CN113436830A

CN113436830A - Plastic molded component and manufacturing method thereof

Info

Publication number: CN113436830A
Application number: CN202110573756.5A
Authority: CN
Inventors: 余鑫树; 李有云; 侯勤田; 姚泽鸿; 王莹莹; 夏胜程
Original assignee: Shenzhen Sunlord Electronics Co Ltd
Current assignee: Shenzhen Sunlord Electronics Co Ltd
Priority date: 2021-05-25
Filing date: 2021-05-25
Publication date: 2021-09-24

Abstract

A plastic mould component and a manufacturing method thereof are provided, the plastic mould component comprises an air coil, a magnetic core, a magnetic plastic package layer and electrodes, the air coil is wound on the periphery of the magnetic core, wherein the magnetic core is a pre-sintered magnetic core, the magnetic plastic package layer is a magnetic plastic package layer which is plastically moulded on the air coil and the pre-sintered magnetic core in a transfer moulding or embedding mode, and the electrodes connected with leads of the air coil are exposed outside the magnetic plastic package layer. Because the presintered magnetic core is introduced into the molding component, and the magnetic molding layer on the coil and magnetic core assembly is formed in a transfer molding or encapsulating mode, the damage, deformation and magnetic core fragmentation of a copper wire during a sintering process and cold pressing or hot pressing molding can be effectively avoided, the electrical characteristics such as inductance, saturation characteristic and the like of the component product can be improved, and the product has high reliability, simple process and low cost.

Description

Plastic molded component and manufacturing method thereof

Technical Field

The invention relates to an electronic component, in particular to a plastic mold component and a manufacturing method thereof.

Background

The traditional manufacturing process of the sheet frame type component generally comprises the steps of winding a coil, spot welding and then hot-pressing or cold-pressing molding, and when the hot-pressing process is adopted, the molding temperature is high, the pressure is high, copper wires are easy to damage and desolder, the risk of open short circuit is high, and the yield is low; when the cold pressing process is adopted, the internal density of the product is uneven, cracks are easy to generate, and the reliability of the product is poor.

The traditional technology for molding the inductor generally adopts single winding plastic package, and needs to perform insulation treatment on a semi-finished product of the plastic package, perform paint stripping on a coil lead, and finally perform metallization treatment to form an electrode. Due to the interaction among different materials, the coating layer of the product is easy to have the defects of bubbling, bulging and the like, the stress between the electrode metalized coating and the bare copper is large, the phenomena of floating height, electrode layer peeling and the like are easy to occur during welding, and the welding reliability is poor. Secondly, the inductor has complex manufacturing process, low production efficiency and high cost.

The prior art lacks an electronic component with simple manufacturing process, low cost and high reliability and a manufacturing method thereof.

It is to be noted that the information disclosed in the above background section is only for understanding the background of the present application and thus may include information that does not constitute prior art known to a person of ordinary skill in the art.

Disclosure of Invention

The main purpose of the present invention is to overcome the above-mentioned drawbacks of the background art, and to provide a molding device with high reliability and good overall performance, and a method for manufacturing the same, which has a simple process, high degree of automation, and low cost.

In order to achieve the purpose, the invention adopts the following technical scheme:

the utility model provides a mould shaping components and parts, includes hollow coil, magnetic core, magnetism plastic envelope layer and electrode, hollow coil coiling in the periphery of magnetic core, wherein, the magnetic core is the magnetic core that the presintering is good, and magnetism plastic envelope layer is in with the mode plastic envelope shaping of transfer molding or embedment hollow coil with magnetism plastic envelope layer on the magnetic core that the presintering is good, with the electrode that the lead wire of hollow coil links to each other exposes in the magnetism plastic envelope layer outside.

Further:

the electrode is formed by cutting a part of an outer sheet frame to which a lead wire of the air-core coil is welded.

The magnetic core is made of ferrite materials, and the magnetic plastic packaging layer is made of soft magnetic alloy; or, the magnetic core is soft magnetic alloy, and the magnetic plastic packaging layer is soft magnetic alloy.

The magnetic plastic package layer is used for plastic packaging of a single hollow coil and the magnetic core to form a single-phase component, or a plurality of hollow coils and the magnetic core are integrated into a whole to form a multi-phase component.

A method for manufacturing a molded component comprises the following steps:

s1, winding an air core coil on the pre-sintered magnetic core, or implanting the pre-sintered magnetic core into the prefabricated air core coil;

and S2, forming a magnetic plastic package layer on the hollow coil and the pre-sintered magnetic core by means of transfer molding or potting, and exposing electrodes connected with leads of the hollow coil outside the magnetic plastic package layer.

Further:

the winding air core coil on will sintering in advance includes: and winding round wires, flat wires, square wires or litz wires on the magnetic core to form a coil winding.

The method further comprises the following steps: before step S2, the lead of the air-core coil is welded to the electrode portion of the outer sheet frame, and after step S2, the electrode portion is cut out from the outer sheet frame, and the electrode of the component is shaped.

The welding is hot pressure welding or laser spot welding.

M hollow coils, N magnetic cores and a rectangular external material sheet frame form a combined body, the combined body is subjected to plastic package in a transfer molding or encapsulation mode, the electrode part of the combined body is exposed outside the magnet, M is larger than or equal to 1, and N is larger than or equal to 1.

In the step S2, the plastic package molding temperature is lower than the failure temperature of the insulating layer and the self-adhesive layer of the self-adhesive wire used for winding the hollow coil, and the molding pressure is 0-100 MPa.

The invention has the following beneficial effects:

the invention provides a plastic molding component and a manufacturing method thereof, wherein a pre-sintered magnetic core and an air core coil are combined, a magnetic plastic sealing layer is formed on the combined body of the air core coil and the pre-sintered magnetic core in a transfer molding or encapsulating mode, the pre-sintered magnetic core is introduced into the plastic molding component, and the magnetic plastic sealing layer on the coil and magnetic core combined body is formed in the transfer molding or encapsulating mode, so that the damage, deformation and magnetic core fragmentation of a copper wire in a sintering process and cold pressing or hot pressing molding can be effectively avoided, the electrical characteristics such as inductance, saturation characteristic and the like of a component product can be improved, the reliability of the product is high, the comprehensive performance is good, the manufacturing process is simple, and the cost is low.

The advantages of the preparation method of the molding inductor provided by the embodiment of the invention are embodied in the following aspects:

1) the presintered magnetic core is introduced to be combined with the coil, a sintering process is not required to be carried out on a coil assembly, a molding or filling and sealing process is adopted, the molding pressure is low, the molding temperature is lower than the failure temperature of a self-adhesive layer of the wire rod, the damage and the deformation of a copper wire can be avoided, and the magnetic core can be prevented from being cracked, so that the product reliability is high;

2) the combination design of the hollow coil, the pre-sintered magnetic core and the plastic package material is adopted, so that the comprehensive electrical characteristics of the product can be improved;

3) the lead of the hollow coil is connected with the rectangular material sheet frame electrode by adopting a spot welding process, the electrode part of the material sheet frame is directly cut, folded and molded, and the process is simple, the automation degree is high, and the cost is low.

Drawings

FIG. 1A is a schematic view of an air core coil configuration in one embodiment of the present invention;

FIG. 1B is a schematic illustration of a welded assembly in one embodiment of the invention;

FIG. 1C is a schematic diagram of an assembly of an air-core coil, T-core, and web frame in one embodiment of the present invention;

FIG. 1D is a schematic view of a molded, semi-finished product in one embodiment of the present invention;

FIG. 1E is a schematic diagram of a single-phase component in one embodiment of the invention;

FIG. 2A is a schematic illustration of an I-core in one embodiment of the present invention;

FIG. 2B is a schematic view of an air core coil winding in one embodiment of the present invention;

FIG. 2C is a schematic view of an assembly of an air-core coil, T-core, and web frame in accordance with an embodiment of the present invention;

FIG. 2D is a schematic view of a molded, semi-finished product in accordance with an embodiment of the present invention;

fig. 2E is a schematic diagram of a multiphase device in an embodiment of the invention.

Detailed Description

The embodiments of the present invention will be described in detail below. It should be emphasized that the following description is merely exemplary in nature and is not intended to limit the scope of the invention or its application.

It will be understood that when an element is referred to as being "secured to" or "disposed on" another element, it can be directly on the other element or be indirectly on the other element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or be indirectly connected to the other element. In addition, the connection may be for either a fixed or coupled or communicating function.

It is to be understood that the terms "length," "width," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," and the like are used in an orientation or positional relationship indicated in the drawings for convenience in describing the embodiments of the present invention and to simplify the description, and are not intended to indicate or imply that the referenced device or element must have a particular orientation, be constructed in a particular orientation, and be in any way limiting of the present invention.

Furthermore, the terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the embodiments of the present invention, "a plurality" means two or more unless specifically limited otherwise.

Referring to fig. 1E and fig. 2E, an embodiment of the invention provides a molded component, which includes an

air core coil

110, 220, a

magnetic core

130, 210, a

magnetic molding layer

140, 240, and electrodes, where the

air core coil

110, 220 is wound around the periphery of the

magnetic core

130, 210, where the

magnetic core

130, 210 is a pre-sintered

magnetic core

130, 210, and the

magnetic molding layer

140, 240 is the

magnetic molding layer

140, 240 that is molded on the

air core coil

110, 220 and the pre-sintered

magnetic core

130, 210 by transfer molding or potting, and the

electrodes

121, 122, 123, 124, 232 ', 233 ', 234 ' connected to leads of the

air core coil

110, 220 are exposed outside the

magnetic molding layer

140, 240.

Referring to fig. 1A to fig. 2E, an embodiment of the invention further provides a method for manufacturing a molded component, including the following steps:

s1, winding the air core coil 220 on the pre-sintered magnetic core 210, or implanting the pre-sintered magnetic core 130 into the pre-fabricated air core coil 110;

s2, forming a

magnetic molding layer

140, 240 on the

hollow coil

110, 220 and the pre-sintered

magnetic core

130, 210 by means of transfer molding or potting, and exposing electrodes connected to leads of the

hollow coil

110, 220 outside the

magnetic molding layer

140, 240.

The combined design of the hollow coil, the pre-sintered magnetic core and the magnetic plastic packaging layer is adopted, so that the comprehensive electrical characteristics of the product can be improved. Because the presintered magnetic core is introduced into the molding component, and the magnetic molding layer on the coil and magnetic core assembly is formed in a transfer molding or encapsulating mode, the damage, deformation and magnetic core fragmentation of a copper wire during a sintering process and cold pressing or hot pressing molding can be effectively avoided, the electrical characteristics such as inductance, saturation characteristic and the like of a component product can be improved, and the product has high reliability, good comprehensive performance, simple manufacturing process and low cost.

In some embodiments, a web frame molded component includes: m (M is more than or equal to 1) hollow coils, N (N is more than or equal to 1) magnetic cores and a rectangular material sheet frame, then the combined body is plastically packaged in a transfer molding or encapsulation mode, and the electrode part of the combined body is exposed outside the magnet.

In some embodiments, the hollow coil is formed by winding on a center pillar of the magnetic core and then welded with the rectangular sheet frame; or after the hollow coil is formed by single winding, the hollow coil is welded with the rectangular sheet frame to form a welding assembly, and then the magnetic core is implanted into the hollow coil.

The lead of the hollow coil and the electrode part of the rectangular material sheet frame can be connected by adopting a spot welding process subsequently, the electrode part of the material sheet frame is directly cut, folded and formed into an electrode of a component, and the process is simple, the automation degree is high, and the cost is low.

In some embodiments, the magnetic core is a ferrite material and the magnetic molding layer is a soft magnetic alloy; or, the magnetic core is soft magnetic alloy, and the magnetic plastic packaging layer is soft magnetic alloy.

In some embodiments, the magnetic molding layer molds the assembly formed by the hollow coil, the magnetic core and the rectangular tablet frame in a transfer molding or potting mode, and the electrode part of the assembly is exposed outside the magnet.

In some embodiments, the molding compound is used for molding a single air-core coil and a magnetic core into a single-phase component, or molding a plurality of air-core coils and magnetic cores into a whole to form a multi-phase component.

In some embodiments, the plastic molding temperature is lower than the failure temperature of the insulating layer and the self-adhesive layer of the self-adhesive wire for winding the hollow coil, and the molding pressure is 0-100 MPa.

In some embodiments, a method for manufacturing a sheet frame type molded component includes the following steps:

a. winding of the hollow coil: self-adhesive wires such as round wires, flat wires, square wires and litz wires are wound along the center pillar of the magnetic core to form a winding comprising a single or a plurality of hollow coils;

b. spot welding of the hollow coil winding and the rectangular sheet frame or spot welding of the hollow coil and the rectangular sheet frame: welding the hollow coil winding and the rectangular material sheet frame by adopting hot-press welding or laser spot welding to connect the lead of the hollow coil with the electrode part of the material sheet frame to form a welding assembly;

or welding the hollow coil and the rectangular material sheet frame by adopting hot pressure welding or laser spot welding to connect the lead of the hollow coil with the electrode part of the material sheet frame, and then implanting the magnetic core into the hollow coil to form a combined body;

c. compression molding: the combined body is subjected to plastic package through a molding or filling and sealing process, and the electrode part of the combined body is exposed outside the magnetic plastic package layer;

d. and (3) heat treatment: curing the organic component of the plastic packaging layer; wherein, the organic component of the plastic packaging layer can be solidified by baking;

e. and cutting and folding the electrode part of the cured semi-finished product to obtain a finished product.

Specific embodiments of the present invention are further described below with reference to the accompanying drawings.

Example one

As shown in fig. 1A to 1E, a sheet frame type molded component and a method for manufacturing the same includes the following steps:

1) making an air-core coil 110

Referring to fig. 1A, the air-core coil 110 is formed by winding a self-adhesive enameled round copper wire in a counter-winding manner.

2) Spot-welded hollow coil and rectangular material sheet frame

The fillet of the rectangular tablet frame 120 and the pin 111 of the air-core coil are fused together by laser spot welding, and the welded assembly of the air-core coil and the tablet is shown in fig. 1B.

3) Implanted T-shaped magnetic core

The T-shaped magnetic core 130 is manufactured by adopting a die pressing integral forming and sintering process, and then the center pillar 131 of the T-shaped magnetic core is implanted into the air core coil 110, wherein the T-shaped magnetic core is FeSiCr metal soft magnetic powder which is subjected to passivation and insulation treatment, the magnetic permeability of the magnetic core is preferably 30-100, and the saturation magnetic flux is 1000-1500 mT. Preferably, the implantation fit clearance of the air core coil and the magnetic core is 20-150 μm, so as to realize the automatic implantation of the T-shaped magnetic core, and the implanted combination body is shown in fig. 1C.

4) Moulding

Transferring the combined body of the hollow coil, the T-shaped magnetic core and the material sheet frame to an injection molding die frame, preferably, coating the combined body (except for an electrode part) of the hollow coil, the T-shaped magnetic core and the material sheet frame in a magnetic plastic packaging layer 140 by adopting an injection molding process, wherein magnetic powder contained in the magnetic plastic packaging layer is FeSiCr metal soft magnetic powder subjected to passivation and insulation treatment, the molding pressure is 100Mpa, and the magnetic conductivity ui is 30-60; demoulding to obtain a semi-finished product, baking the semi-finished product at 170 ℃ for 1 hour to solidify the organic components of the plastic sealing layer, and molding to obtain the semi-finished product shown in figure 1D;

5) electrode formation

Transferring the semi-finished product obtained in the step 4) to a cutting device, cutting the material sheet frame to form a single cut semi-finished product, bending the electrode part 120 of the material sheet frame including the

side electrodes

121 and 122 and the

bottom electrodes

123 and 124, folding the

bottom electrodes

123 and 124 into the electrode grooves 141 and 142, flattening the

electrodes

123 and 124 in the electrode grooves 141 and 142, and finally manufacturing a finished product. Fig. 1E is a schematic diagram of the finished product of this embodiment, which includes a coil 110, an electrode portion 120 (including

side electrodes

121, 122 and bottom electrodes 123, 124) of a matrix web frame, a T-shaped magnetic core 130, and a magnetic molding layer 140.

Example two

As shown in fig. 2A to 2E, a method for manufacturing a sheet frame type molded inductor bank includes the following steps:

1) making an I-shaped core 210

As shown in FIG. 2A, the I-shaped magnetic core 210 is made of ferrite by adopting the processes of die pressing, cutting and sintering, the magnetic conductivity is preferably 3000-5000, and the saturation magnetic flux is 400-500 mT.

2) Making air-core coil windings

A flat self-adhesive wire is used and is wound around the center pillar of the i-shaped core 210 to form an air-core coil winding, as shown in fig. 2B, which is composed of two parts, i-shaped core 210 and air-core coil 220.

3) Welding of hollow coil winding and rectangular tablet frame

The fillet of the rectangular sheet frame 230 is melted by laser spot welding to cover the pins of the air-core coil 220, and the welded assembly of the air-core coil winding and the sheet is shown in fig. 2C.

4) Moulding

The combined body of the hollow coil, the I-shaped magnetic core and the material sheet frame is transferred to an injection mold frame, M (M is more than or equal to 2) hollow coils 220, N (N is more than or equal to 2) I-shaped magnetic cores 210 and a rectangular material sheet frame 230 (except for an electrode part) are completely sealed in a plastic package mode through a glue filling and sealing process, in the embodiment, three hollow coils and three I-shaped magnetic cores are used as a unit, and the plastic package is integrated. The magnetic powder contained in the magnetic plastic packaging layer is FeSiAl metal soft magnetic powder subjected to passivation and insulation treatment, the forming pressure is 10Mpa, and the magnetic conductivity ui is 15-35; demoulding to obtain a semi-finished product of the molding, and then baking the semi-finished product of the molding for 2H at the temperature of 120 ℃ or above to solidify the organic components of the plastic packaging layer;

5) electrode formation

Implanting the semi-finished product obtained in the step 4) into a cutting device, cutting the material sheet frame 230 to form a plurality of cut semi-finished products, bending the electrode part of the semi-finished products, and finally leveling and pin-trimming the bottom electrode to finally manufacture a finished product. Fig. 2E shows a three-phase inductor component finished product of this embodiment, which includes three i-shaped

magnetic cores

210, 210 ', 210 ", three air-

core coils

220, 220 ', 220", and three corresponding pairs of

electrodes

232, 232 ', 233, 233 ', 234, 234 ', and a magnetic plastic-encapsulated layer 240.

The number of the hollow coils and the magnetic cores is not limited to one or two, the shapes and the specifications of the hollow coils, the magnetic cores and the material sheet frame are not limited to one in the same embodiment, and the hollow coils and the magnetic cores can be designed into different shapes according to design requirements, made of different materials and designed into multiphase special-shaped structural components.

The background of the present invention may contain background information related to the problem or environment of the present invention and does not necessarily describe the prior art. Accordingly, the inclusion in the background section is not an admission of prior art by the applicant.

The foregoing is a more detailed description of the invention in connection with specific/preferred embodiments and is not intended to limit the practice of the invention to those descriptions. It will be apparent to those skilled in the art that various substitutions and modifications can be made to the described embodiments without departing from the spirit of the invention, and these substitutions and modifications should be considered to fall within the scope of the invention. In the description herein, references to the description of the term "one embodiment," "some embodiments," "preferred embodiments," "an example," "a specific example," or "some examples" or the like are intended to mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above are not necessarily intended to refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Various embodiments or examples and features of various embodiments or examples described in this specification can be combined and combined by one skilled in the art without contradiction. Although embodiments of the present invention and their advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the scope of the claims.

Claims

1. The utility model provides a mould shaping components and parts, its characterized in that includes hollow coil, magnetic core, magnetism plastic envelope layer and electrode, hollow coil twine in the periphery of magnetic core, wherein, the magnetic core is the magnetic core that the presintering is good, and magnetism plastic envelope layer is in with the mode plastic envelope shaping of transfer molding or embedment hollow coil with the magnetism plastic envelope layer on the magnetic core that the presintering is good, with the electrode that the lead wire of hollow coil links to each other exposes in the magnetism plastic envelope layer outside.

2. A molded component as claimed in claim 1, wherein the electrode is formed by cutting a part of an outer sheet frame to which a lead of the hollow coil is soldered.

3. A moulded component as claimed in claim 1 or claim 2, in which the core is of ferrite material and the magnetic moulding layer is of soft magnetic alloy; or, the magnetic core is soft magnetic alloy, and the magnetic plastic packaging layer is soft magnetic alloy.

4. A molded component as claimed in any one of claims 1 to 3, wherein the magnetic molding layer is molded to form a single phase component by molding a single air core coil and a magnetic core, or a plurality of air core coils and a plurality of magnetic cores are molded to form a multi-phase component by molding them as a single body.

5. A method for manufacturing a molded component is characterized by comprising the following steps:

6. A method of manufacturing a molded component as claimed in claim 5, wherein winding the air-core coil around the pre-sintered core comprises: and winding round wires, flat wires, square wires or litz wires on the magnetic core to form a coil winding.

7. A method of manufacturing a molded component as claimed in claim 5 or 6, further comprising: before step S2, the lead of the air-core coil is welded to the electrode portion of the outer sheet frame, and after step S2, the electrode portion is cut out from the outer sheet frame, and the electrode of the component is shaped.

8. A method of manufacturing a moulded component as claimed in claim 7, in which the weld is a heat and pressure weld or a laser spot weld.

9. A method for manufacturing a molded component as claimed in claim 7, wherein M air-core coils, N magnetic cores and a rectangular outer sheet frame are combined to form a combined body, and the combined body is plastically molded in a transfer molding or potting manner, wherein electrode portions of the combined body are exposed outside the magnets, M is larger than or equal to 1, and N is larger than or equal to 1.

10. A method for manufacturing a molded component as claimed in any one of claims 5 to 9, wherein in step S2, the molding temperature is lower than the failure temperature of the insulating layer and the self-adhesive layer of the self-adhesive wire for winding the hollow coil, and the molding pressure is 0 to 100 MPa.