CN114121477B - Integrally-formed transformer, manufacturing method thereof and electronic equipment - Google Patents
Integrally-formed transformer, manufacturing method thereof and electronic equipment Download PDFInfo
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- CN114121477B CN114121477B CN202210083102.9A CN202210083102A CN114121477B CN 114121477 B CN114121477 B CN 114121477B CN 202210083102 A CN202210083102 A CN 202210083102A CN 114121477 B CN114121477 B CN 114121477B
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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
- H01F41/0246—Manufacturing of magnetic circuits by moulding or by pressing powder
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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
- H01F27/255—Magnetic cores made from particles
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Abstract
The invention relates to an integrally formed transformer, a manufacturing method thereof and electronic equipment, wherein the manufacturing method of the integrally formed transformer comprises the following steps: providing a printed circuit board, printing a first winding and a second winding on the printed circuit board, wherein a first through hole is formed in the inner side of the first winding of the printed circuit board, and a second through hole is formed in the inner side of the second winding of the printed circuit board; putting the printed circuit board into a pressing mold; filling the magnetic powder into a pressing die cavity; the pressing die cavity in the pressing die is pressurized, so that magnetic powder in the pressing die is pressed and formed into the magnetic core, the magnetic core penetrates through the first through hole and the second through hole and is coated on the outer side of the printed circuit board, and the transformer is manufactured. The equipment process of magnetic core has effectively been simplified, has improved the production efficiency of transformer for the transformer is applicable to automated production, and the volume of magnetic core is less, is favorable to the miniaturization of transformer, and the stability of quality of compression molding's magnetic core is higher, makes the magnetic core of production standardized, has effectively improved the reliability of transformer.
Description
Technical Field
The invention relates to the technical field of transformers, in particular to an integrally formed transformer, a manufacturing method thereof and electronic equipment.
Background
With the continuous development of electronic information technology, various electrical components on electronic equipment are also being miniaturized.
The miniaturization of transformers in electronic devices has also been accompanied. The magnetic core on the existing transformer is formed by adopting a high-temperature sintering mode, and the two E-shaped magnetic blocks are bonded together by viscose. Such a magnetic core is complicated in production and assembly processes, which leads to low production efficiency of the transformer, and is difficult to be applied to automatic production.
Disclosure of Invention
Accordingly, there is a need for an integrally formed transformer, a method of manufacturing the same, and an electronic device.
A method of manufacturing an integrally formed transformer, comprising:
providing a printed circuit board, wherein a first winding and a second winding are printed on the printed circuit board in advance, a first through hole is formed in the inner side of the first winding of the printed circuit board, and a second through hole is formed in the inner side of the second winding of the printed circuit board;
putting the printed circuit board into a pressing die;
filling magnetic powder into a pressing die cavity in the pressing die;
and pressurizing the pressing die cavity in the pressing die so as to press and form the magnetic powder in the pressing die into a magnetic core, so that the magnetic core penetrates through the first through hole and the second through hole and is coated on the outer side of the printed circuit board, and the transformer is manufactured.
In one embodiment, in the step of pressurizing the pressing mold, the pressure of pressurizing the pressing mold is 55 to 65 MPa.
In one embodiment, in the step of pressing the pressing mold, the pressing time of the pressing mold is 0.3 to 2 seconds.
In one embodiment, the step of pressurizing the pressing die further comprises:
and baking the transformer.
In one embodiment, in the step of baking the transformer, the baking time is 80 minutes to 90 minutes.
In one embodiment, in the step of baking the transformer, the baking temperature of the transformer is gradually increased.
In one embodiment, in the step of baking the transformer, the baking temperature is 70 ℃ to 150 ℃.
In one embodiment, the magnetic powder is made of any one of iron silicon chromium, carbonyl and Amorphous.
An integrally formed transformer comprises a printed circuit board and an integrally pressed magnetic core; the magnetic core is characterized in that a first winding and a second winding are printed on the printed circuit board, a first through hole is formed in the inner side of the first winding, a second through hole is formed in the inner side of the second winding, and the magnetic core penetrates through the first through hole and the second through hole and is coated on the outer side of the printed circuit board.
An electronic device comprising the integrally formed transformer of any of the above embodiments.
The invention has the beneficial effects that: through putting into the embossing mold utensil with printed circuit board in, and add the magnetic in the embossing mold utensil and suppress, make the last magnetic core that forms integrated into one piece of printed circuit board, the equipment process of magnetic core has effectively been simplified, the production efficiency of transformer has been improved, and the magnetic core of integrated into one piece suppression can make the transformer be applicable to automated production, furthermore, the volume of integrated into one piece's magnetic core is less, be favorable to the miniaturization of transformer, furthermore, the stability of quality of compression molding's magnetic core is higher, make the magnetic core of production standardized, the reliability of transformer has effectively been improved.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the embodiments or the prior art descriptions will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and other drawings can be obtained by those skilled in the art without creative efforts.
Fig. 1 is a schematic flow chart illustrating a manufacturing method of an integrally formed transformer according to an embodiment.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
As shown in fig. 1, a method for manufacturing an integrally formed transformer according to an embodiment of the present invention includes:
In this embodiment, the printed Circuit board is a pcb (printed Circuit board), the printed Circuit board is printed with a Circuit of a transformer, and further printed with a first winding and a second winding connected to the Circuit, one of the first winding and the second winding is a primary winding, the other is a secondary winding, and the printed Circuit board is provided with a first through hole and a second through hole, wherein the first through hole is located inside the first winding, the second through hole is located inside the second winding, and the first through hole and the second through hole are used for installing a magnetic core, so that the first winding and the second winding are respectively wound outside the magnetic core. In this embodiment, the first winding and the second winding are printed on the printed circuit board, so that the volumes of the first winding and the second winding are smaller, and the overall volume of the transformer is smaller.
And step 120, putting the printed circuit board into a pressing mold.
In this embodiment, a pressing mold cavity is provided in the pressing mold, the printed circuit board is placed in the pressing mold, and the first through hole and the second through hole on the printed circuit board correspond to the pressing mold cavity, and the first through hole and the second through hole are communicated with the pressing mold cavity. In one embodiment, the pressing mold includes a first mold and a second mold, when the first mold and the second mold are closed, the inner sides of the first mold and the second mold communicate to form a pressing cavity and close the pressing cavity, the side wall of the first through hole is connected to the side wall of the pressing cavity, the side wall of the second through hole is connected to the side wall of the pressing cavity, such that the first through hole and the second through hole communicate with the pressing cavity and such that the first through hole and the second through hole are isolated from the outside.
In one embodiment, the printed circuit board is placed into a press mold of a press molding machine including the press module, the press molding machine being configured to pressurize the press mold. In this embodiment, the printed circuit board is placed on a first mold of a press molding machine, and a second mold is closed to the first mold, so that the printed circuit board is located between the first mold and the second mold, and the press mold cavity is closed, so that the first through hole and the second through hole of the printed circuit board are communicated with the press mold cavity. In one embodiment, the first mold abuts against the printed circuit board, the second mold abuts against the printed circuit board, a first cushion pad is arranged at a position where the first mold abuts against the printed circuit board, and a second cushion pad is arranged at a position where the second mold abuts against the printed circuit board.
In order to avoid crushing the printed circuit board by closing the pressing mold, in one embodiment, the pressing forming machine is provided with a clamp which is used for clamping one end of the printed circuit board, so that the printed circuit board can be supported by the clamp, the first mold and the second mold are closed from the upper side and the lower side of the printed circuit board, and in the process of closing the mold, the first mold and the second mold are not required to be abutted to the printed circuit board, only the pressing mold cavity is required to be aligned with the first through hole and the second through hole for closing the mold, and after closing the mold, the pressing mold cavity is closed and is communicated with the first through hole and the second through hole, so that the pressing mold is prevented from crushing the printed circuit board.
And step 130, filling the magnetic powder into a pressing die cavity in the pressing die.
In this embodiment, the compacting tool has a compacting cavity therein, and the compacting cavity is used for filling magnetic powder. In one embodiment, the side wall of the pressing mold cavity is provided with a feed channel, and the press forming machine is provided with a feed pipe which is communicated with the feed channel and through which the magnetic powder can be fed to the pressing mold cavity.
In this embodiment, the magnetic powder is charged into the pressing cavity of the pressing die so that the pressing cavity is filled with the magnetic powder, and the magnetic powder also fills the first through hole and the second through hole. In this embodiment, the speed of conveying the magnetic powder into the pressing die cavity through the feeding pipe is 1800mm/s, so that the pressing die cavity can be quickly filled with the magnetic powder. In other embodiments, the speed of feeding the magnetic powder into the pressing cavity through the feeding tube can be set according to the volume of the pressing cavity, so that the pressing cavity can be filled in a preset time, and the feeding speed is related to the inner diameter of the feeding tube and the volume of the pressing cavity, which is not described in detail in this embodiment.
And 140, pressurizing the pressing die cavity in the pressing die to press and form the magnetic powder in the pressing die into a magnetic core, so that the magnetic core passes through the first through hole and the second through hole and is coated on the outer side of the printed circuit board to manufacture the transformer.
In the step, the magnetic powder in the pressing die cavity is pressurized, so that the magnetic powder in the pressing die cavity is subjected to compression molding. It should be noted that the manner of pressurizing the inside of the pressing mold cavity may be realized by pressurizing the first mold and the second mold respectively, so that the first mold and the second mold are closed and the pressing mold cavity on the inner side is pressurized, or by moving the movable pressurizing block in the pressing mold cavity to pressurize the magnetic powder in the pressing mold cavity. It should be understood that the molding can be performed by the existing molding method, and the embodiment is not described redundantly.
Specifically, through pressurizeing the embossing mold utensil for the magnetic in the embossing mold intracavity obtains the pressurization, and then makes the magnetic under the high pressure effect compression moulding, forms integrated into one piece's magnetic core, and first through-hole and second through-hole are passed respectively to the both sides of this magnetic core, and the magnetic core is the closed form setting of day font. Because the magnetic core passes through first through-hole and second through-hole for first winding and second winding are respectively around locating the both sides of magnetic core, and then make first winding and second winding coupling.
Because the magnetic core is suppression integrated into one piece, can make the structure of magnetic core more compact, pass through the viscose with two traditional magnetic cores and be connected differently, integrated into one piece can avoid between the magnetic core because the viscose is connected and there is the clearance for the density distribution of magnetic core is more even, makes magnetic field distribution more even, has improved the stability and the reliability of transformer. In addition, compare in the magnetic core that traditional viscose was connected, the process that the integrated into one piece magnetic core can reduce the transformer and make, reduces the installation degree of difficulty of magnetic core to the production efficiency of transformer has effectively been improved. In addition, in the embodiment, the printed coils on the printed circuit board are used as the first winding and the second winding, so that the consistency of the electrical performance of the circuits and the windings on the printed circuit board can be improved, the production efficiency of the printed circuit board can be improved, in addition, the size of the transformer can be effectively reduced, the integrated planar transformer is obtained by combining the magnetic core which is formed by pressing, the size of the transformer can be effectively reduced, and the integrated planar transformer is adaptive to various miniaturized electronic equipment.
The production efficiency of the transformer can be effectively improved by manufacturing the transformer by integrally forming the magnetic core, at present, a single compression forming machine can produce 50 integrally formed transformers per minute, the integrally formed transformers can be produced for 26 days per month and 10 hours per day, 780,000 integrally formed transformers per month can be produced, and the production efficiency is improved by 18 to 25 percent compared with the traditional transformer assembled by bonding.
Compared with the traditional magnetic core which is formed by sintering and then bonded by glue, the magnetic core can be formed at one time by compression molding in the embodiment without a plurality of processes, so that the assembly process of the magnetic core is effectively simplified, and the production efficiency of the magnetic core and a transformer is effectively improved; the winding printed on the printed circuit board is utilized, manual winding and a compression-molded magnetic core are not needed, the production procedures of the transformer can be effectively reduced, the production of the transformer is suitable for an automatic assembly line, and the production efficiency of the transformer is further improved; the magnetic core formed by integral compression molding has smaller volume, so that the volume of the transformer can be miniaturized; the stability of quality of compression molding's magnetic core is higher for the quality homogeneous of the magnetic core of each transformer makes the production of magnetic core and transformer standardized, and has effectively improved the reliability of transformer.
In addition, through putting into the embossing mold utensil with printed circuit board to add the magnetic in the embossing mold utensil and suppress, make the last magnetic core that forms integrated into one piece of printed circuit board, on the one hand, can make magnetic core density distribution more even, on the other hand, can avoid the clearance that the magnetic core junction produced, make the bulk density of magnetic core more even, thereby make the magnetic field intensity of magnetic core even, thereby improved the stability and the reliability of transformer.
In this embodiment, the magnetic powder is formed into the magnetic core under the action of high pressure, and in order to enable the magnetic powder to be effectively bonded and formed under high pressure, in one embodiment, the step of filling the magnetic powder into the pressing die cavity in the pressing die further includes providing the magnetic powder, and in this embodiment, the magnetic powder is prepared in advance. In one embodiment, the process for preparing the magnetic powder comprises: providing raw powder, providing glue, mixing the glue and the raw powder, and stirring the mixed glue and the mixed raw powder to obtain the magnetic powder.
In this embodiment, the raw powder is a magnetic metal powder, for example, the raw powder is iron-silicon-chromium powder, for example, the raw powder is carbonyl powder, for example, the raw powder is amophorus powder, for example, the raw powder is Amorphous ferroalloy powder. In this embodiment, former powder forms the powdered magnetic that has glue after mixing with glue, and through the adhesion stress of glue, the magnetic can effectively condense and be massive magnetic core under the high pressure effect to make magnetic core bulk strength and hardness higher, can effectively avoid the magnetic core after the shaping to produce the powder.
In one embodiment, a process for preparing a magnetic powder comprises: providing raw powder, providing glue, mixing the glue and the raw powder, stirring the mixed glue and the mixed raw powder, feeding the glue and the raw powder obtained after stirring into a granulator for granulation to obtain particles with the glue, and carrying out wet roasting on the particles with the glue, wherein the temperature of the wet roasting is 65-75 ℃, screening the particles subjected to the wet roasting to screen out particles with preset particle size, and then carrying out secondary stirring on the particles to obtain magnetic powder.
In this example, the predetermined particle size is 5 μm to 65 μm, and in this example, particles having a particle size of 5 μm to 65 μm are selected. Glue and former powder through after will mixing stir for glue and former powder obtain the intensive mixing, make glue distribute evenly, send into the granulator with the former powder of glue afterwards and carry out the granulation, and wet roast with the granulation obtains the powder, make the humidity of glue reduce, with the viscosity that improves the powder, avoid because humidity is too big and can't the shaping. And then, screening, and stirring the screened powder particles again to obtain magnetic powder, so that the magnetic powder has higher viscosity and proper particle size, and the magnetic powder is efficiently and fully molded into a magnetic core under high pressure.
In one embodiment, the predetermined particle size is 5 μm to 40 μm, and in this embodiment, particles having a particle size of 5 μm to 40 μm are selected. In this embodiment, the magnetic powder is prepared by using particles having a particle size of 5 to 40 μm, and the magnetic powder can be molded better.
In order to make the magnetic powder more effective for forming into the magnetic core, in one embodiment, the process of manufacturing the magnetic powder includes: providing raw powder, providing glue, mixing the glue and the raw powder, stirring the mixed glue and the mixed raw powder, feeding the glue and the raw powder obtained after stirring into a granulator for granulation to obtain particles with the glue, baking the particles with the glue, screening the baked particles to screen out first particles with a first preset particle size and second particles with a second preset particle size, mixing the first particles with the second particles, and stirring for the second time to obtain magnetic powder.
In this embodiment, the first predetermined particle size is not equal to the second predetermined particle size, and the first predetermined particle size is larger than the second predetermined particle size, in this embodiment, the first predetermined particle size is larger than 40 μm, and the second predetermined particle size is smaller than 35 μm; the magnetic powder is obtained by mixing the first powder particles and the second powder particles with different sizes, so that the magnetic powder can be better molded into a magnetic core in compression molding.
It should be understood that the powder particles with smaller particle size are easy to bond and easy to form, but are easy to crack or partially collapse and be crushed into powder due to lack of support after forming; the powder particles with larger particle sizes have higher hardness after being formed, are not easy to crack and collapse and are not easy to crush locally, but the powder particles with larger particle sizes are not easy to bond and are not easy to form, the magnetic powder with larger particle sizes is adopted to carry out mould pressing on a plurality of magnetic cores in the same batch, and after the mould is opened, the situation that part of the magnetic cores are failed to be formed may exist, so that the magnetic powder with larger particle sizes needs longer pressurizing time and larger mould pressing pressure, the efficiency is lower, and the probability of forming failure is higher. Therefore, when magnetic powder having a uniform or close particle size is used, the molding quality of the magnetic core may be unstable and the efficiency may be low regardless of whether the particle size is small or large. In this embodiment, adopt the first powder of the first predetermined particle size of bigger particle size and the second powder of the second predetermined particle size of less particle size to mix and obtain the magnetic powder, and the difference between first predetermined particle size and the second predetermined particle size is greater than 5 μm, because the particle size of second powder is less, can make the magnetic core easily shaping, improve the shaping efficiency of magnetic core, and the bigger first powder of particle size can provide the support for the forming process well, provide the support to the fashioned magnetic core, make the magnetic core difficult to crack, the difficult local crushing that collapses, make the magnetic core have higher intensity, make the structure of magnetic core more firm.
In one embodiment, the first predetermined particle size is 40 μm to 65 μm and the second predetermined particle size is 5 μm to 35 μm. In the embodiment, the first powder particles have the particle size of 40-65 μm, the second powder particles have the particle size of 5-35 μm, and the first powder particles and the second powder particles are mixed to obtain the magnetic powder, so that the first powder particles in the magnetic powder can effectively support the formed magnetic core, the structure of the magnetic core is more stable, the second powder particles in the magnetic powder can effectively form the magnetic core, and the forming rate and the forming efficiency of the magnetic core are effectively improved.
In one embodiment, the process for preparing a magnetic powder comprises: providing raw powder, providing glue, mixing the glue and the raw powder, stirring the mixed glue and the mixed raw powder, feeding the stirred glue and the raw powder into a granulator for granulation to obtain particles with the glue, baking the particles with the glue, screening the baked particles, screening first particles with a first preset particle size and second particles with a second preset particle size, mixing the first particles with the second particles according to the ratio of the second particles to the first particles of 1: 0.2-1: 0.35, and stirring for the second time to obtain magnetic powder.
In the embodiment, the particle size of the first powder particles is 40-65 μm, the particle size of the second powder particles is 5-35 μm, the second powder particles and the first powder particles are mixed according to the proportion of 1: 0.2-1: 0.35, and the first powder particles and the second powder particles can be uniformly mixed through secondary stirring, so that the forming efficiency and the forming rate of the magnetic core can be effectively improved, and the strength of the magnetic core can be effectively improved. In addition, in this embodiment, the raw powder is ferrosilicon chromium powder, and the ferrosilicon chromium powder of different particle sizes is mixed according to above-mentioned proportion, and the magnetic powder that obtains can be the magnetic core better shaping for the intensity of magnetic core is higher, in addition, can also make the magnetic core be applicable to the high frequency and use.
It should be understood that, although the strength of the magnetic core can be improved if the proportion of the larger particles is too high and the proportion of the smaller particles is too low, the magnetic core is not stable enough and is easy to collapse and crush locally, and therefore, in this embodiment, the second particles and the first particles are mixed in a ratio of 1:0.2 to 1:0.35, and the ratio of the second particles is too low and the proportion of the smaller particles is too high, so that the magnetic core can be formed efficiently, and the proportion of the first particles in the range of 16.7% to 25.9% can effectively provide support during the magnetic core forming process, so that the magnetic core structure is more stable.
In one embodiment, the second powder particles and the first powder particles are mixed according to the ratio of 1:0.25, and the mixture is stirred for the second time to obtain the magnetic powder.
In the embodiment, the second powder particles and the first powder particles are mixed according to the ratio of 4:1, so that the second powder particles accounting for 80% of the total ratio can enable the magnetic core to be rapidly molded in the die pressing process, and the first powder particles accounting for 20% of the total ratio can support the magnetic core in the molding process, so that the molded magnetic core is higher in strength, more stable in structure and capable of effectively avoiding local collapse and crushing of the magnetic core. In the embodiment, the magnetic powder is obtained by mixing the iron-silicon-chromium powder with the particle size of 40-65 microns and the iron-silicon-chromium powder with the particle size of 5-35 microns according to the proportion of 1:0.25, wherein the iron-silicon-chromium powder with the particle size of 40-65 microns and the iron-silicon-chromium powder with the particle size of 5-35 microns are adopted, so that the quality of the magnetic core can be effectively improved, and the stability of the transformer is improved.
In addition, in the above embodiment, the baking of the particles with glue can reduce the humidity of the glue in the particles, but in the process, the baking time and temperature should be controlled to avoid the complete drying of the glue, and in the process, only the humidity is reduced, so that the particles with glue have reduced humidity but have viscosity. In one embodiment, the baking temperature of the glue-bearing powder particles is 70 ℃, and the baking time is 15-20 minutes. Thus, the humidity of the glue is reduced, and the powder particles are in solid granular shape and have viscosity. It will be appreciated that if the temperature is too high, or the baking time is too long, the glue will solidify, whereas if the temperature is too low and the baking time is short, the moisture content of the glue will not be reduced well, resulting in semi-fluid particles, which are not conducive to molding.
In addition, it is worth mentioning that in the above embodiment, after mixing with the glue and baking, the particles with different particle sizes are screened out, because the baked glue is fully adhered to the particles, then screening is performed, the particles with particle sizes more meeting the requirement of magnetic powder molding can be screened out, the screening precision of the first particle size and the second particle size can be effectively improved, and if the particles with different particle sizes are firstly screened, then mixing with the glue and baking are performed, the particles with other particle sizes are easily formed in the granulator early, so that the particle sizes of the particles do not meet the requirement of the above embodiment. Therefore, in the embodiment, the powder particles are firstly mixed with the glue, then baked and screened, so that the screening precision of the first particle size and the second particle size can be effectively improved.
In one embodiment, the magnetic powder is made of any one of iron silicon chromium, carbonyl and Amorphous.
In this embodiment, the magnetic powder is iron silicon chromium (FeSiCr) powder, carbonyl powder or amophorus powder. In one embodiment, the magnetic powder is any one of iron-silicon-chromium powder, carbonyl iron powder, and amorphous alloy powder, for example, the magnetic powder is iron-silicon-chromium powder, for example, the magnetic powder is carbonyl iron powder, for example, the magnetic powder is amorphous iron alloy powder.
In one embodiment, the preparation process of the carbonyl iron powder comprises the following steps: preparing carbon monoxide, pressurizing the carbon monoxide to a preset pressure, for example, 22MPa, and mixing sponge iron (Fe) and carbon monoxide to react to obtain iron pentacarbonyl (Fe (CO)5) And heating and decomposing the pentacarbonyl iron to obtain carbonyl iron powder.
It should be understood that the conventional Ferrite is suitable for high temperature sintering and difficult to be pressed, and in this embodiment, the iron-silicon-chromium, carbonyl iron powder or amorphous iron alloy powder is used to rapidly press and form the core, and make the core suitable for ultra-high frequency transformers.
In one embodiment, the process for preparing a magnetic powder comprises: providing iron-silicon-chromium powder, providing glue, mixing the glue with the iron-silicon-chromium powder, stirring the mixed glue and the iron-silicon-chromium powder, feeding the stirred glue and the iron-silicon-chromium powder into a granulator for granulation to obtain iron-silicon-chromium powder particles with the glue, baking the iron-silicon-chromium powder particles with the glue, screening the baked iron-silicon-chromium powder particles, and screening iron-silicon-chromium powder particles with a third preset particle size; providing carbonyl iron powder, providing glue, mixing the glue and the carbonyl iron powder, stirring the mixed glue and the carbonyl iron powder, feeding the stirred glue and the carbonyl iron powder into a granulator for granulation to obtain carbonyl iron powder particles with the glue, baking the carbonyl iron powder particles with the glue, screening the baked carbonyl iron powder particles, and screening carbonyl iron powder particles with a fourth preset particle size; mixing the iron-silicon-chromium powder particles and the carbonyl iron powder particles according to the ratio of the iron-silicon-chromium powder particles to the carbonyl iron powder particles of 1:0.15, and stirring for the second time to obtain magnetic powder, wherein the third preset particle size is 5-30 mu m, and the fourth preset particle size is 35-55 mu m.
In this embodiment, through adopting iron silicon chromium powder and carbonyl iron powder as the raw powder of magnetic, the magnetic that the mixture obtained, not only easily shaping can also effectively improve the intensity of shaping back magnetic core to the magnetic core has the characteristic of iron silicon chromium and carbonyl iron concurrently, can use in the high frequency and use, and has low-loss, high saturation magnetic induction strength.
In one embodiment, in the step of pressurizing the pressing die, the pressure of pressurizing the pressing die is 55 to 65 MPa.
In this embodiment, the pressing die is pressurized, so that the pressure applied to the magnetic powder in the pressing die cavity is 55 to 65MPa, and the magnetic powder can be effectively pressed and molded. It should be understood that if the pressure in the pressing mold cavity is too large, the formed magnetic core is prone to crack after the mold is opened due to the large pressure difference after the mold is opened, and if the pressure in the pressing mold cavity is too small, the magnetic powder is not prone to be formed into a block-shaped magnetic core and still is in a powder shape or is in a powder shape partially. Therefore, in the present embodiment, the pressurization pressure of the pressing mold is set to 55 to 65MPa, the magnetic powder can be made to be agglomerated better and molded into the magnetic core, and after the mold is opened, the molding can be maintained, and the magnetic core is prevented from being cracked or partially collapsed and crushed.
In one embodiment, in the step of pressurizing the pressing mold, the pressure for pressurizing the pressing mold is 60 MPa. In this embodiment, under 60 MPa's pressure, the magnetic can be the magnetic core by the high-efficient shaping to after the die sinking, can effectively keep the shaping, avoid magnetic core fracture or local collapse to smash, effectively improved magnetic core compression molding's efficiency and shaping rate.
In one embodiment, in the step of pressing the pressing mold, the pressing time of the pressing mold is 0.3 to 2 seconds.
In this embodiment, the magnetic powder in the pressing mold is pressurized for 0.3 to 2 seconds, and the magnetic powder can be compression molded into the magnetic core by a high pressure of 55 to 65 MPa. In the embodiment, through die assembly and die pressing for 0.3 to 2 seconds, magnetic powder in the pressing die cavity can be fully formed into the magnetic core under the pressure of 55 to 65MPa, and the forming efficiency of the magnetic core can be effectively improved. In one embodiment, in the step of pressing the pressing mold, the pressing time of the pressing mold is 0.3 to 1 second. Therefore, the method is favorable for quick forming, and the production efficiency of the magnetic core is further improved.
In one embodiment, before the step of pressurizing the pressing mold cavity in the pressing mold to press and mold the magnetic powder in the pressing mold into the magnetic core, the method further includes: and vibrating the pressing die and blowing air to the pressing die.
Specifically, air is blown to the outside of the pressing mold, for example, to the mold-closing portion of the first mold and the second mold of the pressing mold. In this embodiment, pack the magnetic powder into the embossing mold intracavity of embossing mold utensil back, before pressurizeing, shake the embossing mold utensil, make the magnetic powder in the embossing mold intracavity can evenly distributed, in addition, through blowing to the embossing mold utensil, can blow away the magnetic powder that the outside of embossing mold utensil dropped carelessly, especially blow away the magnetic powder of the part in the outside of the compound die department of first mould and second mould, like this, can avoid outside scattered magnetic powder to blow away, avoid the magnetic powder adhesion of this part scattering on fashioned magnetic core, so that the outward appearance of magnetic core is more level and more smooth. In one embodiment, before the pressing die is pressurized, the pressing die is vibrated, air is blown to the outer side of the pressing die, wherein the air blowing time is 1-1.5 seconds, magnetic powder is added into the pressing die cavity after the vibration and air blowing, and the powder adding interval is 0.1-0.2 seconds, so that a gap generated by the vibration and air blowing can be filled with the added magnetic powder, and the pressing die cavity is fully filled with the magnetic powder. In one embodiment, before the pressing die is pressurized, the pressing die is vibrated, air is blown to the outer side of the pressing die, and the magnetic powder in the pressing die cavity is impacted, in this embodiment, impacting the magnetic powder refers to impacting the pressing die, so that the magnetic powder in the pressing die cavity is further uniformly distributed, the pressing die cavity is fully filled with the powder, and the density is more uniform, so that the density of the magnetic core formed under the action of high pressure is more uniform.
In one embodiment, the step of pressurizing the pressing die further comprises: and baking the transformer.
In this embodiment, after the pressing mold is pressurized, the transformer with the formed magnetic core is obtained, and then the transformer with the formed magnetic core is sent into an oven or a baking tunnel furnace to be baked, so that the shaped magnetic core can be dried, so that the glue in the magnetic core and the moisture around the transformer can be dried, the structure of the magnetic core is more stable, the impurities on the printed circuit board can be volatilized at high temperature, the short circuit of the transformer due to the existence of liquid and impurities in the work process is avoided, and the reliability and the safety of the transformer are improved.
In one embodiment, after the step of pressurizing the pressing die and before baking the transformer, the method further comprises: and blowing air to the transformer.
In this embodiment, adopt the air gun, encircle the transformer and blow, like this, can blow away remaining impurity and remaining magnetic on the transformer surface before the transformer toasts, avoid remaining magnetic to glue the short circuit that leads to printed circuit board on printed circuit board, effectively improved printed circuit board's security and reliability.
In one embodiment, in the step of baking the transformer, the baking time is 80 minutes to 90 minutes.
In the embodiment, after the magnetic core is formed, the transformer is sent into the oven or the baking tunnel furnace to be baked and heated for 80-90 minutes, so that the glue in the magnetic core and the moisture around the transformer can be dried, impurities on the printed circuit board can be fully volatilized at high temperature, and the reliability and the safety of the transformer are improved.
In one embodiment, in the step of baking the transformer, the baking temperature of the transformer is gradually increased.
In this embodiment, improve the stoving temperature gradually in the oven at the transformer to different materials on the transformer obtain evaporation or volatilize in proper order, utilize the evaporating temperature of different materials, the temperature of volatilizing is different, utilizes the temperature that increases gradually, makes glue, moisture on the transformer obtain fully drying, in addition, can also effectively guarantee the electrical characteristics of transformer, avoids the transformer inefficacy. In addition, the baking temperature is gradually increased, so that the temperature of the magnetic core can be gradually increased, and the phenomenon that the temperature of the magnetic core is too fast to crack is avoided.
In one embodiment, in the step of baking the transformer, the baking temperature is 70 ℃ to 150 ℃.
In this embodiment, right in the step that the transformer toasted, improve gradually the stoving temperature to the transformer, the stoving temperature is increased to 150 ℃ by 70 ℃ gradually, like this, can make the transformer can heat up gradually, avoids the magnetic core fracture, in addition, when guaranteeing the characteristic of transformer, can also make unnecessary moisture, glue, impurity on the transformer can evaporate gradually or volatilize, improves the reliability and the security of transformer.
In one embodiment, the step of baking the transformer comprises: will the transformer is put into and is toasted in the baking tunnel furnace, wherein, toast the tunnel furnace and include six roast districts, toast the district through the conveyer belt with the transformer and carry along six in proper order, along the direction of delivery of transformer, the temperature in six roast districts increases in proper order, in one embodiment, along the direction of delivery of transformer, the temperature in six roast districts sets up respectively to 70 ℃, 90 ℃, 110 ℃, 130 ℃, 150 ℃.
In this embodiment, the transformer carries to six baking zones in proper order on the conveyer belt, and the time of staying in each baking zone is 10 minutes to 15 minutes, 70 ℃ baking zone is passed through in proper order, 90 ℃ baking zone, 110 ℃ baking zone, 130 ℃ baking zone, 150 ℃ baking zone and 150 ℃ baking zone, thus, can make the transformer can obtain preheating, and glue in the magnetic core of transformer after preheating, air around the transformer and impurity on the transformer evaporate gradually or volatilize, not only can effectively get rid of unnecessary moisture and impurity, can also make the transformer adapt to high temperature gradually, effectively guarantee that the electrical characteristics of transformer does not receive high temperature to influence, and then effectively improve the reliability of transformer.
In other embodiments, gradually increasing the baking temperature of the transformer can be achieved by placing the transformer in a baking oven, gradually increasing the temperature in the baking oven, and controlling the temperature in the baking oven to gradually increase from 70 ℃ to 150 ℃, for example, the temperature control of the baking oven is divided into six stages, the temperatures in the six stages are 70 ℃, 90 ℃, 110 ℃, 130 ℃, 150 ℃ and 150 ℃, respectively, and the baking time in each stage is 10 minutes to 15 minutes, so that the transformer can be preheated, and glue in the magnetic core of transformer after preheating, air around the transformer and the impurity on the transformer evaporate gradually or volatilize, not only can effectively get rid of unnecessary moisture and impurity, can also make the transformer adapt to the high temperature gradually, effectively guarantee that the electrical characteristics of transformer does not receive the high temperature influence, and then effectively improve the reliability of transformer.
An integrally formed transformer comprises a printed circuit board and an integrally pressed magnetic core; the magnetic core is characterized in that a first winding and a second winding are printed on the printed circuit board, a first through hole is formed in the inner side of the first winding, a second through hole is formed in the inner side of the second winding, and the magnetic core penetrates through the first through hole and the second through hole and is coated on the outer side of the printed circuit board.
In this embodiment, the integrally formed transformer is manufactured by the method for manufacturing an integrally formed transformer in any of the above embodiments.
In one embodiment, there is provided an electronic device comprising the integrally formed transformer described in any of the above embodiments.
The invention has the beneficial effects that: through putting into the embossing mold utensil with printed circuit board in to add the magnetic in the embossing mold utensil and suppress, make the last integrated into one piece's that forms of printed circuit board magnetic core, on the one hand, can make magnetic core density distribution more even, on the other hand, can avoid the clearance that the magnetic core junction produced, make the bulk density of magnetic core more even, thereby make the magnetic field intensity of magnetic core even, thereby improved the stability and the reliability of transformer.
All possible combinations of the technical features of the above embodiments may not be described for the sake of brevity, but should be considered as within the scope of the present disclosure as long as there is no contradiction between the combinations of the technical features.
The above-mentioned embodiments only express several embodiments of the present invention, and the description thereof is more specific and detailed, but not construed as limiting the scope of the invention. It should be noted that, for a person skilled in the art, several variations and modifications can be made without departing from the inventive concept, which falls within the scope of the present invention. Therefore, the protection scope of the present patent shall be subject to the appended claims.
Claims (10)
1. A method for manufacturing an integrally formed transformer, comprising:
providing a printed circuit board, wherein a first winding and a second winding are printed on the printed circuit board in advance, a first through hole is formed in the inner side of the first winding of the printed circuit board, and a second through hole is formed in the inner side of the second winding of the printed circuit board;
putting the printed circuit board into a pressing die;
providing magnetic powder, and filling the magnetic powder into a pressing die cavity in the pressing die;
pressurizing a pressing die cavity in the pressing die, wherein the pressurizing pressure of the pressing die is 55-65 MPa, and the pressurizing time of the pressing die is 0.3-2 seconds, so that the magnetic powder in the pressing die is pressed and molded into a magnetic core, and the magnetic core penetrates through the first through hole and the second through hole and is coated on the outer side of the printed circuit board to manufacture the transformer;
wherein, the preparation process of the magnetic powder comprises the following steps: providing raw powder, providing glue, mixing the glue and the raw powder, stirring the mixed glue and the raw powder, feeding the glue and the raw powder obtained after stirring into a granulator for granulation to obtain particles with the glue, baking the particles with the glue, screening the baked particles, screening first particles with a first preset particle size and second particles with a second preset particle size, mixing the first particles with the second particles according to the ratio of the second particles to the first particles being 1: 0.2-1: 0.35, and stirring for the second time to obtain magnetic powder; the grain size of the first powder particles is 40-65 μm, and the grain size of the second powder particles is 5-35 μm;
the step of pressurizing the pressing die further comprises the following steps: baking the transformer;
wherein, the step of baking the transformer comprises: putting the transformer into a baking tunnel furnace for baking, wherein the baking tunnel furnace comprises six baking areas, conveying the transformer along the six baking areas in sequence through a conveying belt, and setting the temperatures of the six baking areas to be 70 ℃, 90 ℃, 110 ℃, 130 ℃, 150 ℃ and 150 ℃ respectively along the conveying direction of the transformer; and the residence time in each baking zone is from 10 minutes to 15 minutes.
2. A method as claimed in claim 1, characterized in that the baking temperature for the glue-loaded powder particles is 70 ℃ and the baking time is 15 to 20 minutes.
3. The method according to claim 2, wherein the predetermined particle size is 5 μm to 65 μm.
4. The method of claim 1, further comprising, after the step of pressurizing the compaction die and prior to baking the transformer: and blowing air to the transformer.
5. The method of claim 4, wherein the step of baking the transformer comprises baking for 80 to 90 minutes.
6. The method of claim 4, wherein in the step of baking the transformer, a baking temperature of the transformer is gradually increased.
7. The method of claim 6, wherein in the step of baking the transformer, the baking temperature is 70 ℃ to 150 ℃.
8. The method according to claim 1, wherein the magnetic powder is made of any one of ferrochrome, carbonyl and Amorphous.
9. An integrally formed transformer manufactured by the method of manufacturing an integrally formed transformer as claimed in any one of claims 1 to 8, comprising a printed circuit board and an integrally press-formed magnetic core; the printed circuit board is printed with a first winding and a second winding, the printed circuit board is provided with a first through hole in the inner side of the first winding, the printed circuit board is provided with a second through hole in the inner side of the second winding, and the magnetic core penetrates through the first through hole and the second through hole and is coated on the outer side of the printed circuit board.
10. An electronic device comprising the integrally formed transformer as claimed in claim 9.
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| CN107275033B (en) * | 2017-05-23 | 2019-01-08 | 深圳顺络电子股份有限公司 | A kind of magnetically soft alloy material and preparation method thereof |
| CN111383835A (en) * | 2020-03-19 | 2020-07-07 | 蚌埠市双环电感股份有限公司 | FeSiCr granule for integrally formed inductor and preparation method thereof |
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| JP2010199407A (en) * | 2009-02-26 | 2010-09-09 | Fuji Electric Systems Co Ltd | Method of manufacturing powder magnetic core |
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