CN108766737B - Combined inductor and preparation method thereof - Google Patents
Combined inductor and preparation method thereof Download PDFInfo
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- CN108766737B CN108766737B CN201811027070.0A CN201811027070A CN108766737B CN 108766737 B CN108766737 B CN 108766737B CN 201811027070 A CN201811027070 A CN 201811027070A CN 108766737 B CN108766737 B CN 108766737B
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- 238000002360 preparation method Methods 0.000 title claims abstract description 6
- 239000000463 material Substances 0.000 claims abstract description 36
- 238000004804 winding Methods 0.000 claims abstract description 31
- 239000003292 glue Substances 0.000 claims abstract description 12
- 238000003466 welding Methods 0.000 claims abstract description 9
- 238000004806 packaging method and process Methods 0.000 claims abstract description 4
- 239000011810 insulating material Substances 0.000 claims description 32
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 24
- 238000004544 sputter deposition Methods 0.000 claims description 24
- 238000009434 installation Methods 0.000 claims description 19
- 239000002002 slurry Substances 0.000 claims description 14
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 12
- 229910052759 nickel Inorganic materials 0.000 claims description 12
- 239000011248 coating agent Substances 0.000 claims description 10
- 238000000576 coating method Methods 0.000 claims description 10
- 239000011347 resin Substances 0.000 claims description 9
- 229920005989 resin Polymers 0.000 claims description 9
- 229910001289 Manganese-zinc ferrite Inorganic materials 0.000 claims description 7
- JIYIUPFAJUGHNL-UHFFFAOYSA-N [O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[Mn++].[Mn++].[Mn++].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Zn++].[Zn++] Chemical compound [O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[Mn++].[Mn++].[Mn++].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Fe+3].[Zn++].[Zn++] JIYIUPFAJUGHNL-UHFFFAOYSA-N 0.000 claims description 7
- 238000000034 method Methods 0.000 claims description 7
- OAYXUHPQHDHDDZ-UHFFFAOYSA-N 2-(2-butoxyethoxy)ethanol Chemical compound CCCCOCCOCCO OAYXUHPQHDHDDZ-UHFFFAOYSA-N 0.000 claims description 6
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 6
- 239000001856 Ethyl cellulose Substances 0.000 claims description 6
- ZZSNKZQZMQGXPY-UHFFFAOYSA-N Ethyl cellulose Chemical compound CCOCC1OC(OC)C(OCC)C(OCC)C1OC1C(O)C(O)C(OC)C(CO)O1 ZZSNKZQZMQGXPY-UHFFFAOYSA-N 0.000 claims description 6
- 229910001053 Nickel-zinc ferrite Inorganic materials 0.000 claims description 6
- 229910045601 alloy Inorganic materials 0.000 claims description 6
- 239000000956 alloy Substances 0.000 claims description 6
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 6
- 229910052782 aluminium Inorganic materials 0.000 claims description 6
- 229910052804 chromium Inorganic materials 0.000 claims description 6
- 239000011651 chromium Substances 0.000 claims description 6
- 229920001249 ethyl cellulose Polymers 0.000 claims description 6
- 235000019325 ethyl cellulose Nutrition 0.000 claims description 6
- 238000005240 physical vapour deposition Methods 0.000 claims description 6
- 239000000377 silicon dioxide Substances 0.000 claims description 6
- 235000012239 silicon dioxide Nutrition 0.000 claims description 6
- 238000005245 sintering Methods 0.000 claims description 6
- NTIZESTWPVYFNL-UHFFFAOYSA-N Methyl isobutyl ketone Chemical compound CC(C)CC(C)=O NTIZESTWPVYFNL-UHFFFAOYSA-N 0.000 claims description 5
- UIHCLUNTQKBZGK-UHFFFAOYSA-N Methyl isobutyl ketone Natural products CCC(C)C(C)=O UIHCLUNTQKBZGK-UHFFFAOYSA-N 0.000 claims description 5
- 238000005520 cutting process Methods 0.000 claims description 5
- HNJBEVLQSNELDL-UHFFFAOYSA-N pyrrolidin-2-one Chemical compound O=C1CCCN1 HNJBEVLQSNELDL-UHFFFAOYSA-N 0.000 claims description 4
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 claims description 3
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 claims description 3
- 238000007747 plating Methods 0.000 claims description 3
- 229910052709 silver Inorganic materials 0.000 claims description 3
- 239000004332 silver Substances 0.000 claims description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 abstract description 11
- 230000002708 enhancing effect Effects 0.000 abstract description 3
- 239000012467 final product Substances 0.000 abstract description 3
- 229910000859 α-Fe Inorganic materials 0.000 description 5
- 239000011701 zinc Substances 0.000 description 4
- 239000000047 product Substances 0.000 description 3
- OTYYBJNSLLBAGE-UHFFFAOYSA-N CN1C(CCC1)=O.[N] Chemical compound CN1C(CCC1)=O.[N] OTYYBJNSLLBAGE-UHFFFAOYSA-N 0.000 description 2
- 229910052757 nitrogen Inorganic materials 0.000 description 2
- 230000035699 permeability Effects 0.000 description 2
- 229910018605 Ni—Zn Inorganic materials 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000000696 magnetic material Substances 0.000 description 1
- 239000004065 semiconductor Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
Classifications
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- 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
-
- 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
- H01F1/34—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 non-metallic substances, e.g. ferrites
- H01F1/342—Oxides
- H01F1/344—Ferrites, e.g. having a cubic spinel structure (X2+O)(Y23+O3), e.g. magnetite Fe3O4
-
- 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
-
- 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
- H01F27/30—Fastening or clamping coils, windings, or parts thereof together; Fastening or mounting coils or windings on core, casing, or other support
- H01F27/306—Fastening or mounting coils or windings on core, casing or other support
-
- 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
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- 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
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- 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
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Chemical & Material Sciences (AREA)
- Dispersion Chemistry (AREA)
- Coils Or Transformers For Communication (AREA)
Abstract
The invention provides a preparation method of a combined inductor, which comprises the following steps: dispensing magnetic core, automatically winding, assembling soft magnetic core, spot welding coil, removing wire end, dispensing, assembling magnetic core, baking glue, appearance testing, and packaging to obtain the final product, wherein the baking glue temperature is 130 ℃ and the time is 90 minutes; according to the scheme, the traditional inductor production mode is changed, and the materials are assembled, so that the consistency and the yield of the inductor performance (the inductance L and the saturation current Isat) are improved; therefore, the production difficulty of the inductor is reduced, the semi-automatic production is changed into full-automatic production, and the purposes of reducing the cost and enhancing the efficiency are achieved.
Description
Technical Field
The invention relates to an inductor, in particular to a combined inductor and a preparation method thereof.
Background
At present, the traditional production method adopted by the assembled inductor is that coils are wound on a soft magnetic ferrite core and a DR magnetic core center pillar, the consistency of the wound coils is poor, so that the coil plumpness is large or small, when the DR magnetic core and the RH magnetic core are assembled, the DR magnetic core is very difficult to control, and finally, the electric consistency of an inductance device is poor (mainly the inductance L of the inductor and the saturation current Isat of the inductor) is finally caused.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide the combined inductor which is reasonable in structure and good in use effect.
In order to achieve the above purpose, the technical scheme provided by the invention is as follows: a preparation method of a combined inductor comprises the following steps: dispensing magnetic core, automatically winding, assembling soft magnetic core, spot welding coil, removing wire end, dispensing, assembling magnetic core, baking glue, appearance testing, and packaging to obtain the final product, wherein the baking glue temperature is 130 ℃ and the time is 90 minutes; wherein,
the magnetic core is composed of a cup-shaped soft magnetic core and a sheet-shaped soft magnetic core, or is composed of a cup-shaped soft magnetic core and a T-shaped soft magnetic core,
when the magnetic core is formed by a cup-shaped soft magnetic core and a sheet-shaped soft magnetic core, a middle column is formed on the cup-shaped soft magnetic core, the cup-shaped soft magnetic core and the sheet-shaped soft magnetic core are made of one of nickel zinc ferrite, manganese zinc ferrite and an alloy magnetic core, glue is added into the cup-shaped soft magnetic core before the assembly, a coiled coil is assembled on the middle column of the cup-shaped magnetic core through automatic equipment, a wire cutting head is welded by spot welding, and finally the sheet-shaped soft magnetic core is glued and assembled, so that an inductor is assembled, and as the middle column of the cup-shaped soft magnetic core is provided with a groove, the sheet-shaped soft magnetic core is provided with a bump, the air gap distance between the cup-shaped soft magnetic core and the sheet-shaped magnetic core can be accurately positioned, and the consistency and the stability of electricity are accurately and effectively controlled;
when the magnetic core is composed of a cup-shaped soft magnetic core and a T-shaped soft magnetic core, a groove is formed in the wall thickness of the lower surface of the cup-shaped soft magnetic core, the cup-shaped soft magnetic core and the T-shaped soft magnetic core are made of one of nickel-zinc ferrite, manganese-zinc ferrite and an alloy magnetic core, glue is added into the cup-shaped magnetic core during assembly, a coiled coil is assembled on a T-shaped magnetic core center post through automatic equipment, and finally the T-shaped magnetic core with the coil assembled is reversely buckled in the cup-shaped magnetic core, and a wire end is welded by spot welding, so that an inductor is assembled.
The surface of the magnetic core is coated by a high-voltage-resistant insulating material, and then is subjected to electrode treatment by a water plating or PVD vacuum sputtering coating mode; the high-voltage resistant insulating material layer is prepared by dissolving silicon dioxide and ethyl cellulose in diethylene glycol butyl ether to prepare slurry, coating the slurry on the outer surface of the whole soft magnetic core body, and baking and sintering the slurry to form the high-voltage resistant insulating material layer, wherein the temperature resistant range of the high-voltage resistant insulating material layer is 700-900 ℃, and the high-voltage resistant insulating material layer is an inorganic insulating layer; the silicon dioxide: ethyl cellulose: the weight percentages of the diethylene glycol butyl ether are respectively 50-70 percent: 2-20%:15-40%; the high-voltage resistant insulating material layer is formed by baking and sintering the slurry which is prepared by dissolving high-temperature resin, nitrogen methyl pyrrolidone and a small amount of special resin in methyl isobutyl ketone, wherein the temperature resistant range of the high-voltage resistant insulating material layer is 350-450 ℃, and the high-voltage resistant insulating material layer is an organic insulating layer; the high temperature resistant resin: azomethyl pyrrolidone: the weight percentages of the methyl isobutyl ketone are respectively 2-15 percent: 50-75%:15-41%;
the PVD vacuum sputtering coating comprises the steps of sputtering a chromium material layer on a high-pressure-resistant insulating material layer in a vacuum manner, sputtering a nickel material layer on the chromium material layer in a vacuum manner, and finally sputtering a silver material layer on the nickel material layer in a vacuum manner; or sputtering an aluminum material layer on the high-pressure-resistant insulating material layer in a vacuum way, sputtering a nickel material layer on the aluminum material layer in a vacuum way, and sputtering a tin material layer on the nickel material layer in a vacuum way.
The combined inductor prepared by the method comprises a cup-shaped soft magnetic core and a winding soft magnetic core, wherein the winding soft magnetic core is a sheet-shaped soft magnetic core or a T-shaped soft magnetic core, a concave coil installation chamber is arranged at the center of the cup-shaped soft magnetic core, wire head guide grooves are arranged on two opposite sides of the coil installation chamber, and concave pole leg grooves are arranged on the cup-shaped soft magnetic core at the top of the wire head guide grooves; the surface of the winding soft magnetic core is coated with an insulating layer, the coil is installed in the coil installation chamber through the winding soft magnetic core, and an air gap distance is reserved between the cup-shaped soft magnetic core and the winding soft magnetic core after the coil is installed.
The winding soft magnetic core is a sheet soft magnetic core, a center pillar is arranged at the center of a coil installation chamber of the cup-shaped soft magnetic core, a concave positioning counter bore is formed in the top of the center pillar, a convex bump is arranged at the center of the sheet soft magnetic core, the coil is sleeved on the center pillar, the sheet soft magnetic core is reversely buckled at the top of the center pillar, and the bump is embedded in the positioning counter bore after reversely buckling.
The winding soft magnetic core is a T-shaped soft magnetic core, a concave positioning groove is formed in the bottom of a coil installation chamber of the cup-shaped soft magnetic core, a vertical arm of the T-shaped soft magnetic core is a center pillar, the coil is sleeved on the center pillar of the T-shaped soft magnetic core, and the bottom of the center pillar is embedded in the positioning groove.
The reason for selecting the Mn-Zn ferrite material to manufacture the magnetic core body is that the Mn-Zn ferrite material has the initial magnetic permeability which is more than 5 times that of the Ni-Zn ferrite material relative to the semiconductor soft magnetic material, the quality factor is good, the coercive force is low, the eddy current loss is low, the wire winding type inductor manufactured by the Mn-Zn ferrite material has the AL value (inductance coefficient) of the Mn-Zn magnetic core proportional to the ui (initial magnetic permeability) value, L is the inductance according to L=AL×N, and N is the number of enamelled wire turns, therefore, the number of winding turns of the wire package can be reduced, the length of the enamelled wire is reduced, the direct current impedance of an inductance device is reduced, the heating value of the product in the working process is finally reduced, and the product efficiency is improved.
Compared with the prior art, the technical advantage of this scheme lies in:
1. the traditional inductor production mode is changed, and the inductor is assembled by materials, so that the consistency and the yield of the inductor performance (the inductance L and the saturation current Isat) are improved;
2. the production difficulty of the inductor is reduced, and the semi-automatic production is changed into full-automatic production, so that the purposes of reducing the cost and enhancing the efficiency are achieved;
3. the manganese-zinc ferrite soft magnetic core coated by the high-voltage resistant insulating material can greatly reduce the number of turns, reduce direct current impedance, increase the outer diameter of a central column of the DR magnetic core, and increase the current carrying capacity (Isat) of the inductor.
Drawings
Fig. 1, 2, 3 and 4 are schematic structural views of a cup-shaped soft magnetic core and a T-shaped soft magnetic core according to the present invention.
Fig. 5, 6, 7, 8, 9 and 10 are schematic views of the cup-shaped soft magnetic core and the sheet-shaped soft magnetic core according to the present invention.
Detailed Description
The invention is further described below with reference to all drawings, in which preferred embodiments of the invention are:
example 1
Referring to fig. 1 to 4, the method for manufacturing the combined inductor according to the embodiment includes the following steps: dispensing magnetic core, automatically winding, assembling soft magnetic core, spot welding coil, removing wire end, dispensing, assembling magnetic core, baking glue, appearance testing, and packaging to obtain the final product, wherein the baking glue temperature is 130 ℃ and the time is 90 minutes; wherein,
the magnetic core is composed of a cup-shaped soft magnetic core and a sheet-shaped soft magnetic core, or is composed of a cup-shaped soft magnetic core and a T-shaped soft magnetic core,
when the magnetic core is formed by a cup-shaped soft magnetic core and a sheet-shaped soft magnetic core, a middle column is formed on the cup-shaped soft magnetic core, the cup-shaped soft magnetic core and the sheet-shaped soft magnetic core are made of one of nickel zinc ferrite, manganese zinc ferrite and an alloy magnetic core, glue is added into the cup-shaped soft magnetic core before the assembly, a coiled coil is assembled on the middle column of the cup-shaped magnetic core through automatic equipment, a wire cutting head is welded by spot welding, and finally the sheet-shaped soft magnetic core is glued and assembled, so that an inductor is assembled. The surface of the magnetic core is coated by high-voltage resistant insulating material, and then electrode treatment is carried out by a water plating or PVD vacuum sputtering coating mode; the high-voltage resistant insulating material layer is prepared by dissolving silicon dioxide and ethyl cellulose in diethylene glycol butyl ether to prepare slurry, coating the slurry on the outer surface of the whole soft magnetic core body, and baking and sintering the slurry to form the high-voltage resistant insulating material layer, wherein the temperature resistant range of the high-voltage resistant insulating material layer is 700-900 ℃, and the high-voltage resistant insulating material layer is an inorganic insulating layer; the silicon dioxide: ethyl cellulose: the weight percentages of the diethylene glycol butyl ether are respectively 50-70 percent: 2-20%:15-40%; the high-voltage resistant insulating material layer is formed by baking and sintering the slurry which is prepared by dissolving high-temperature resin, nitrogen methyl pyrrolidone and a small amount of special resin in methyl isobutyl ketone, wherein the temperature resistant range of the high-voltage resistant insulating material layer is 350-450 ℃, and the high-voltage resistant insulating material layer is an organic insulating layer; the high temperature resistant resin: azomethyl pyrrolidone: the weight percentages of the methyl isobutyl ketone are respectively 2-15 percent: 50-75%:15-41%;
the PVD vacuum sputtering coating comprises the steps of sputtering a chromium material layer on a high-pressure-resistant insulating material layer in a vacuum manner, sputtering a nickel material layer on the chromium material layer in a vacuum manner, and finally sputtering a silver material layer on the nickel material layer in a vacuum manner; or sputtering an aluminum material layer on the high-pressure-resistant insulating material layer in a vacuum way, sputtering a nickel material layer on the aluminum material layer in a vacuum way, and sputtering a tin material layer on the nickel material layer in a vacuum way.
The combined inductor prepared by the method comprises a cup-shaped soft magnetic core 4 and a winding soft magnetic core 1, wherein the winding soft magnetic core 1 is a T-shaped soft magnetic core, a concave coil installation chamber 7 is arranged at the center of the cup-shaped soft magnetic core 4, wire head guide grooves 5 are arranged on two opposite sides of the coil installation chamber 7, and a concave pole leg groove 8 is arranged on the cup-shaped soft magnetic core 1 at the top of the wire head guide groove 5; the insulating layer 2 is coated on the surface of the winding soft magnetic core 1, the coil 3 is installed in the coil installation chamber 7 through the winding soft magnetic core 1, an air gap distance is reserved between the installed cup-shaped soft magnetic core 4 and the winding soft magnetic core 1, a concave positioning groove is formed in the bottom of the inner cavity of the coil installation chamber 7 of the cup-shaped soft magnetic core 4, a vertical arm of the T-shaped soft magnetic core is a center pillar, the coil 3 is sleeved on the center pillar of the T-shaped soft magnetic core, and the bottom of the center pillar is embedded in the positioning groove.
Example 2
Referring to fig. 5 to 10, this embodiment is different from embodiment 1 in that: when the magnetic core is formed by a cup-shaped soft magnetic core and a T-shaped soft magnetic core, a groove is formed in the wall thickness below the cup-shaped soft magnetic core, the cup-shaped soft magnetic core and the T-shaped soft magnetic core are made of one of nickel-zinc ferrite, manganese-zinc ferrite and an alloy magnetic core, glue is added into the cup-shaped magnetic core during assembly, a coiled coil is assembled on a T-shaped magnetic core center post through automatic equipment, and finally the T-shaped magnetic core with the coil assembled is reversely buckled in the cup-shaped magnetic core, and a wire cutting head is welded by spot welding, so that an inductor is assembled; the yield of the product is improved, thereby achieving the aims of reducing the cost and enhancing the efficiency.
The combined inductor prepared by the method comprises a cup-shaped soft magnetic core 4 and a winding soft magnetic core 1, wherein the winding soft magnetic core 1 is a sheet-shaped soft magnetic core, a concave coil installation chamber 7 is arranged at the center of the cup-shaped soft magnetic core 4, wire head guide grooves 5 are arranged on two opposite sides of the coil installation chamber 7, and a concave pole leg groove 8 is arranged on the cup-shaped soft magnetic core 1 at the top of the wire head guide groove 5; the surface of the winding soft magnetic core 1 is coated with an insulating layer 2, a coil 3 is arranged in a coil installation chamber 7 through the winding soft magnetic core 1, and an air gap distance is reserved between the cup-shaped soft magnetic core 4 and the winding soft magnetic core 1 after the installation; in this embodiment, a center pillar is arranged at the center of an inner cavity of a coil installation chamber 7 of a cup-shaped soft magnetic core 4, a concave positioning counter bore is arranged at the top of the center pillar, a convex bump is arranged at the center of a sheet-shaped soft magnetic core, a coil 3 is sleeved on the center pillar, the sheet-shaped soft magnetic core is reversely buckled at the top of the center pillar, and the bump is embedded in the positioning counter bore after reversely buckling.
The above embodiments are merely for fully disclosing the present invention, but not limiting the present invention, and substitution of equivalent technical features based on the gist of the present invention, which can be achieved without inventive labor, should be considered as the scope of the present disclosure.
Claims (4)
1. A preparation method of a combined inductor is characterized by comprising the following steps: the method comprises the following steps: dispensing magnetic core, automatically winding, assembling soft magnetic core, spot welding coil, removing wire end, dispensing, assembling magnetic core, baking, testing appearance, and packaging,
the magnetic core is composed of a cup-shaped soft magnetic core and a sheet-shaped soft magnetic core, or is composed of a cup-shaped soft magnetic core and a T-shaped soft magnetic core,
when the magnetic core is formed by a cup-shaped soft magnetic core and a sheet-shaped soft magnetic core, a middle column is formed on the cup-shaped soft magnetic core, the cup-shaped soft magnetic core and the sheet-shaped soft magnetic core are made of one of nickel zinc ferrite, manganese zinc ferrite and an alloy magnetic core, glue is added into the cup-shaped soft magnetic core before the assembly, a coiled coil is assembled on the middle column of the cup-shaped magnetic core through automatic equipment, a wire cutting head is welded by spot welding, and finally the sheet-shaped soft magnetic core is glued and assembled, so that an inductor is assembled, and as the middle column of the cup-shaped magnetic core is provided with a groove, the sheet-shaped soft magnetic core is provided with a convex point, and the consistency and the stability of the electrical property are accurately and effectively controlled;
when the magnetic core is formed by a cup-shaped soft magnetic core and a T-shaped soft magnetic core, a groove is formed in the wall thickness below the cup-shaped soft magnetic core, the cup-shaped soft magnetic core and the T-shaped soft magnetic core are made of one of nickel zinc ferrite, manganese zinc ferrite and an alloy magnetic core, glue is added into the cup-shaped magnetic core during assembly, a coiled coil is assembled on a T-shaped magnetic core center post through automatic equipment, and finally the T-shaped magnetic core with the coil assembled is reversely buckled in the cup-shaped magnetic core, and a wire cutting head is welded in a spot mode, so that an inductor is assembled;
the surface of the magnetic core is coated by a high-voltage resistant insulating material, and then is subjected to electrode treatment by a water plating or PVD vacuum sputtering coating mode; the high-voltage resistant insulating material layer is prepared by dissolving silicon dioxide and ethyl cellulose in diethylene glycol butyl ether to prepare slurry, coating the slurry on the outer surface of the whole soft magnetic core body, and baking and sintering the slurry to form the high-voltage resistant insulating material layer, wherein the temperature resistant range of the high-voltage resistant insulating material layer is 700-900 ℃, and the high-voltage resistant insulating material layer is an inorganic insulating layer; the silicon dioxide: ethyl cellulose: the weight percentages of the diethylene glycol butyl ether are respectively 50-70 percent: 2-20%:15-40%; or the high-pressure resistant insulating material layer is prepared by dissolving high-temperature resistant resin and azomethyl pyrrolidone in a small amount of special resin to prepare slurry, coating the slurry on the outer surface of the whole soft magnetic core body, and baking and sintering the slurry to form the high-pressure resistant insulating material layer, wherein the temperature resistant range of the high-pressure resistant insulating material layer is 350-450 ℃, and the high-pressure resistant insulating material layer is an organic insulating layer; the high temperature resistant resin: azomethyl pyrrolidone: the weight percentages of the methyl isobutyl ketone are respectively 2-15 percent: 50-75%:15-41%;
the PVD vacuum sputtering coating comprises the steps of sputtering a chromium material layer on a high-pressure-resistant insulating material layer in a vacuum manner, sputtering a nickel material layer on the chromium material layer in a vacuum manner, and finally sputtering a silver material layer on the nickel material layer in a vacuum manner; or sputtering an aluminum material layer on the high-pressure-resistant insulating material layer in a vacuum way, sputtering a nickel material layer on the aluminum material layer in a vacuum way, and sputtering a tin material layer on the nickel material layer in a vacuum way.
2. A combined inductor prepared by the method of claim 1, wherein: the novel magnetic field winding device comprises a cup-shaped soft magnetic core (4) and a winding soft magnetic core (1), wherein the winding soft magnetic core (1) is a sheet-shaped soft magnetic core or a T-shaped soft magnetic core, a concave coil installation chamber (7) is arranged at the center of the cup-shaped soft magnetic core (4), wire head guide grooves (5) are arranged on two opposite sides of the coil installation chamber (7), and concave pole leg grooves (8) are formed in the cup-shaped soft magnetic core (4) at the top of the wire head guide grooves (5); the surface of the winding soft magnetic core (1) is coated with an insulating layer (2), the coil (3) is installed in a coil installation chamber (7) through the winding soft magnetic core (1), and an air gap distance is reserved between the installed cup-shaped soft magnetic core (4) and the winding soft magnetic core (1).
3. A combined inductor according to claim 2, characterized in that: the winding soft magnetic core (1) is a flaky soft magnetic core, a center pillar is arranged at the center of an inner cavity of a coil installation chamber (7) of the cup-shaped soft magnetic core (4), a concave positioning counter bore is formed in the top of the center pillar, a convex bump is arranged at the center of the flaky soft magnetic core, the coil (3) is sleeved on the center pillar, the flaky soft magnetic core is reversely buckled at the top of the center pillar, and the bump is embedded in the positioning counter bore after reversely buckling.
4. A combined inductor according to claim 2, characterized in that: the winding soft magnetic core (1) is a T-shaped soft magnetic core, a concave positioning groove is formed in the bottom of an inner cavity of a coil installation chamber (7) of the cup-shaped soft magnetic core (4), a vertical arm of the T-shaped soft magnetic core is a center pillar, the coil (3) is sleeved on the center pillar of the T-shaped soft magnetic core, and the bottom of the center pillar is embedded in the positioning groove.
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| CN109360731A (en) * | 2018-12-03 | 2019-02-19 | 东莞市高东电子科技有限公司 | A kind of integrated inductance production method and the inductance using this method production |
| CN111724980B (en) * | 2020-07-01 | 2021-11-30 | 广州市德珑电子器件有限公司 | Manufacturing method of inductor with side surface provided with air gap and two-in-one structure |
| CN114203424A (en) * | 2021-11-05 | 2022-03-18 | 深圳市博亿精科科技有限公司 | High-temperature-resistant coil and sensor |
| CN114050036A (en) * | 2021-11-24 | 2022-02-15 | 横店集团东磁股份有限公司 | Integrally-formed cup-core inductor and preparation method thereof |
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| JP2007027461A (en) * | 2005-07-19 | 2007-02-01 | Sumida Corporation | Core and inductor with core |
| US9087634B2 (en) * | 2013-03-14 | 2015-07-21 | Sumida Corporation | Method for manufacturing electronic component with coil |
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| CN201348912Y (en) * | 2008-09-11 | 2009-11-18 | 清流县鑫磁线圈制品有限公司 | Copper-saving coil induction part |
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