different Magnaglo of hardness to form magnetic, so the strain that Magnaglo is produced in moulding process significantly reduces, and then can reduce the magnetic loss of inductor of the present invention.In addition, the present invention can avoid that inductor is carried out high-temperature heat treatment and eliminates the strain of Magnaglo and can prevent that lead is because of bearing the problem of high temperature oxidation.
In sum, inductor of the present invention and preparation method thereof, this inductor comprise a magnetic and a lead.Magnetic comprises one first Magnaglo and one second Magnaglo, wherein the Vickers hardness of first Magnaglo is greater than the Vickers hardness of second Magnaglo, and the average grain diameter of first Magnaglo is greater than the average grain diameter of second Magnaglo, and first Magnaglo mixes mutually with second Magnaglo.The present invention has obvious improvement technically, and has tangible good effect, really is a new and innovative, progressive, practical new design.
Above-mentioned explanation only is the general introduction of technical solution of the present invention, for can clearer understanding technological means of the present invention, and can be implemented according to the content of specification, and for above-mentioned and other purposes, feature and advantage of the present invention can be become apparent, below especially exemplified by preferred embodiment, and conjunction with figs., be described in detail as follows.
Description of drawings
Fig. 1 illustrates the profile of the inductor of one embodiment of the invention.
Fig. 2 A～Fig. 2 D is the process section of the inductor of Fig. 1 of the present invention.
Fig. 3 illustrates the schematic diagram of the inductor of another embodiment of the present invention.
Fig. 4 illustrates the profile of the inductor of further embodiment of this invention.
Fig. 5 A～Fig. 5 C is the process section of the inductor of Fig. 4 of the present invention.
Fig. 6 illustrates the schematic diagram of the inductor of yet another embodiment of the invention.
When Fig. 7 illustrates first Magnaglo and second Magnaglo ratio in magnetic and changes, the variation situation schematic diagram of the inductance value of inductor under two kinds of frequencies.
Fig. 8 illustrates when first Magnaglo and second Magnaglo ratio in magnetic changes, the variation situation schematic diagram of the inductance value of inductor under two kinds of frequencies.
Fig. 9 illustrates the not inductance value change curve of the inductor of the lead in collinear footpath of employing.
When Figure 10 A illustrates first Magnaglo and second Magnaglo ratio in magnetic and changes, the variation situation schematic diagram of the inductance value of inductor and magnetic density.
When Figure 10 B illustrates first Magnaglo and second Magnaglo ratio in magnetic and changes, the variation situation schematic diagram of the magnetic density of inductor and permeability.
Figure 11 A illustrates when first Magnaglo and second Magnaglo ratio in magnetic changes, and the inductance value of inductor changes situation, and illustrates inductor and change the situation schematic diagrames two kinds of inductance value that apply under the frequency.
Figure 11 B illustrates when first Magnaglo and second Magnaglo ratio in magnetic changes, and the inductance value of inductor changes situation, and the inductance value that illustrates with two kinds of formed inductors of briquetting pressure changes the situation schematic diagram.
Figure 12 illustrates when first Magnaglo and second Magnaglo ratio in magnetic changes, the variation situation schematic diagram of the inductance value of inductor under two kinds of frequencies.
100,200,300: inductor 110,210,310,410: magnetic
114: the second Magnaglos of 112: the first Magnaglos
116: adhesive agent 120,320,420,320: lead
122,222: in bury the 222a of portion: bending structure
124,322,422,322: winding section 312: center pillar
316: the second plate bodys of 314: the first plate bodys
312a, 312b: end 330: magnetic material
412: first surface 414: second surface
416: 418: the three surfaces of perforation
310: formed body C: winding space
D1, D2: average grain diameter E1, E2: end
G: slit M: mixture
S1, S2: sidewall S3: a side
Embodiment
Reach technological means and the effect that predetermined goal of the invention is taked for further setting forth the present invention, below in conjunction with accompanying drawing and preferred embodiment, the inductor that foundation the present invention is proposed and preparation method thereof its embodiment, structure, method, step, feature and effect thereof, describe in detail as after.
Relevant aforementioned and other technology contents, characteristics and effect of the present invention can be known to present in the following detailed description that cooperates with reference to graphic preferred embodiment.By the explanation of embodiment, when can being to reach technological means that predetermined purpose takes and effect to get one more deeply and concrete understanding to the present invention, yet appended graphic only provide with reference to the usefulness of explanation, be not to be used for the present invention is limited.
Fig. 1 illustrates the profile of the inductor of one embodiment of the invention.Please refer to Fig. 1, the inductor 100 of present embodiment comprises a magnetic 110 and a lead 120.Magnetic 110 comprises one first Magnaglo 112 and one second Magnaglo 114, and first Magnaglo 112 mixes mutually with second Magnaglo 114.Wherein, magnetic 110 utilizes moulding process and forms.The Vickers hardness of first Magnaglo 112 (Vicker ' s Hardness) is greater than the Vickers hardness of second Magnaglo 114.The Vickers hardness of first Magnaglo 112 for example is more than or equal to 150, and preferably, the Vickers hardness of first Magnaglo 112 is more than or equal to 250.The Vickers hardness of second Magnaglo 114 for example is to be less than or equal to 100, and preferably, the Vickers hardness of second Magnaglo 114 is less than or equal to 80.
The average grain diameter of first Magnaglo 112 (Mean particle diameter) D1 is greater than the average grain diameter D2 of second Magnaglo 114, and the average grain diameter D2 of second Magnaglo 114 is less than or equal to 10 microns.
The average grain diameter D1 of first Magnaglo 112 can be 10 microns to 40 microns in fact, and the average grain diameter D2 of second Magnaglo 114 can be in fact and is less than or equal to 4 microns.The proportionality of the average grain diameter D2 of the average grain diameter D1 of first Magnaglo 112 and second Magnaglo 114 is in this way greater than 2, and preferably, the ratio of average grain diameter D1 and average grain diameter D2 is 2.5 to 10.
The material of first Magnaglo 112 for example is a metal alloy, and metal alloy for example is siderochrome silicon alloy, iron-nickel alloy, noncrystalline (Amorphous) alloy, ferro-silicium or iron alusil alloy.The material of second Magnaglo 114 for example is iron or ferroalloy.Preferably, the material of first Magnaglo 112 for example is an amorphous alloy, and the material of second Magnaglo 114 for example is an iron.Magnetic 110 more comprises an adhesive agent (not illustrating), and adhesive agent mixes with second Magnaglo 114 mutually with first Magnaglo 112.First Magnaglo 112 and second Magnaglo 114 can be bonded with each other by adhesive agent.The material of adhesive agent can be thermosetting resin, for example epoxy resin.The content of adhesive agent is 2 percentage by weights (the wt%)～3wt% of the total weight of magnetic 110, and the content of first Magnaglo 112 and second Magnaglo 114 is the 98wt%～97wt% of the total weight of magnetic 110.And the part by weight of first Magnaglo is the ratio of the 20wt%～80wt% and second Magnaglo is 80wt%～20wt%, and promptly the ratio of the weight of the weight of first Magnaglo 112 and second Magnaglo 114 can be 0.25 to 4.
Lead 120 have be embedded in one in the magnetic 110 in bury portion 122 and respectively from bury portion 122 two ends extend two end E1, the E2 of magnetic stamen 110, end E1, E2 are suitable for electrically connecting with other electronic component (not illustrating).Specifically, magnetic 110 is a cuboid, end E1, E2 can be respectively along the relative two sidewall S1 of magnetic 110, the side S3 that S2 extends to magnetic 110, and thus, the mode that inductor 100 can surface mount is electrically connected to other electronic component.Lead 120 for example is a copper conductor, and in to bury portion 122 for example be a coil of reeling.
It should be noted that, the average grain diameter of first Magnaglo 112 that present embodiment adopts and hardness are all greater than the average grain diameter and the hardness of second Magnaglo 114, therefore, in moulding process, second Magnaglo 114 can be filled up easily in the space of 112 of first Magnaglos, and second Magnaglo 114 and first Magnaglo, 112 mutual extrusion and the strain that produces also can reduce, can promote the permeability of formed inductor so make pressed density increase, and can avoid utilizing bigger briquetting pressure and high-temperature heat treatment to promote pressed density and permeability.
Moreover owing to comprise magnetic loss first Magnaglo 112 low than iron powder in the magnetic 110, so known whole in the inductor of iron powder as magnetic compared to having now, present embodiment can provide magnetic loss lower inductor, and makes the improved efficiency of inductor.Moreover the cost of material is low to adopt magnetic 110 its material costs that comprise first Magnaglo 112 and second Magnaglo 114 all to make magnetic with metal alloy.
Fig. 2 A～Fig. 2 D is the process section of the inductor of Fig. 1 of the present invention.The detailed manufacturing process of the inductor 100 of relevant Fig. 1 please refer to Fig. 2 A～Fig. 2 D.At first, please refer to Fig. 2 A, a lead 120 is provided.Then, please refer to Fig. 2 B, a mixture M is provided, mixture M comprises first Magnaglo 112, second Magnaglo 114 and adhesive agent (not illustrating).Afterwards, please refer to Fig. 2 C, with lead 120 one in bury portion 122 and be disposed in the die cavity (figure do not show), and two end E1, the E2 of lead 120 extend outside the die cavity, mixture M is filled in the die cavity again.Afterwards, mixture M is carried out a moulding process, to form the magnetic 110 that buries portion 122 in the coating, moulding process for example is that mixture M is applied a briquetting pressure, with pressing first Magnaglo 112, second Magnaglo 114 and the adhesive agent.In the present embodiment, the moulding process that mixture M is carried out is a pressure molding, and the pressure that puts on mixture M for example is 6 tons every square centimeter to 11 tons every square centimeter.In other embodiments, moulding process also can be the moulding process that cast shaping process or jetting formation process etc. are fit to.Afterwards, for example solidify adhesive agent, and the temperature of heating equals or a little more than the curing temperature of adhesive agent, for example be below 300 ℃, it should be noted that the temperature of the heating of adopting in the present embodiment only is suitable for solidifying adhesive agent in the mode of heating.At last, please refer to Fig. 2 D, folded end E1, E2 are so that end E1, E2 are respectively along the relative two sidewall S1 of magnetic 110, the side S3 that S2 extends to magnetic 110.
Fig. 3 is the schematic diagram that illustrates the inductor of another embodiment of the present invention.Please refer to Fig. 3, in the present embodiment, the material of the magnetic stamen 110 among the material of magnetic 210 and Fig. 1 is identical, does not repeat them here.The inductor 200 of present embodiment is with the difference part of the inductor 100 of Fig. 1, in bury portion 222 and can have a plurality of bending structure 222a, and these bending structures 222a is positioned at same plane in fact.
Fig. 4 illustrates the profile of the inductor of further embodiment of this invention.Please refer to Fig. 4, in the present embodiment, the material of the magnetic stamen 110 among the material of magnetic 310 and Fig. 1 is identical, does not repeat them here.The inductor 300 of present embodiment is that with the difference part of the inductor 100 of Fig. 1 the magnetic 310 of present embodiment is a drum type structure, and lead 320 is to be positioned at outside the magnetic 310.The magnetic 310 of present embodiment comprises a center pillar 312, one first plate body 314 and one second plate body 316, and wherein two ends 312a, the 312b of center pillar 312 connect first plate body 314 and second plate body 316 respectively, and lead 320 is wound on the center pillar 312.Particularly, form a winding space C between first plate body 314, second plate body 316 and the center pillar 312, and lead 320 have two end E1, E2 and be positioned at winding section 322 between two end E1, E2.Winding section 322 is positioned at winding space C and is wound on the center pillar 312, and two end E1, E2 extend to winding space C outside by winding space C inside, electrically connects with the electronic component (not illustrating) with other.In addition, also can in winding space C, optionally fill a magnetic material 330 or a resin material (figure does not show), to fill up the winding section 322 of winding space C and coated wire 320.
Fig. 5 A～Fig. 5 C is the process section of the inductor of Fig. 4 of the present invention.The detailed manufacturing process of the inductor 300 of relevant Fig. 4 please refer to Fig. 5 A～Fig. 5 C.At first, please refer to Fig. 5 A, a mixture M is provided, the material of mixture M is same as the material of the mixture M of Fig. 2 B.Then, please refer to Fig. 5 B, mixture M is carried out a moulding process, to form magnetic 310.In the present embodiment, moulding process comprises pressure molding, cast shaping process or jetting formation process, and in pressure molding, the pressure that puts on mixture M for example is 6 tons every square centimeter to 11 tons every square centimeter.Afterwards, for example solidify adhesive agent (not illustrating), and the temperature of heating equals or a little more than the curing temperature of adhesive agent, for example be below 300 ℃, it should be noted that the temperature of the heating of adopting in the present embodiment only is suitable for solidifying adhesive agent in the mode of heating.At last, please refer to Fig. 5 C, the winding section 322 of lead 320 is wound on the magnetic 310.
Fig. 6 illustrates the schematic diagram of the inductor of yet another embodiment of the invention.Please refer to Fig. 6, in the present embodiment, the material of the magnetic 110 among the material of magnetic 410 and Fig. 1 is identical, does not repeat them here.In the present embodiment, magnetic 410 has the perforation 416 that a first surface 412, a second surface 414 and with respect to first surface 412 run through first surface 412 and second surface 414.Lead 420 for example is an additional conductive strips, and lead 420 has two end E1, E2 and is positioned at winding section 422 between two end E1, E2.Perforation 416 is run through in winding section 422, and end E1, E2 extend to one the 3rd surface 418 of magnetic 410 respectively along first surface 412 and second surface 414.The 3rd surface 418 is connected between first surface 412 and the second surface 414.Magnetic 410 optionally has a slit G who runs through the 3rd surface 418 and be communicated with perforation 416.
Below will introduce first Magnaglo with different proportion and the inductor 100 of second Magnaglo, the result of 300 testing electrical properties of being done.
[experiment 1]
The structure of experiment 1 inductor is same as the structure of the inductor 100 of Fig. 1, and the line of lead 120 footpath A is 0.32 millimeter, and the diameter B of coil is 2.4 millimeters, and the number of turns of coil is 11.5 circles, and the briquetting pressure of magnetic 110 is 11 tons every square centimeter.Main component, average grain diameter and the hardness of experiment 1 first Magnaglo that is adopted and second Magnaglo is all detailed lists in the table 1.
Table 1
As shown in Table 1, the ratio of D1 and D2 is 2.5.When Fig. 7 illustrates first Magnaglo and second Magnaglo ratio in magnetic and changes, the variation situation of the inductance value of inductor under two kinds of frequencies (25KHz and 100KHz).Please refer to Fig. 7, the inductance value of the inductor the when inductance value of the inductor the when ratio of first Magnaglo is 20wt%～80wt% all is 100wt% greater than the ratio of first Magnaglo or second Magnaglo.Preferable situation is that the ratio of first Magnaglo is that the ratio of the 60wt% and second Magnaglo is 40wt%, promptly the ratio of the weight of the weight of first Magnaglo and second Magnaglo is 1.5, or the ratio of first Magnaglo is that the ratio of the 60wt%～80wt% and second Magnaglo is 40wt%～20wt%, and promptly the ratio of the weight of the weight of first Magnaglo and second Magnaglo is 1.5 to 4.
[experiment 2]
The structure of experiment 2 inductor is same as the structure of the inductor 100 of Fig. 1, and the line of lead 120 footpath A is 0.32 millimeter, and the diameter B of coil is 2.4 millimeters, and the number of turns of coil is 11.5 circles, and the briquetting pressure of magnetic 110 is 11 tons every square centimeter.Main component, average grain diameter and the hardness of experiment 2 first Magnaglos that adopted and second Magnaglo is all detailed lists in the table 2.
Table 2
Fig. 8 illustrates when first Magnaglo and second Magnaglo ratio in magnetic changes, the variation situation of the inductance value of inductor under two kinds of frequencies.Please refer to Fig. 8, when the composition of second Magnaglo is the ratio of iron and D1 and D2 when being 10, the inductance value of the inductor the when inductance value of the inductor the when ratio of first Magnaglo is 20wt%～80wt% all is 100wt% greater than the ratio of first Magnaglo or second Magnaglo.Preferable situation is that the ratio of first Magnaglo is that the ratio of the 40wt% and second Magnaglo is 60wt%, promptly the ratio of the weight of the weight of first Magnaglo and second Magnaglo is 0.67, or the ratio of first Magnaglo is that the ratio of the 40wt%～60wt% and second Magnaglo is 60wt%～40wt%, and promptly the ratio of the weight of the weight of first Magnaglo and second Magnaglo is 0.67 to 1.5.
And when the composition of second Magnaglo be that the ratio of siderochrome silicon alloy and D1 and D2 is when being 4, the inductance value of the inductor the when inductance value of the inductor the when ratio of first Magnaglo is 20wt%～80wt% is 100wt% greater than the ratio of first Magnaglo, and the inductance value of the inductor of the inductance value of the inductor of the ratio of first Magnaglo when being 20wt%～40wt% when being 100wt% a little more than the ratio of second Magnaglo, therefore, preferable situation is that the ratio of first Magnaglo is that the ratio of the 20wt%～40wt% and second Magnaglo is 80wt%～60wt%, and promptly the ratio of the weight of the weight of first Magnaglo and second Magnaglo is 0.25 to 0.67.
As from the foregoing, with the first identical Magnaglo of second Magnaglo collocation of different average grain diameters, it is more little to obtain average grain diameter, and the effect of the inductance value of lifting inductor is better.
Below experimentize with the magnetic of the iron powder 60wt% that contains 40 microns amorphous alloy 40wt% and 4 microns.Table 3 is listed the variation situation of magnetic loss, and table 4 is listed the variation situation of efficient, and Fig. 9 illustrates the not inductance value change curve of the inductor of the lead in collinear footpath of employing.The frequency of the experiment of table 3 is 300KHz, and magnetic flux density is 30mT.The electric current that applies of table 4 is 2 amperes.
Table 3
Table 4
As shown in Table 3, adopting 40 microns amorphous alloy in the present embodiment is first Magnaglo, 4 microns iron powder is second Magnaglo, and the ratio of first Magnaglo is 40wt%, and the ratio of second Magnaglo is 60wt%, resulting magnetic loss can be that 100wt%, amorphous alloy ratio are that 100wt% and amorphous alloy ratio are that 100wt% (carrying out high-temperature heat treatment behind forming technology) is low than the iron powder ratio, and the big more magnetic loss of briquetting pressure is low more.Therefore, the susceptible of proof present embodiment sees through suitably selects for use first Magnaglo of different average grain diameters and hardness and the second Magnaglo magnetic need not carrying out obtaining lower magnetic loss under the high-temperature heat treatment, thus can save high temperature heat treatment step, and simplify technology.And to adopt magnetic 110 its material costs comprise first Magnaglo 112 and second Magnaglo 114 can be that the cost of material is low for 100wt% than the ratio of first Magnaglo.
As shown in Table 4, frequency is when 25KHz, and the efficient of present embodiment inductor can reach more than 76%, and frequency is when 300KHz, and the efficient of present embodiment inductor can reach more than 90%, and the inductor of visible present embodiment has splendid efficient performance.Notably be that briquetting pressure is good than 11 tons every square centimeter efficient 8.5 tons every square centimeter efficient.
As shown in Figure 9, under the identical coil diameter B and the number of turns, the line of lead is directly little, and the inductance value of inductor is higher.Therefore, can directly adjust the inductance value of inductor by the line that changes lead.
[experiment 3]
The structure of experiment 3 inductor is same as the structure of the inductor 100 of Fig. 1, and the line of lead 120 footpath A is 0.32 millimeter, and the diameter B of coil is 2.4 millimeters, and the number of turns of coil is 13.5 circles, and the briquetting pressure of magnetic 110 is 11 tons every square centimeter.Main component, average grain diameter and the hardness of experiment 3 first Magnaglos that adopted and second Magnaglo is all detailed lists in the table 5.
Table 5
As shown in Table 5, the ratio of D1 and D2 is 5.When Figure 10 A illustrates first Magnaglo and second Magnaglo ratio in magnetic and changes, the variation situation of the inductance value of inductor and magnetic density.When Figure 10 B illustrates first Magnaglo and second Magnaglo ratio in magnetic and changes, the magnetic density of inductor and the variation situation of permeability.
Please refer to Figure 10 A and Figure 10 B, inductance value, magnetic density and the permeability of the inductor when inductance value, magnetic density and the permeability of the inductor the when ratio of first Magnaglo is 20wt%～60wt% all is 100wt% greater than the ratio of first Magnaglo or second Magnaglo.Preferable situation is that the ratio of first Magnaglo is that the ratio of the 40wt% and second Magnaglo is 60wt%, promptly the ratio of the weight of the weight of first Magnaglo and second Magnaglo is 0.67, or the ratio of first Magnaglo is that the ratio of the 40wt%～60wt% and second Magnaglo is 60wt%～40wt%, and promptly the ratio of the weight of the weight of first Magnaglo and second Magnaglo is 0.67 to 1.5.
Table 6 is listed the efficient performance under same current (2 amperes), identical briquetting pressure (11 tons every square centimeter) and two kinds of frequencies of the inductor of present embodiment.
Table 6
As shown in Table 6, the ratio of amorphous alloy is the inductor of the ratio of 20wt%～40wt% and iron powder when being 80wt%～60wt%, in frequency during in 25KHz, efficient can reach more than 75%, and frequency is when 300KHz, efficient can reach more than 90%, and the inductor of visible present embodiment has splendid efficient performance.
[experiment 4]
The structure of experiment 4 inductor is same as the structure of the inductor 300 of Fig. 4, and the line of lead 320 footpath A is 0.32 millimeter, and the diameter B of coil is 2.4 millimeters, and the number of turns of coil is 11.5 circles, and the briquetting pressure of magnetic 310 is 8 or 11 tons every square centimeter.Main component, average grain diameter and the hardness of experiment 4 first Magnaglos that adopted and second Magnaglo is all detailed lists in the table 7.
Table 7
As shown in Table 7, the ratio of D1 and D2 is 2.5.Figure 11 A illustrates when first Magnaglo and second Magnaglo ratio in magnetic changes, and the inductance value of inductor changes situation, and illustrates inductor and change situations two kinds of inductance value that apply under the frequency.Figure 11 B illustrates when first Magnaglo and second Magnaglo ratio in magnetic changes, and the inductance value of inductor changes situation, and the inductance value that illustrates with two kinds of formed inductors of briquetting pressure changes situation.
The inductance value of the inductor the when inductance value of the inductor when by Figure 11 A as can be known, the ratio of first Magnaglo is 20wt%～80wt% all is 100wt% greater than the ratio of first Magnaglo or second Magnaglo.Preferable situation is that the ratio of first Magnaglo is that the ratio of the 60wt% and second Magnaglo is 40wt%, promptly the ratio of the weight of the weight of first Magnaglo and second Magnaglo is 1.5, or the ratio of first Magnaglo is that the ratio of the 60wt%～80wt% and second Magnaglo is 40wt%～20wt%, and promptly the ratio of the weight of the weight of first Magnaglo and second Magnaglo is 1.5 to 4.In addition, by Figure 11 B as can be known, when moulding pressure is healed when big, the permeability of inductor is bigger.Therefore, can adjust the permeability of inductor by changing briquetting pressure.
[experiment 5]
The structure of experiment 5 inductor is same as the structure of the inductor 300 of Fig. 4, and the line of lead 320 footpath A is 0.32 millimeter, and the diameter B of coil is 2.4 millimeters, and the number of turns of coil is 11.5 circles, and the briquetting pressure of magnetic 310 is 11 tons every square centimeter.Main component, average grain diameter and the hardness of experiment 5 first Magnaglos that adopted and second Magnaglo is all detailed lists in the table 8.
Table 8
Please refer to Figure 12, when the composition of second Magnaglo is the ratio of iron and D1 and D2 when being 10, the inductance value of the inductor the when inductance value of the inductor the when ratio of first Magnaglo is 20wt%～80wt% all is 100wt% greater than the ratio of first Magnaglo or second Magnaglo.Preferable situation is that the ratio of first Magnaglo is that the ratio of the 40wt% and second Magnaglo is 60wt%, promptly the ratio of the weight of the weight of first Magnaglo and second Magnaglo is 0.67, or the ratio of first Magnaglo is that the ratio of the 40wt%～60wt% and second Magnaglo is 60wt%～40wt%, and promptly the ratio of the weight of the weight of first Magnaglo and second Magnaglo is 0.67 to 1.5.
And when the composition of second Magnaglo be that the ratio of siderochrome silicon alloy and D1 and D2 is when being 4, the inductance value of the inductor the when inductance value of the inductor the when ratio of first Magnaglo is 20wt%～80wt% is 100wt% greater than the ratio of first Magnaglo, and the inductance value of the inductor of the ratio of first Magnaglo when being 20wt%～40wt% is slightly larger than the inductance value of the inductor of the ratio of second Magnaglo when being 100wt%, therefore, preferable situation is that the ratio of first Magnaglo is that the ratio of the 20wt%～40wt% and second Magnaglo is 80wt%～60wt%, and promptly the ratio of the weight of the weight of first Magnaglo and second Magnaglo is 0.25 to 0.67.
As from the foregoing, with the first identical Magnaglo of second Magnaglo collocation of different average grain diameters, it is more little to obtain average grain diameter, and the effect of the inductance value of lifting inductor is better.
In sum, the present invention has following advantage at least:
1. the present invention adopts the different Magnaglo of average grain diameter to form magnetic, therefore, in moulding process, the Magnaglo that average grain diameter is little can be filled up in the space between the big Magnaglo of average grain diameter, and make pressed density increase, and then promote the permeability of inductor.
2. the present invention adopts the different Magnaglo of hardness to form magnetic, and the Magnaglo that average grain diameter is little is filled up in the space between the big Magnaglo of average grain diameter easily, so Magnaglo required forming pressure and the strain that is produced in moulding process significantly reduce, and then can reduce the magnetic loss of inductor of the present invention.And the present invention can avoid that inductor is carried out high-temperature heat treatment and eliminate the strain of Magnaglo and can prevent that lead is because of bearing the problem of high temperature oxidation.
3. the present invention adopts first Magnaglo and second Magnaglo to make magnetic, thus inductor of the present invention under the situation of high-frequency (25KHz or 100KHz), permeability and corresponding inductance value are made the magnetic height than having known employing iron powder now.
4. the present invention adopts first Magnaglo and second Magnaglo of metal alloy powders to make magnetic, and its material cost can all be made magnetic with metal alloy powders, and the cost of material is low.
The above, it only is preferred embodiment of the present invention, be not that the present invention is done any pro forma restriction, though the present invention discloses as above with preferred embodiment, yet be not in order to limit the present invention, any those skilled in the art, in not breaking away from the technical solution of the present invention scope, when the method that can utilize above-mentioned announcement and technology contents are made a little change or be modified to the equivalent embodiment of equivalent variations, in every case be the content that does not break away from technical solution of the present invention, according to technical spirit of the present invention to any simple modification that above embodiment did, equivalent variations and modification all still belong in the scope of technical solution of the present invention.
Claims (25)
1. inductor is characterized in that it comprises:
One magnetic comprises:
One first Magnaglo; And
One second Magnaglo, wherein the Vickers hardness of this first Magnaglo is greater than the Vickers hardness of this second Magnaglo, and the average grain diameter of this first Magnaglo is greater than the average grain diameter of this second Magnaglo, and this first Magnaglo mixes mutually with this second Magnaglo; And
One lead.
2. inductor according to claim 1, the Vickers hardness that it is characterized in that wherein said first Magnaglo are more than or equal to 150, and the Vickers hardness of this second Magnaglo is less than or equal to 100.
3. inductor according to claim 1, the Vickers hardness that it is characterized in that wherein said first Magnaglo are more than or equal to 250, and the Vickers hardness of this second Magnaglo is less than or equal to 80.
4. inductor according to claim 1, the average grain diameter that it is characterized in that wherein said first Magnaglo are 10 microns to 40 microns.
5. inductor according to claim 1 is characterized in that the average grain diameter of wherein said second Magnaglo is less than or equal to 10 microns.
6. inductor according to claim 1, the average grain diameter that it is characterized in that wherein said second Magnaglo is for being less than or equal to 4 microns.
7. inductor according to claim 1, the ratio of average grain diameter that it is characterized in that the average grain diameter of this first Magnaglo wherein and this second Magnaglo is greater than 2.
8. inductor according to claim 1 is characterized in that the ratio of the average grain diameter of the average grain diameter of this first Magnaglo wherein and this second Magnaglo is 2.5 to 10.
9. inductor according to claim 1 is characterized in that the material of wherein said first Magnaglo comprises metal alloy.
10. inductor according to claim 1 is characterized in that the material of wherein said first Magnaglo comprises siderochrome silicon alloy, iron-nickel alloy, amorphous alloy, ferro-silicium or iron alusil alloy.
11. inductor according to claim 1 is characterized in that the material of wherein said second Magnaglo comprises iron or ferroalloy.
12. inductor according to claim 1 it is characterized in that the material of wherein said first Magnaglo comprises amorphous alloy, and the material of this second Magnaglo comprises iron.
13. inductor according to claim 1 is characterized in that the ratio of the weight of the weight of this first Magnaglo wherein and this second Magnaglo is 0.25 to 4.
14. inductor according to claim 1, it is characterized in that the material of wherein working as this first Magnaglo comprises amorphous alloy, and when the material of this second Magnaglo comprised iron, the ratio of the weight of the weight of this first Magnaglo and this second Magnaglo was 0.67 to 1.5.
15. inductor according to claim 1, it is characterized in that the material of wherein working as this first Magnaglo comprises the siderochrome silicon alloy, and when the material of this second Magnaglo comprised iron, the ratio of the weight of the weight of this first Magnaglo and this second Magnaglo was 1.5 to 4.
16. inductor according to claim 1 is characterized in that it more comprises an adhesive agent, engages this first Magnaglo and this second Magnaglo, the content of this adhesive agent is the 2wt%～3wt% of the total weight of this magnetic.
17. inductor according to claim 16, the material that it is characterized in that wherein said adhesive agent is a thermosetting resin.
18. inductor according to claim 1, it is characterized in that wherein said lead have be embedded in one in this magnetic in bury portion or have a winding section that is wound on this magnetic.
19. inductor according to claim 1 is characterized in that wherein said magnetic utilizes a moulding process and forms, the briquetting pressure of this moulding process is 6 tons every square centimeter to 11 tons every square centimeter.
20. inductor according to claim 1 is characterized in that wherein said magnetic imposes a heating process, the temperature of this heating process is below 300 ℃.
21. the manufacture method of an inductor is characterized in that it may further comprise the steps:
One lead is provided;
One mixture is provided, and this mixture comprises:
One first Magnaglo;
One second Magnaglo, wherein the Vickers hardness of this first Magnaglo is greater than the Vickers hardness of this second Magnaglo, and the average grain diameter of this first Magnaglo is greater than the average grain diameter of this second Magnaglo; And
One adhesive agent mixes mutually with this first Magnaglo and this second magnetic powder powder;
This mixture is carried out a moulding process, to form a magnetic; And
Solidify this adhesive agent.
22. the manufacture method of inductor according to claim 21 is characterized in that wherein solidifying this adhesive agent in the mode of a heating, the temperature of this heating is below 300 ℃.
23. the manufacture method of inductor according to claim 21 is characterized in that wherein applying a briquetting pressure in this mixture in this moulding process, this briquetting pressure is 6 tons every square centimeter to 11 tons every square centimeter.
24. the manufacture method of inductor according to claim 21, it is characterized in that wherein said magnetic coat this lead one in bury portion.
25. the manufacture method of inductor according to claim 21 is characterized in that wherein after solidifying this adhesive agent a winding section of this lead being wound on this magnetic.
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| CN106816277A (en) * | 2015-11-30 | 2017-06-09 | Tdk株式会社 | Coil component |
| CN106816277B (en) * | 2015-11-30 | 2019-10-29 | Tdk株式会社 | Coil component |
| TWI707961B (en) * | 2015-11-30 | 2020-10-21 | 日商Ｔｄｋ股份有限公司 | Coil element |
| US11049641B2 (en) | 2015-11-30 | 2021-06-29 | Tdk Corporation | Coil device |
| CN110192257A (en) * | 2017-01-10 | 2019-08-30 | Lg伊诺特有限公司 | Magnetic core and coil block including the magnetic core |
| JP2020505758A (en) * | 2017-01-10 | 2020-02-20 | エルジー イノテック カンパニー リミテッド | Magnetic core and coil component including the same |
| CN113661549A (en) * | 2021-06-30 | 2021-11-16 | 东莞顺络电子有限公司 | Integrally formed inductor and manufacturing method thereof |
| WO2021197513A3 (en) * | 2021-06-30 | 2022-04-28 | 东莞顺络电子有限公司 | Integrally formed inductor and manufacturing method therefor |
Also Published As
| Publication number | Publication date |
|---|---|
| CN105914002B (en) | 2018-08-31 |
| CN105914003B (en) | 2018-09-04 |
| CN101901668B (en) | 2016-07-13 |
| CN105914003A (en) | 2016-08-31 |
| CN105914002A (en) | 2016-08-31 |
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