CN111724980B - Manufacturing method of inductor with side surface provided with air gap and two-in-one structure - Google Patents

Manufacturing method of inductor with side surface provided with air gap and two-in-one structure Download PDF

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CN111724980B
CN111724980B CN202010616841.0A CN202010616841A CN111724980B CN 111724980 B CN111724980 B CN 111724980B CN 202010616841 A CN202010616841 A CN 202010616841A CN 111724980 B CN111724980 B CN 111724980B
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magnetic core
coil
electrode
inductor
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CN111724980A (en
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汪洋
汪民
许玉方
陈燕凌
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Guangzhou Deloop Electronic Devices Co ltd
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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
    • H01F27/28—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
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/08—Cooling; Ventilating
    • 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
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2823—Wires
    • 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
    • H01F27/2876—Cooling
    • 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
    • H01F27/34—Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
    • H01F27/346—Preventing or reducing leakage fields
    • 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

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Abstract

The invention discloses a manufacturing method of an inductor with a side surface provided with an air gap and a two-in-one structure. The Z type that the electrode was pressed close to coil end extends the piece and makes the end of extending piece parcel coil compress tightly with the instrument, and the extension piece of electrode is Z form setting and can makes the extension piece just in time wrap up the coil end, and the parcel of both rewelds, and electrically conductive effect is better, effectively reduces the loss. Compared with the inductor with the air gap on the front surface, the inductor with the two-in-one structure with the air gap on the side surface prepared by the manufacturing method has the advantages of compact integral structure, small volume and good performance. The preparation method provided by the invention is simple to operate and convenient to assemble, and has the advantages that the air gaps are formed on the side surfaces of the assembled independent parts during production, and the working efficiency is high.

Description

Manufacturing method of inductor with side surface provided with air gap and two-in-one structure
Technical Field
The invention relates to the technical field of inductor manufacturing, in particular to a manufacturing method of an inductor with a side surface air gap two-in-one structure.
Background
The electric principle and magnetic structure of the two-in-one inductor product on the market are shown in fig. 1 and fig. 2, the structure is that an air gap is formed on the front surface of a magnetic core, the position of the air gap is shown in fig. 3, the magnetic core of the structure is assembled by two independent products, each product uses a pair of E-shaped magnetic materials, the product is large in size, inconvenient to install and not in line with the trend of light, thin and small electronic components at present. In addition, in the inductor in the prior art, a round copper wire wound coil is used as a conductor, and the D.D.R. is large, so that the direct-current loss is increased. In addition, the overload capacity of the round copper wire is small, and the cross section of the round copper wire is circular, so that the space waste and the large distributed capacitance are caused by the large distance between wires and the large distance between layers in the winding process, the leakage inductance is large, the EMC performance is poor, and the electromagnetic interference is caused to peripheral components and equipment. . Once the technical personnel in China want to solve the problems for a long time, the existing problems can not be solved at the same time, or the product cost is too high, the competitiveness is reduced, or the problem of large product volume can not be solved, so that the problems are lost.
Therefore, it is important to provide a technology for manufacturing an inductor with small size, convenient installation, low cost, large current, low loss and strong electromagnetic interference resistance, which is suitable for the problems in the prior art.
Disclosure of Invention
The invention aims to avoid the defects in the prior art and provides the method for manufacturing the inductor, which has the advantages of small volume, convenient installation, low cost, high current, low loss and strong electromagnetic interference resistance.
The purpose of the invention is realized by the following technical scheme:
a manufacturing method of an inductor with a side surface having an air gap and a two-in-one structure is provided, which comprises the following steps:
(1) preparing accessories:
i, injection molding of a base: the base is produced by injection molding of a base raw material by using an injection molding machine, wherein the base is provided with four electrode grooves, the middle part of the base is transversely provided with a partition wall, two electrode grooves positioned on the same side of the partition wall form a group of electrode groove positions, a bearing seat is arranged between the two electrode grooves of each group of electrode groove positions, the bearing seat is provided with an arc-shaped concave surface, and the outer side of the arc-shaped concave surface is provided with a magnetic core adhesive area;
II, electrode forming: punching and forming the cut metal sheet to obtain an electrode, wherein the electrode is in a U-shaped clamp shape and is provided with a bent Z-shaped extension sheet;
III, winding a coil: winding the flat wire into an air-core coil by using a full-automatic flat wire winding machine, wherein the number of winding turns is 3.73-12.75, removing paint coats by using a 60-watt laser, and plating tin;
IV, preparing a magnetic core: preparing an EP type magnetic core and an I type magnetic core;
(2) assembling an electrode base: pressing the four electrodes into four electrode grooves of the base;
(3) gluing the partition wall: spreading glue on the top of the partition wall;
(4) assembling a coil: placing the coil on the arc concave surface of the cushion bearing seat, enabling the tail end of the coil to be close to the Z-shaped extension sheet of the electrode, enabling the extension sheet to wrap the tail end of the coil and tightly press the coil by using a tool, and finally soldering tin at the temperature of 320 +/-10 ℃ in a tin furnace;
(5) assembling the I-type magnetic core: placing the I-shaped magnetic core on glue water on the partition wall to enable the I-shaped magnetic core to be adhered to the partition wall;
(6) gluing a bearing seat and an I magnetic core: gluing water on the magnetic core gluing areas of the two cushion bearing seats, and gluing water on two sides of the top of the I-shaped magnetic core;
(7) assembling an EP type magnetic core: respectively installing an EP type magnetic core in the two magnetic core adhesive areas and enabling the side surface of the EP type magnetic core to be attached to the I type magnetic core, wherein the central column of the EP type magnetic core penetrates through the coil;
(8) glue solidification: and (5) baking the semi-finished product prepared in the step (7) by using an oven at the temperature of 115 +/-10 ℃ until the glue is completely solidified.
Preferably, the EP-type core and the I-type core are both manganese-zinc-ferrite.
Preferably, in the step (8), the baking time is 60 +/-10 minutes.
Preferably, when the coil is wound, a flat wire with the wire thickness of 0.3mm and the width of 1.2mm is adopted.
Preferably, the method further comprises the step (9) of electrically testing: and testing the inductance value, the direct current resistance value and the withstand voltage condition of the inductor.
Preferably, in step (9),
testing inductance conditions: 100KHz 0.25V, inductance value 1.0 uH +/-20%
Testing the direct current resistance condition: D.C.R. value of less than 7.0 m omega at 20 DEG C
Thirdly, withstand voltage test: coil-core, dc voltage 120V, current 2 ma, time 2 seconds.
The invention has the beneficial effects that:
(1) the base provided by the invention is provided with four electrode grooves, so that the electrodes can be conveniently installed without using an additional positioning device for positioning. The middle part transversely has the partition wall, lies in the partition wall and constitutes a set of electrode trench with two electrode tank one side, and the partition wall separates two sets of electrodes and avoids mutual interference, guarantees the good performance of inductor performance. The bearing seat is arranged between the two electrode grooves of each group of electrode groove positions and provided with an arc concave surface, and the coil is placed on the arc concave surface of the bearing seat, so that the coil with the structure is more stable to install. The electrode dress is in the electrode trench, and the Z type that the electrode was pressed close to the coil end extends the piece and makes the end of extending piece parcel coil compress tightly with the instrument, and the extension piece of electrode is Z form setting and can makes the extension piece just in time wrap up the coil end, and the parcel of both rewelds, and electrically conductive effect is better, effectively reduces the loss. Compared with the inductor with the air gap on the front surface, the inductor with the two-in-one structure with the air gap on the side surface prepared by the manufacturing method has the advantages of compact integral structure, small volume and good performance.
(2) The preparation method provided by the invention is simple to operate and convenient to assemble, and has the advantages that the air gaps are formed on the side surfaces of the assembled independent parts during production, and the working efficiency is high. The inductor with the air gap on the front surface in the prior art is required to complete the production of two independent products and then assembled together, so that the operation is troublesome and the working efficiency is low.
(3) The flat copper wire is used for winding the hollow coil, the current density is high, the heat dissipation performance is good, the carried current is high, the D.C.R. is smaller than that of a round enameled wire, so that the direct current loss is low, the gap between flat wire turns and turns is small, the distributed capacitance is small, the leakage inductance is small, the anti-electromagnetic interference performance is high, meanwhile, the contact surface of the flat copper wire and the extension piece is larger, the wire effect is better when the extension piece wraps the tail end of the coil, and the loss is lower.
(4) Two of the side surface air gap two-in-one structure inductor manufactured by the method only use the I-shaped magnetic core as the magnetic loop, and the front surface air gap product uses two pairs of E-shaped magnetic cores to form the magnetic loop, and the materials are more, so that the side surface air gap two-in-one structure inductor manufactured by the method saves one I-shaped magnetic core compared with the inductor in the prior art, thereby not only ensuring good integral effect, but also reducing the product cost and improving the market competitiveness.
(5) The flat wire of the inductor prepared by the method has higher conductive density than a round wire, can provide higher current load capacity, has low D.C.R. and lower direct current loss, small gap between the wires, small distributed capacitance, magnetic leakage, small distributed capacitance, higher reliability and excellent MEC performance.
Drawings
The invention is further illustrated by means of the attached drawings, the content of which is not in any way limitative of the invention.
FIG. 1 is an electrical schematic of a prior art inductor;
FIG. 2 is a magnetic structure diagram of a prior art inductor;
FIG. 3 is a schematic structural diagram of a base according to the present invention;
FIG. 4 is a schematic structural view of an electrode of the present invention;
FIG. 5 is a schematic structural view of an air core coil of the present invention;
FIG. 6 is a schematic diagram of the structure of an EP type magnetic core of the present invention;
FIG. 7 is a schematic diagram of a type I core of the present invention;
FIG. 8 is a schematic view of the glue applied to the partition wall of the present invention;
FIG. 9 is a schematic view of the present invention with coils installed;
FIG. 10 is a schematic view of the present invention with a type I core installed;
FIG. 11 is a schematic view illustrating the application of glue to the cushion pad of the present invention;
FIG. 12 is a schematic view of the present invention assembled with an EP core;
FIG. 13 is an electrical schematic of the inductor of the present invention;
FIG. 14 is a magnetic schematic of the inductor of the present invention;
FIG. 15 is a flow chart of the method operations of the present invention.
In fig. 1 to 15:
the device comprises a base 1, an electrode groove 1-1, a cushion seat 1-2, an arc-shaped curved surface 1-3, a magnetic core gluing area 1-4, a partition wall 1-5, an electrode 2, an extension piece 2-1, a coil 3, a coil end 3-1, a magnetic core 4 EP type, a central column 4-1, a magnetic core 5I type and an air gap 6.
Detailed Description
The invention is further illustrated by the following examples.
Example 1
The manufacturing method of the inductor with the side surface having the air gap two-in-one structure comprises the following steps:
(1) preparing accessories:
i, injection molding of a base: the base is produced by injection molding of a base raw material by using an injection molding machine, wherein the base is provided with four electrode grooves, the middle part of the base is transversely provided with a partition wall, two electrode grooves positioned on the same side of the partition wall form a group of electrode groove positions, a bearing seat is arranged between the two electrode grooves of each group of electrode groove positions, the bearing seat is provided with an arc-shaped concave surface, the outer side of the arc-shaped concave surface is provided with a magnetic core adhesive area, and the structure of the base is shown in figure 3;
II, electrode forming: punching and forming the cut metal sheet to obtain an electrode, wherein the electrode is in a U-shaped clamp shape and is provided with a bent Z-shaped extension sheet, and the electrode is used as a conductive carrier for connecting a product and a circuit board, and the electrode structure of the embodiment is shown in figure 4;
III, winding a coil: the full-automatic flat wire winding machine is used for winding 3.75 circles of flat wire hollow coils 13, the thickness of the wires is 0.3mm, the width of the wires is 1.2mm, and the wire suppliers are domestic manufacturers such as Dongmu, Jiateng and Songta and the like and require temperature resistance of more than 200 ℃. Removing paint coat with 60W high power laser, tin-plating on the surface after removing paint at 320 + -10 deg.C, and making the hollow coil structure shown in FIG. 5;
IV, preparing a magnetic core: preparing an EP type magnetic core and an I type magnetic core, wherein the structures of the EP type magnetic core and the I type magnetic core are respectively shown in figures 6 and 7, the I type magnetic core and the EP type magnetic core are both made of manganese-zinc ferrite, the AL value is about 68, and suppliers are domestic manufacturers such as Tiantong, horizontal Shangdong magnetic field and the like;
(2) assembling an electrode base: pressing the four electrodes into four electrode grooves of the base;
(3) gluing the partition wall: spreading glue on the top of the partition wall, wherein the amount of the glue is controlled to be 0.75 +/-0.10 mg, as shown in figure 8;
(4) assembling a coil: placing the coil on the arc concave surface of the cushion bearing seat, enabling the tail end of the coil to be close to the Z-shaped extension sheet of the electrode, enabling the extension sheet to wrap the tail end of the coil and tightly press the extension sheet with a tool, finally soldering tin at the temperature of 320 +/-10 ℃ in a tin furnace, and assembling the coil as shown in figure 9; compared with a round wire, the flat wire has the advantages of lower internal resistance, lower loss, smaller distributed capacitance, higher current bearing capacity and better direct current overlapping characteristic in the same occupied space.
(5) Assembling the I-type magnetic core: placing the I-shaped magnetic core on the glue on the partition wall to adhere the I-shaped magnetic core to the partition wall, as shown in FIG. 10;
(6) sizing a cushion bearing seat: glue is coated on the gluing areas of the magnetic cores of the two cushion bearing seats, glue XNR3622SR is coated on the two ends of the base, the dosage is controlled to be 1.1 +/-0.10 mg/position, and then glue XNR3501SL is coated on the two sides of the top of the I-shaped magnetic core, the dosage is controlled to be 0.36 +/-0.05 mg/position, as shown in figure 11;
(7) assembling an EP type magnetic core: attaching an EP-type magnetic core to each of the two magnetic core adhesive regions and attaching a side surface of the EP-type magnetic core to the I-type magnetic core, with the center pole of the EP-type magnetic core passing through the coil, as shown in FIG. 12;
(8) glue solidification: and (5) baking the semi-finished product prepared in the step (7) by using an oven at the temperature of 115 +/-10 ℃ until the glue is completely solidified.
The inductor with the side surface and the air gap in the two-in-one structure prepared by the method is the inductor with the magnetic core and the side surface and the air gap (as shown in fig. 12), and compared with the prior art, the flat copper wire low-loss inductor has the advantages that the size is small, and is about 2/3 of the size of the traditional inductor; an air gap is formed on the side surface, so that the assembly is convenient; the flat copper wire has the advantages of large overcurrent capacity, low direct current resistance, small loss, small distributed capacitance and strong anti-electromagnetic interference performance; the method is suitable for small-sized digital amplifiers (D-AMP stages), radio audio amplifiers, vehicle AV and the like. In addition, the invention can be made into series products according to the needs of customers, thus saving the development cost; one I-shaped magnetic core is saved, the product cost is reduced, and the market competitiveness is improved.
No. 1-6 inductors are prepared by using the method for the wire rods, the magnetic cores and the winding turns which are not used, the inductance value and the D.C.R value are tested, and the test results are as follows:
Figure 903057DEST_PATH_IMAGE001
the test data in the table shows that the inductor manufactured by the method of the invention not only has small volume, but also can provide higher current load capacity, lower direct current loss and small distributed capacitance, higher reliability and excellent MEC performance.
Example 2
The main technical solution of this embodiment is substantially the same as that of embodiment 1, and the features that are not explained in this embodiment adopt the explanations in embodiment 1, and are not described herein again. The method further comprises an electrical testing step (9) for testing inductance, current resistance and voltage withstanding degree, wherein the inductance condition is tested: 100KHz 0.25V, inductance value 1.0 muH plus or minus 20%; testing the direct current resistance condition: D.C.R. value is less than 7.0 m omega at 20 ℃; thirdly, withstand voltage test: coil-core, dc voltage 120V, current 2 ma, time 2 seconds. Other electrical characteristics can be measured according to the needs of customers.
Finally, it should be noted that the above embodiments are only used for illustrating the technical solutions of the present invention and do not limit the protection scope of the claims. It will be understood by those skilled in the art that various modifications and equivalents may be made to the embodiments of the present invention without departing from the spirit and scope of the invention.

Claims (6)

1. The manufacturing method of the inductor with the side surface provided with the air gap two-in-one structure is characterized in that: the method comprises the following steps:
(1) preparing accessories:
i, injection molding of a base: the base is produced by injection molding of a base raw material by using an injection molding machine, wherein the base is provided with four electrode grooves, the middle part of the base is transversely provided with a partition wall, two electrode grooves positioned on the same side of the partition wall form a group of electrode groove positions, a bearing seat is arranged between the two electrode grooves of each group of electrode groove positions, the bearing seat is provided with an arc-shaped concave surface, and the outer side of the arc-shaped concave surface is provided with a magnetic core adhesive area;
II, electrode forming: punching and forming the cut metal sheet to obtain an electrode, wherein the electrode is in a U-shaped clamp shape and is provided with a bent Z-shaped extension sheet;
III, winding a coil: winding the flat wire into an air-core coil by using a full-automatic flat wire winding machine, wherein the number of winding turns is 3.73-12.75, removing paint coats by using a 60-watt laser, and plating tin;
IV, preparing a magnetic core: preparing an EP type magnetic core and an I type magnetic core;
(2) assembling an electrode base: pressing the four electrodes into four electrode grooves of the base;
(3) gluing the partition wall: spreading glue on the top of the partition wall;
(4) assembling a coil: placing the coil on the arc concave surface of the cushion bearing seat, enabling the tail end of the coil to be close to the Z-shaped extension sheet of the electrode, enabling the extension sheet to wrap the tail end of the coil and tightly press the coil by using a tool, and finally soldering tin at the temperature of 320 +/-10 ℃ in a tin furnace;
(5) assembling the I-type magnetic core: placing the I-shaped magnetic core on glue water on the partition wall to enable the I-shaped magnetic core to be adhered to the partition wall;
(6) gluing a bearing seat and an I magnetic core: gluing water on the magnetic core gluing areas of the two cushion bearing seats, and gluing water on two sides of the top of the I-shaped magnetic core;
(7) assembling an EP type magnetic core: respectively installing an EP type magnetic core in the two magnetic core adhesive areas and enabling the side surface of the EP type magnetic core to be attached to the I type magnetic core, wherein the central column of the EP type magnetic core penetrates through the coil;
(8) glue solidification: and (5) baking the semi-finished product prepared in the step (7) by using an oven at the temperature of 115 +/-10 ℃ until the glue is completely solidified.
2. The method for manufacturing an inductor with a side-surface air-gap two-in-one structure according to claim 1, wherein: the EP type magnetic core and the I type magnetic core are both manganese-zinc ferrite.
3. The method for manufacturing an inductor with a side-surface air-gap two-in-one structure according to claim 1, wherein: in the step (8), the baking time is 60 +/-10 minutes.
4. The method for manufacturing an inductor with a side-surface air-gap two-in-one structure according to claim 1, wherein: when the coil is wound, a flat wire with the wire thickness of 0.3mm and the width of 1.2mm is adopted.
5. The method for manufacturing an inductor with a side-surface air-gap two-in-one structure according to claim 1, wherein: the method also comprises the following step (9) of electrical testing: and testing the inductance value, the direct current resistance value and the withstand voltage condition of the inductor.
6. The method for manufacturing an inductor with a side-surface air-gap two-in-one structure according to claim 5, wherein: in the step (9), the step (c),
testing inductance conditions: 100KHz 0.25V, inductance value 1.0 uH +/-20%
Testing the direct current resistance condition: D.C.R. value of less than 7.0 m omega at 20 DEG C
Thirdly, withstand voltage test: coil-core, dc voltage 120V, current 2 ma, time 2 seconds.
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