CN114597015B - Laminated inductor and preparation method and application thereof - Google Patents
Laminated inductor and preparation method and application thereof Download PDFInfo
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- CN114597015B CN114597015B CN202210258149.4A CN202210258149A CN114597015B CN 114597015 B CN114597015 B CN 114597015B CN 202210258149 A CN202210258149 A CN 202210258149A CN 114597015 B CN114597015 B CN 114597015B
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- 239000000843 powder Substances 0.000 claims abstract description 148
- 229910001004 magnetic alloy Inorganic materials 0.000 claims abstract description 121
- 239000006247 magnetic powder Substances 0.000 claims abstract description 103
- 239000004020 conductor Substances 0.000 claims abstract description 98
- 239000010410 layer Substances 0.000 claims abstract description 84
- 238000000748 compression moulding Methods 0.000 claims abstract description 35
- 238000005096 rolling process Methods 0.000 claims abstract description 35
- 238000005266 casting Methods 0.000 claims abstract description 25
- 239000011229 interlayer Substances 0.000 claims abstract description 15
- 238000011282 treatment Methods 0.000 claims description 77
- 238000000034 method Methods 0.000 claims description 62
- YKYONYBAUNKHLG-UHFFFAOYSA-N propyl acetate Chemical compound CCCOC(C)=O YKYONYBAUNKHLG-UHFFFAOYSA-N 0.000 claims description 56
- 239000002002 slurry Substances 0.000 claims description 54
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- 238000002156 mixing Methods 0.000 claims description 35
- 238000007639 printing Methods 0.000 claims description 31
- 238000004519 manufacturing process Methods 0.000 claims description 28
- 238000009413 insulation Methods 0.000 claims description 24
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 claims description 22
- 238000000137 annealing Methods 0.000 claims description 19
- 229910045601 alloy Inorganic materials 0.000 claims description 17
- 239000000956 alloy Substances 0.000 claims description 17
- 238000001035 drying Methods 0.000 claims description 17
- 238000010345 tape casting Methods 0.000 claims description 17
- 239000002245 particle Substances 0.000 claims description 16
- 238000010030 laminating Methods 0.000 claims description 15
- 238000003475 lamination Methods 0.000 claims description 14
- 239000003795 chemical substances by application Substances 0.000 claims description 13
- 239000011248 coating agent Substances 0.000 claims description 12
- 238000000576 coating method Methods 0.000 claims description 12
- VAWNDNOTGRTLLU-UHFFFAOYSA-N iron molybdenum nickel Chemical compound [Fe].[Ni].[Mo] VAWNDNOTGRTLLU-UHFFFAOYSA-N 0.000 claims description 12
- -1 iron silicon aluminum Chemical compound 0.000 claims description 12
- 229910000147 aluminium phosphate Inorganic materials 0.000 claims description 11
- 239000002904 solvent Substances 0.000 claims description 10
- 235000019353 potassium silicate Nutrition 0.000 claims description 9
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 9
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 claims description 8
- XEVZIAVUCQDJFL-UHFFFAOYSA-N [Cr].[Fe].[Si] Chemical compound [Cr].[Fe].[Si] XEVZIAVUCQDJFL-UHFFFAOYSA-N 0.000 claims description 8
- 238000011049 filling Methods 0.000 claims description 8
- XWHPIFXRKKHEKR-UHFFFAOYSA-N iron silicon Chemical compound [Si].[Fe] XWHPIFXRKKHEKR-UHFFFAOYSA-N 0.000 claims description 8
- 238000012545 processing Methods 0.000 claims description 8
- 229910052709 silver Inorganic materials 0.000 claims description 8
- 239000004332 silver Substances 0.000 claims description 8
- 239000012299 nitrogen atmosphere Substances 0.000 claims description 6
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- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 4
- 229910052710 silicon Inorganic materials 0.000 claims description 4
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- UGKDIUIOSMUOAW-UHFFFAOYSA-N iron nickel Chemical compound [Fe].[Ni] UGKDIUIOSMUOAW-UHFFFAOYSA-N 0.000 description 10
- 239000000696 magnetic material Substances 0.000 description 10
- 238000012360 testing method Methods 0.000 description 6
- 238000004804 winding Methods 0.000 description 6
- 229910000859 α-Fe Inorganic materials 0.000 description 6
- 239000000463 material Substances 0.000 description 5
- 229910000519 Ferrosilicon Inorganic materials 0.000 description 4
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- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
- 229910002796 Si–Al Inorganic materials 0.000 description 2
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- 229910052802 copper Inorganic materials 0.000 description 2
- 239000010949 copper Substances 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000009713 electroplating Methods 0.000 description 2
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- 229910052751 metal Inorganic materials 0.000 description 2
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- 238000004806 packaging method and process Methods 0.000 description 2
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- 229920002799 BoPET Polymers 0.000 description 1
- 229910000599 Cr alloy Inorganic materials 0.000 description 1
- 229910000676 Si alloy Inorganic materials 0.000 description 1
- 229910008458 Si—Cr Inorganic materials 0.000 description 1
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Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/0006—Printed inductances
- H01F17/0013—Printed inductances with stacked layers
-
- 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
-
- 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
Abstract
The invention provides a laminated inductor, a preparation method and application thereof, wherein the laminated inductor comprises 2 layers of first soft magnets and at least 2 layers of second soft magnets which are arranged in a laminated way; the at least 2 layers of second soft magnets are arranged at the interlayer part of the 2 layers of first soft magnets in a stacked manner; the first soft magnetic body is formed by adopting flat soft magnetic alloy powder through casting and rolling; the second soft magnetic body comprises a soft magnetic powder core, a first conductor and a soft magnetic sheet, wherein the first conductor and the soft magnetic sheet are printed on the surface of the soft magnetic powder core and are in a nested structure; the soft magnetic powder core is a soft magnetic body formed by adopting soft magnetic alloy powder through compression molding; the surface of the soft magnetic powder core is provided with a through hole, and the inside of the through hole is filled with a second conductor; the second conductor and the first conductor are mutually communicated to form a conductor coil. The laminated inductor provided by the invention solves the problem of low magnetic permeability of the laminated inductor in the prior art, and ensures that the laminated inductor can realize high inductance while coping with large current.
Description
Technical Field
The invention belongs to the technical field of inductance components, relates to a laminated inductor, and particularly relates to a laminated inductor, a preparation method and application thereof.
Background
The inductor is divided into three main types according to the manufacturing process: wound inductances, stacked inductances, and thin film inductances. The winding inductance is generally obtained by winding copper wires into a spiral shape on a hollow core, a ceramic core non-magnetic material or a ferrite and other soft magnetic materials, and has the characteristics of high quality factor and capability of coping with large current. In the conventional laminated inductor, a conductor pattern is printed on a ceramic green material containing ferrite or the like, and then these green sheets are laminated and baked to form an integrated structure. Compared with the winding structure, the laminated structure can realize miniaturization, standardized packaging and low cost. The thin film inductor also adopts a laminated structure, a process similar to IC manufacture is adopted in coil manufacture, a layer of conductor film is plated on a substrate, then a photoetching process is adopted to form a coil, and finally a dielectric layer, an insulating layer and an electrode layer are added, and packaging and molding are carried out. Thin film inductors have smaller dimensions, finer steps of inductance, smaller tolerances and frequency stability, however thin film lithographic process equipment is expensive and raw material complexity is high.
With the development of miniaturization of IC technology, the power supply voltage is lower and the current is larger, which is called as the development trend of "low voltage large current. Soft magnetic materials are indispensable raw materials in the process of manufacturing the inductor, and mainly include metallic soft magnetic materials and ferrite soft magnetic materials. The saturated magnetic flux density of the ferrite soft magnetic material is between 0.3 and 0.5T, the magnetic permeability is low, the Curie temperature is low, and the capability of the ferrite soft magnetic material for coping with large current is severely limited; the metal soft magnetic material has the advantage of high saturation magnetic flux density, which is generally between 0.75 and 1.6T, and can meet the requirements of the inductor on both size and performance.
CN 112397295a discloses a method for manufacturing an integrally formed inductor, which comprises the following steps: (1) Uniformly mixing the main soft magnetic alloy powder, and then mixing with a binder, a curing agent and acetone; (2) pressing a flat blank of a predetermined size and a T-shaped blank; (3) winding the enameled wire; (4) Pressing the flat plate blank and a T-shaped blank for winding the enameled wire to form and baking; (5) Spraying and coating an insulating resin protective material, and then baking; (6) And stripping the resin and the paint at the copper electrode and electroplating the electrode to generate the integrated inductor. The integrated inductor is made of metal soft magnetic materials, but still belongs to a winding inductor, has large volume, is unfavorable for the application of small equipment, and has poor heat dissipation performance and short service life.
CN 108847343a discloses a preparation method of a laminated inductor and the laminated inductor, the preparation method comprises the following steps: (1) Uniformly mixing PVB resin, a first solvent and a first plasticizer to obtain an adhesive; (2) Uniformly mixing the adhesive, the porcelain powder, the second solvent and the second plasticizer through a ball milling process or a sand milling process to obtain casting slurry; (3) Carrying out casting operation on the casting slurry on a casting machine, and coating the casting slurry on the PET film in a doctor blade coating mode to obtain an insulating layer film; (4) Printing an inner electrode on the insulating layer film through a screen printing process to obtain a single-layer coil; (5) Repeating the steps to obtain a plurality of single-layer coils, laminating and cutting the single-layer coils to form a complete inductance coil; (6) After the inductance coil is subjected to glue discharging and sintering treatment, the inductance coil is assembled in a shell through a blocking and electroplating process to manufacture the laminated inductance. The inductor, while belonging to the laminated inductor, the carrier of its conductors is an insulator, the purpose of which is to control conductor distribution only and not to provide a beneficial effect on the inductance of the laminated inductor.
US 8558652B2 discloses a laminated inductor and a method for manufacturing the same, wherein soft magnetic alloy powder is used as a magnetic material of the laminated inductor, and the conventional ferrite material is replaced by the laminated inductor. The preparation method comprises the following steps: mixing soft magnetic alloy powder with a large amount of resin to form liquid slurry, coating the liquid slurry into a film form by using a coating machine, and drying to obtain a magnetic green sheet; and then combining the traditional perforation, conductor printing, lamination and sintering processes to obtain the novel laminated inductor. The magnetic green sheet provided by the invention uses alloy powder as a raw material, and solves the problem of low saturation magnetic flux density, but the magnetic layer has low magnetic permeability due to the fact that a large amount of resin is doped at the same time, and high inductance is difficult to realize under the condition that the conductor layer is kept consistent.
Therefore, how to provide a laminated inductor and a preparation method thereof, solve the problem of low magnetic permeability of the laminated inductor in the prior art, ensure that the laminated inductor realizes high inductance while coping with high current, and become the problem that needs to be solved by those skilled in the art.
Disclosure of Invention
The invention aims to provide a laminated inductor, a preparation method and application thereof, wherein the laminated inductor solves the problem of low magnetic permeability of the laminated inductor in the prior art, and ensures that the laminated inductor realizes high inductance while coping with large current.
In order to achieve the aim of the invention, the invention adopts the following technical scheme:
in a first aspect, the present invention provides a laminated inductor, where the laminated inductor includes 2 layers of first soft magnetic bodies and at least 2 layers of second soft magnetic bodies, and the laminated inductor may include 2 layers, 3 layers, 4 layers, 5 layers or 6 layers, for example, but is not limited to the listed values, and other non-listed values in the range of values are equally applicable.
The at least 2 layers of second soft magnets are stacked and arranged at interlayer positions of the 2 layers of first soft magnets.
The first soft magnetic body is formed by adopting flat soft magnetic alloy powder through casting and rolling, and the long axis direction of the flat soft magnetic alloy powder is mutually perpendicular to the lamination direction of the laminated inductor.
The second soft magnetic body comprises a soft magnetic powder core, a first conductor and a soft magnetic sheet, wherein the first conductor and the soft magnetic sheet are printed on the surface of the soft magnetic powder core and are in a nested structure.
The soft magnetic powder core is a soft magnetic body formed by adopting soft magnetic alloy powder through compression molding.
The surface of the soft magnetic powder core is provided with a through hole, and the inside of the through hole is filled with a second conductor.
The second conductor and the first conductor are mutually communicated to form a conductor coil.
On one hand, the invention adopts the soft magnetic body formed by casting and rolling the flat soft magnetic alloy powder as the first soft magnetic body, so that the magnetic circuit presents a horizontal direction in the first soft magnetic body, thereby obviously improving the magnetic permeability of the magnetic layers on the upper surface and the lower surface of the laminated inductor along the horizontal direction.
On the other hand, the soft magnetic powder is adopted as the soft magnetic powder core by adopting the soft magnetic powder subjected to compression molding, and compared with the soft magnetic powder obtained by adopting the tape casting and rolling in the traditional method, a large amount of organic resin is not required to be doped in the soft magnetic powder core, so that the proportion of the soft magnetic alloy powder is obviously improved, and the magnetic conductivity of the laminated inductor is further improved.
The organic combination of the first soft magnetic body and the second soft magnetic body solves the problem of low magnetic permeability of the laminated inductor in the prior art, and ensures that the laminated inductor realizes high inductance while coping with large current.
In addition, the soft magnetic sheet and the first conductor are in a mutually nested structure, so that a lamination gap between adjacent soft magnetic sheets is filled, and the magnetic permeability of the lamination inductor is further improved.
Preferably, the flat soft magnetic alloy powder in the first soft magnetic body and the soft magnetic powder in the soft magnetic powder core each independently include any one or a combination of at least two of iron silicon, iron silicon aluminum, iron nickel molybdenum, or iron silicon chromium, typically but not limited to combinations including iron silicon and iron silicon aluminum, iron silicon aluminum and iron nickel, iron nickel and iron nickel molybdenum, iron nickel molybdenum and iron silicon chromium, iron silicon aluminum and iron nickel, iron silicon aluminum, iron nickel and iron nickel molybdenum, or iron nickel, iron nickel molybdenum and iron silicon chromium.
The soft magnetic powder in the soft magnetic powder core preferably has an average particle diameter D50 of 1 to 30 μm, and may be, for example, 1 μm, 2 μm, 4 μm, 6 μm, 8 μm, 10 μm, 12 μm, 14 μm, 16 μm, 18 μm, 20 μm, 22 μm, 24 μm, 26 μm, 28 μm or 30 μm, and more preferably 1 to 10 μm, but is not limited to the recited values, and other non-recited values within the range are equally applicable.
Preferably, the soft magnetic sheet is a magnetic sheet printed by spherical soft magnetic alloy powder.
Preferably, the spherical soft magnetic alloy powder in the soft magnetic sheet comprises any one or a combination of at least two of iron silicon, iron silicon aluminum, iron nickel molybdenum or iron silicon chromium, and typical but non-limiting combinations include combinations of iron silicon and iron silicon aluminum, combinations of iron silicon aluminum and iron nickel, combinations of iron nickel and iron nickel molybdenum, combinations of iron nickel molybdenum and iron silicon chromium, combinations of iron silicon, iron silicon aluminum and iron nickel, combinations of iron silicon aluminum, iron nickel and iron nickel molybdenum, or combinations of iron nickel, iron nickel molybdenum and iron silicon chromium.
Preferably, the average particle diameter D50 of the spherical soft magnetic alloy powder in the soft magnetic sheet is 1 to 30. Mu.m, for example, 1 μm, 2 μm, 4 μm, 6 μm, 8 μm, 10 μm, 12 μm, 14 μm, 16 μm, 18 μm, 20 μm, 22 μm, 24 μm, 26 μm, 28 μm or 30 μm, and more preferably 1 to 10 μm, but not limited to the recited values, and other non-recited values within the range are equally applicable.
In a second aspect, the present invention provides a method for manufacturing a laminated inductor according to the first aspect, the method comprising the steps of:
(1) Preparing 2 layers of first soft magnets by adopting a tape casting rolling method;
(2) Preparing at least 2 layers of second soft magnets by adopting a compression molding and printing matching method;
(3) Laminating at least 2 layers of second soft magnetic body layers obtained in the step (2) on interlayer parts of 2 layers of first soft magnetic bodies obtained in the step (1), and performing lamination and heating treatment to obtain laminated inductors;
wherein, the step (1) and the step (2) are not in sequence.
In the present invention, the at least 2 layers of the second soft magnetic body in the step (2) may be prepared by a combination of one-time compression molding and cutting, or may be prepared by multiple compression molding, so long as the preparation of the at least 2 layers of the second soft magnetic body can be achieved, and the number of times of compression molding is not particularly limited.
Preferably, the preparation method of the first soft magnetic body in the step (1) specifically includes the following steps:
(1.1) mixing flat soft magnetic alloy powder, organic resin and solvent to obtain first soft magnetic slurry;
(1.2) carrying out tape casting and rolling on the first soft magnetic slurry obtained in the step (1.1) to obtain a first soft magnetic body.
Preferably, the preparation method of the second soft magnetic body in the step (2) specifically includes the following steps:
(2.1) sequentially performing insulation treatment, compression molding, annealing treatment and through hole processing on the soft magnetic alloy powder to obtain a soft magnetic powder core;
(2.2) printing a first conductor on the surface of the soft magnetic powder core obtained in the step (2.1) by utilizing silver paste, and filling through holes to form a second conductor;
(2.3) mixing spherical soft magnetic alloy powder, organic resin and solvent to obtain soft magnetic slurry;
and (2.4) printing a soft magnetic sheet on the part of the soft magnetic powder core surface, which is not printed with the first conductor, by using the soft magnetic slurry obtained in the step (2.3), and drying to obtain a second soft magnetic body.
Preferably, the organic resins of step (1.1) and step (2.3) each independently comprise a PVB resin.
Preferably, the solvents of step (1.1) and step (2.3) each independently comprise n-propyl acetate.
Preferably, the mixing mass ratio of the organic resin to the solvent in the step (1.1) and the step (2.3) is (1-2): (4-6) independently, and may be, for example, 1:4, 1:5, 1:6, 2:4, 2:5 or 2:6, but is not limited to the recited values, and other non-recited values within the range of values are equally applicable.
Preferably, the mass ratio of the flat soft magnetic alloy powder in the step (1.1) in the first soft magnetic slurry is 85% -95%, for example, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94% or 95%, but not limited to the recited values, and other non-recited values in the range of the values are equally applicable.
Preferably, the mass ratio of the spherical soft magnetic alloy powder in the step (2.3) in the soft magnetic slurry is 85% -95%, for example, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94% or 95%, but not limited to the recited values, and other non-recited values in the range of the values are equally applicable.
Preferably, the insulating treatment in step (2.1) is specifically: and (5) insulating and coating the soft magnetic alloy powder by using an insulating agent and drying.
In the invention, the insulation treatment helps to improve the insulation resistance of the soft magnetic alloy powder and prevent the powder from being oxidized.
Preferably, the insulating agent comprises any one or a combination of at least two of phosphoric acid, silicone resin or water glass, typically but not limited to a combination of phosphoric acid and silicone resin, a combination of silicone resin and water glass, a combination of phosphoric acid and water glass, or a combination of phosphoric acid, silicone resin and water glass.
Preferably, the mass ratio of the insulating agent to the soft magnetic alloy powder is (0.5-3): 100, for example, it may be 0.5:100, 1:100, 1.5:100, 2:100, 2.5:100 or 3:100, but is not limited to the recited values, and other non-recited values within the range of values are equally applicable.
Preferably, the compression molding of step (2.1) is performed in a hydraulic press, a mechanical press or a servo press.
Preferably, the annealing treatment of step (2.1) is performed in a nitrogen atmosphere or an argon atmosphere.
Preferably, the annealing treatment in step (2.1) is performed at a temperature of 650 to 750 ℃, for example, 650 ℃, 660 ℃, 670 ℃, 680 ℃, 690 ℃, 700 ℃, 710 ℃, 720 ℃, 730 ℃, 740 ℃, or 750 ℃, but the annealing treatment is not limited to the above-mentioned values, and other values not mentioned in the above-mentioned range are equally applicable.
Preferably, the annealing treatment in step (2.1) is performed for 40-80min, for example, 40min, 45min, 50min, 55min, 60min, 65min, 70min, 75min or 80min, but not limited to the recited values, and other non-recited values within the range of values are equally applicable.
Preferably, the relative density of the soft magnetic powder core obtained in step (2.1) is 85% -95%, and the relative density is specifically the ratio of the density of the soft magnetic powder core to the true density of the soft magnetic alloy powder, and may be, for example, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94% or 95%, but is not limited to the recited values, and other non-recited values within this range are equally applicable.
Taking Fe-Si-Al alloy powder as an example, the true density is 7.0g/cm 3 The density of the soft magnetic powder core obtained after compression molding is 6.0-6.5g/cm 3 The relative density of the resulting soft magnetic powder core is 85.7% -92.8%. Compared with the traditional tape casting method, the density of the magnetic sheet obtained after rolling is 4.5-5.0g/cm 3 The relative density is 64.3% -71.4%, the compression molding mode adopted by the invention can improve the relative density of the soft magnetic body by more than 30%, and the proportion of alloy powder in the soft magnetic body is obviously improved. Therefore, the permeability of the obtained magnetic sheet is greatly improved.
Specifically, according to the Olerdorf formula:
wherein: n is the effective demagnetizing field coefficient in the magnetic core; η is the relative packing density of the powder; mu (mu) i Is the initial permeability of the soft magnetic body; mu (mu) t Is the true magnetic permeability of the alloy.
Assuming that the true density of the Fe-Si-Al alloy powder is 1000, the demagnetizing field coefficient of the spherical powder is 1/3, the magnetic permeability of the magnetic sheet manufactured by the traditional tape casting method can be obtained according to the formula and is 6-9, and the magnetic permeability of the soft magnet manufactured by the compression molding method can reach 18-39, namely the magnetic permeability is improved to 2-4 times.
Preferably, in the step (3), the second conductor inside the through hole and the first conductor on the surface of the soft magnetic powder core are mutually communicated after being stacked and placed to form a conductor coil.
Preferably, the heating treatment of step (3) includes a first heating treatment and a second heating treatment which are sequentially performed.
The temperature of the first heat treatment is preferably 280 to 320 ℃, and may be 280 ℃, 285 ℃, 290 ℃, 295 ℃, 300 ℃, 305 ℃, 310 ℃, 315 ℃ or 320 ℃, for example, but is not limited to the values listed, and other values not listed in the range are equally applicable.
Preferably, the time of the first heating treatment is 40-80min, for example, 40min, 45min, 50min, 55min, 60min, 65min, 70min, 75min or 80min, but not limited to the recited values, and other non-recited values within the range of values are equally applicable.
The temperature of the second heat treatment is preferably 720 to 780 ℃, and may be 720 ℃, 730 ℃, 740 ℃, 750 ℃, 760 ℃, 770 ℃, or 780 ℃, for example, but is not limited to the values listed, and other values not listed in the range are equally applicable.
Preferably, the time of the second heating treatment is 100-140min, for example, 100min, 105min, 110min, 115min, 120min, 125min, 130min, 135min or 140min, but not limited to the recited values, and other non-recited values within the range of values are equally applicable.
As a preferred technical solution of the second aspect of the present invention, the preparation method includes the following steps:
(1) Preparing 2 layers of first soft magnets by adopting a tape casting rolling method;
(1.1) mixing flat soft magnetic alloy powder, PVB resin and n-propyl acetate to obtain first soft magnetic slurry; the mixing mass ratio of the PVB resin to the n-propyl acetate is (1-2) (4-6), and the mass ratio of the flat soft magnetic alloy powder in the first soft magnetic slurry is 85% -95%;
(1.2) carrying out tape casting rolling on the first soft magnetic slurry obtained in the step (1.1) to obtain a first soft magnetic body;
(2) Preparing at least 2 layers of second soft magnets by adopting a compression molding and printing matching method;
(2.1) sequentially performing insulation treatment, compression molding, annealing treatment and through hole processing on the soft magnetic alloy powder to obtain a soft magnetic powder core with the relative density of 85% -95%, wherein the relative density is specifically the ratio of the density of the soft magnetic powder core to the true density of the soft magnetic alloy powder; the insulation treatment is specifically to perform insulation coating and drying on the soft magnetic alloy powder by using an insulating agent, wherein the mass ratio of the insulating agent to the soft magnetic alloy powder is (0.5-3) 100, and the insulating agent comprises any one or a combination of at least two of phosphoric acid, organic silicon resin and water glass; the compression molding is carried out in a hydraulic press, a mechanical press or a servo press; the annealing treatment is carried out in nitrogen atmosphere or argon atmosphere, the temperature is 650-750 ℃ and the time is 40-80min;
(2.2) printing a first conductor on the surface of the soft magnetic powder core obtained in the step (2.1) by utilizing silver paste, and filling through holes to form a second conductor;
(2.3) mixing spherical magnetically soft alloy powder, PVB resin and n-propyl acetate to obtain soft magnetic slurry; wherein, the mixing mass ratio of the PVB resin and the n-propyl acetate is (1-2): (4-6), and the mass ratio of the spherical soft magnetic alloy powder in the soft magnetic slurry is 85% -95%;
(2.4) printing a soft magnetic sheet on the part of the soft magnetic powder core surface, which is not printed with the first conductor, by using the soft magnetic slurry obtained in the step (2.3), and drying to obtain a second soft magnetic body;
(3) Laminating at least 2 layers of second soft magnetic body layers obtained in the step (2) on interlayer parts of 2 layers of first soft magnetic bodies obtained in the step (1), enabling second conductors inside the through holes to be mutually communicated with first conductors on the surface of the soft magnetic powder core to form conductor coils, and laminating and heating to obtain laminated inductors; the heating treatment comprises a first heating treatment and a second heating treatment which are sequentially carried out, wherein the temperature of the first heating treatment is 280-320 ℃, the time is 40-80min, the temperature of the second heating treatment is 720-780 ℃, and the time is 100-140min.
Wherein, the step (1) and the step (2) are not in sequence.
In a third aspect, the present invention provides a use of the laminated inductor according to the first aspect in a notebook computer, a digital television, a digital video recorder, a printer or a hard disk drive.
Compared with the prior art, the invention has the following beneficial effects:
(1) The invention adopts the soft magnetic body formed by casting and rolling the flat soft magnetic alloy powder as the first soft magnetic body, so that the magnetic circuit presents a horizontal direction in the first soft magnetic body, thereby obviously improving the magnetic permeability of the magnetic layers on the upper surface and the lower surface of the laminated inductor along the horizontal direction;
(2) Compared with the soft magnetic powder obtained by casting and rolling in the traditional method, the soft magnetic powder core does not need to be doped with a large amount of organic resin, so that the proportion of the soft magnetic alloy powder is obviously improved, and the magnetic conductivity of the laminated inductor is further improved;
(3) According to the invention, the first soft magnetic body and the second soft magnetic body are organically combined, so that the problem of low magnetic permeability of the laminated inductor in the prior art is solved, the high inductance is realized while the laminated inductor is used for coping with large current, the soft magnetic sheet and the first conductor are in a mutually nested structure, the laminated gap between adjacent soft magnetic bodies is filled, and the magnetic permeability of the laminated inductor is further improved.
Drawings
FIG. 1 is an exploded view of a laminated inductor structure provided by the present invention;
fig. 2 is a schematic structural diagram of a first soft magnetic body in a laminated inductor according to the present invention;
FIG. 3 is a magnetic circuit pattern in a laminated inductor provided by the present invention;
fig. 4 is a schematic structural diagram of a second soft magnetic body in the laminated inductor provided by the invention;
fig. 5 is an exploded view of a second soft magnetic structure in the laminated inductor provided by the present invention.
Wherein: 10-a first soft-magnetic body; 20-a second soft magnet; 21-a soft magnetic powder core; 22-a first conductor; 23-soft magnetic sheets; 24-through holes.
Detailed Description
The technical scheme of the invention is further described by the following specific embodiments. It will be apparent to those skilled in the art that the examples are merely to aid in understanding the invention and are not to be construed as a specific limitation thereof.
Example 1
The embodiment provides a laminated inductor and a manufacturing method thereof, as shown in fig. 1, the laminated inductor includes 2 layers of first soft magnets 10 and 3 layers of second soft magnets 20 which are laminated, and the 3 layers of second soft magnets 20 are laminated on the interlayer part of the 2 layers of first soft magnets 10. As shown in fig. 2, the first soft magnetic body 10 is a soft magnetic body formed by casting and rolling a flat soft magnetic alloy powder, and the long axis direction of the flat soft magnetic alloy powder is perpendicular to the lamination direction of the laminated inductor, and the magnetic path direction in the laminated inductor is shown in fig. 3.
As shown in fig. 4 and 5, the second soft magnetic body 20 includes a soft magnetic powder core 21, and a first conductor 22 and a soft magnetic sheet 23 printed on the surface of the soft magnetic powder core 21 and having a nested structure. The soft magnetic powder core 21 is a soft magnetic body formed by adopting soft magnetic alloy powder through compression molding; the surface of the soft magnetic powder core 21 is provided with a through hole 24, and the inside of the through hole 24 is filled with a second conductor; the second conductor and the first conductor 22 communicate with each other to form a conductor coil.
In this embodiment, the flat soft magnetic alloy powder in the first soft magnetic body 10 and the soft magnetic alloy powder in the soft magnetic powder core 21 are each independently sendust powder, and the soft magnetic alloy powder in the soft magnetic powder core 21 has an average particle diameter D50 of 10 μm. The soft magnetic sheet 23 is a magnetic sheet obtained by printing spherical soft magnetic alloy powder, and the spherical soft magnetic alloy powder is ferrosilicon alloy powder, and the average particle diameter D50 is 10 μm.
The preparation method provided by the embodiment comprises the following steps:
(1) Preparing 2 layers of first soft magnets 10 by adopting a casting rolling method;
(1.1) mixing flat soft magnetic alloy powder, PVB resin and n-propyl acetate to obtain first soft magnetic slurry; the mixing mass ratio of the PVB resin to the n-propyl acetate is 1.5:5, and the mass ratio of the flat soft magnetic alloy powder in the first soft magnetic slurry is 90%;
(1.2) carrying out tape casting and rolling on the first soft magnetic slurry obtained in the step (1.1) to obtain a first soft magnetic body 10;
(2) Preparing 3 layers of second soft magnets 20 by adopting a compression molding and printing matching method;
(2.1) subjecting the soft magnetic alloy powder to insulation treatment, compression molding, annealing treatment and processing through holes in order to obtain a soft magnetic powder core 21 with a relative density of 90%, wherein the relative density is specifically the ratio of the density of the soft magnetic powder core 21 to the true density of the soft magnetic alloy powder; the insulation treatment is specifically to perform insulation coating and drying on the soft magnetic alloy powder by utilizing phosphoric acid, wherein the mass ratio of the phosphoric acid to the soft magnetic alloy powder is 1.5:100; the compression molding is carried out in a hydraulic press; the annealing treatment is carried out in nitrogen atmosphere, the temperature is 700 ℃, and the time is 60min;
(2.2) printing a first conductor on the surface of the soft magnetic powder core 21 obtained in the step (2.1) by using silver paste, and filling the through holes 24 to form a second conductor;
(2.3) mixing spherical magnetically soft alloy powder, PVB resin and n-propyl acetate to obtain soft magnetic slurry; wherein, the mixing mass ratio of the PVB resin and the n-propyl acetate is 1.5:5, and the mass ratio of the spherical soft magnetic alloy powder in the soft magnetic slurry is 90%;
(2.4) printing soft magnetic sheets 23 on the parts of the soft magnetic powder core 21 surface obtained in the step (2.2) where the first conductors 22 are not printed by using the soft magnetic slurry obtained in the step (2.3), and drying to obtain second soft magnetic bodies 20;
(3) Laminating the 3 layers of second soft magnets 20 obtained in the step (2) on the interlayer part of the 2 layers of first soft magnets 10 obtained in the step (1), so that the second conductors in the through holes 24 are mutually communicated with the first conductors 22 on the surface of the soft magnetic powder core 21 to form conductor coils, and laminating and heating to obtain laminated inductors; the heating treatment comprises a first heating treatment and a second heating treatment which are sequentially carried out, wherein the temperature of the first heating treatment is 300 ℃, the time is 60min, and the temperature of the second heating treatment is 750 ℃ and the time is 120min.
Example 2
The embodiment provides a laminated inductor and a manufacturing method thereof, as shown in fig. 1, the laminated inductor includes 2 layers of first soft magnets 10 and 3 layers of second soft magnets 20 which are laminated, and the 3 layers of second soft magnets 20 are laminated on the interlayer part of the 2 layers of first soft magnets 10. As shown in fig. 2, the first soft magnetic body 10 is a soft magnetic body formed by casting and rolling a flat soft magnetic alloy powder, and the long axis direction of the flat soft magnetic alloy powder is perpendicular to the lamination direction of the laminated inductor, and the magnetic path direction in the laminated inductor is shown in fig. 3.
As shown in fig. 4 and 5, the second soft magnetic body 20 includes a soft magnetic powder core 21, and a first conductor 22 and a soft magnetic sheet 23 printed on the surface of the soft magnetic powder core 21 and having a nested structure. The soft magnetic powder core 21 is a soft magnetic body formed by adopting soft magnetic alloy powder through compression molding; the surface of the soft magnetic powder core 21 is provided with a through hole 24, and the inside of the through hole 24 is filled with a second conductor; the second conductor and the first conductor 22 communicate with each other to form a conductor coil.
In this embodiment, the flat soft magnetic alloy powder in the first soft magnetic body 10 is sendust powder, the soft magnetic alloy powder in the soft magnetic powder core 21 is sendust powder, and the average grain size D50 of the soft magnetic alloy powder in the soft magnetic powder core 21 is 30 μm. The soft magnetic sheet 23 is a magnetic sheet obtained by printing spherical soft magnetic alloy powder, and the spherical soft magnetic alloy powder is ferrosilicon alloy powder, and the average particle diameter D50 is 2 μm.
The preparation method provided by the embodiment comprises the following steps:
(1) Preparing 2 layers of first soft magnets 10 by adopting a casting rolling method;
(1.1) mixing flat soft magnetic alloy powder, PVB resin and n-propyl acetate to obtain first soft magnetic slurry; the mixing mass ratio of the PVB resin to the n-propyl acetate is 1:4, and the mass ratio of the flat soft magnetic alloy powder in the first soft magnetic slurry is 85%;
(1.2) carrying out tape casting and rolling on the first soft magnetic slurry obtained in the step (1.1) to obtain a first soft magnetic body 10;
(2) Preparing 3 layers of second soft magnets 20 by adopting a compression molding and printing matching method;
(2.1) subjecting the soft magnetic alloy powder to insulation treatment, compression molding, annealing treatment and processing through holes in order to obtain a soft magnetic powder core 21 with a relative density of 95%, wherein the relative density is specifically the ratio of the density of the soft magnetic powder core 21 to the true density of the soft magnetic alloy powder; the insulation treatment is specifically to perform insulation coating and drying on soft magnetic alloy powder by using organic silicon resin, wherein the mass ratio of the organic silicon resin to the soft magnetic alloy powder is 0.5:100; the compression molding is performed in a mechanical press; the annealing treatment is carried out in argon atmosphere, the temperature is 650 ℃, and the time is 80min;
(2.2) printing a first conductor on the surface of the soft magnetic powder core 21 obtained in the step (2.1) by using silver paste, and filling the through holes 24 to form a second conductor;
(2.3) mixing spherical magnetically soft alloy powder, PVB resin and n-propyl acetate to obtain soft magnetic slurry; wherein, the mixing mass ratio of the PVB resin and the n-propyl acetate is 1:4, and the mass ratio of the spherical magnetically soft alloy powder in the soft magnetic slurry is 85%;
(2.4) printing soft magnetic sheets 23 on the parts of the soft magnetic powder core 21 surface obtained in the step (2.2) where the first conductors 22 are not printed by using the soft magnetic slurry obtained in the step (2.3), and drying to obtain second soft magnetic bodies 20;
(3) Laminating the 3 layers of second soft magnets 20 obtained in the step (2) on the interlayer part of the 2 layers of first soft magnets 10 obtained in the step (1), so that the second conductors in the through holes 24 are mutually communicated with the first conductors 22 on the surface of the soft magnetic powder core 21 to form conductor coils, and laminating and heating to obtain laminated inductors; the heating treatment comprises a first heating treatment and a second heating treatment which are sequentially carried out, wherein the temperature of the first heating treatment is 280 ℃, the time is 80min, the temperature of the second heating treatment is 720 ℃, and the time is 140min.
Example 3
The embodiment provides a laminated inductor and a manufacturing method thereof, as shown in fig. 1, the laminated inductor includes 2 layers of first soft magnets 10 and 3 layers of second soft magnets 20 which are laminated, and the 3 layers of second soft magnets 20 are laminated on the interlayer part of the 2 layers of first soft magnets 10. As shown in fig. 2, the first soft magnetic body 10 is a soft magnetic body formed by casting and rolling a flat soft magnetic alloy powder, and the long axis direction of the flat soft magnetic alloy powder is perpendicular to the lamination direction of the laminated inductor, and the magnetic path direction in the laminated inductor is shown in fig. 3.
As shown in fig. 4 and 5, the second soft magnetic body 20 includes a soft magnetic powder core 21, and a first conductor 22 and a soft magnetic sheet 23 printed on the surface of the soft magnetic powder core 21 and having a nested structure. The soft magnetic powder core 21 is a soft magnetic body formed by adopting soft magnetic alloy powder through compression molding; the surface of the soft magnetic powder core 21 is provided with a through hole 24, and the inside of the through hole 24 is filled with a second conductor; the second conductor and the first conductor 22 communicate with each other to form a conductor coil.
In this embodiment, the flat soft magnetic alloy powder in the first soft magnetic body 10 and the soft magnetic alloy powder in the soft magnetic powder core 21 are each independently a ferrosilicon chromium alloy powder, and the soft magnetic alloy powder in the soft magnetic powder core 21 has an average particle diameter D50 of 5 μm. The soft magnetic sheet 23 is a magnetic sheet obtained by printing spherical soft magnetic alloy powder, and the spherical soft magnetic alloy powder is Fe-Si-Cr alloy powder, and the average particle diameter D50 is 15 μm.
The preparation method provided by the embodiment comprises the following steps:
(1) Preparing 2 layers of first soft magnets 10 by adopting a casting rolling method;
(1.1) mixing flat soft magnetic alloy powder, PVB resin and n-propyl acetate to obtain first soft magnetic slurry; the mixing mass ratio of the PVB resin to the n-propyl acetate is 1:3, and the mass ratio of the flat soft magnetic alloy powder in the first soft magnetic slurry is 95%;
(1.2) carrying out tape casting and rolling on the first soft magnetic slurry obtained in the step (1.1) to obtain a first soft magnetic body 10;
(2) Preparing 3 layers of second soft magnets 20 by adopting a compression molding and printing matching method;
(2.1) subjecting the soft magnetic alloy powder to insulation treatment, compression molding, annealing treatment and processing through holes in order to obtain a soft magnetic powder core 21 with a relative density of 85%, wherein the relative density is specifically the ratio of the density of the soft magnetic powder core 21 to the true density of the soft magnetic alloy powder; the insulation treatment is specifically to perform insulation coating on soft magnetic alloy powder by using water glass and drying, wherein the mass ratio of the water glass to the soft magnetic alloy powder is 3:100; the compression molding is performed in a servo press; the annealing treatment is carried out in nitrogen atmosphere, the temperature is 750 ℃, and the time is 40min;
(2.2) printing a first conductor on the surface of the soft magnetic powder core 21 obtained in the step (2.1) by using silver paste, and filling the through holes 24 to form a second conductor;
(2.3) mixing spherical magnetically soft alloy powder, PVB resin and n-propyl acetate to obtain soft magnetic slurry; wherein, the mixing mass ratio of the PVB resin and the n-propyl acetate is 1:3, and the mass ratio of the spherical magnetically soft alloy powder in the soft magnetic slurry is 95%;
(2.4) printing soft magnetic sheets 23 on the parts of the soft magnetic powder core 21 surface obtained in the step (2.2) where the first conductors 22 are not printed by using the soft magnetic slurry obtained in the step (2.3), and drying to obtain second soft magnetic bodies 20;
(3) Laminating the 3 layers of second soft magnets 20 obtained in the step (2) on the interlayer part of the 2 layers of first soft magnets 10 obtained in the step (1), so that the second conductors in the through holes 24 are mutually communicated with the first conductors 22 on the surface of the soft magnetic powder core 21 to form conductor coils, and laminating and heating to obtain laminated inductors; the heating treatment comprises a first heating treatment and a second heating treatment which are sequentially carried out, wherein the temperature of the first heating treatment is 320 ℃, the time is 40min, the temperature of the second heating treatment is 780 ℃, and the time is 100min.
Example 4
The present embodiment provides a laminated inductor and a method for manufacturing the same, and the laminated inductor has the same structure and conditions as those of embodiment 1 except that the second soft magnetic body 20 is replaced by 2 layers, and the method for manufacturing the laminated inductor is adaptively adjusted, so that the description thereof will not be repeated here.
Example 5
The present embodiment provides a laminated inductor and a method for manufacturing the same, and the laminated inductor has the same structure and conditions as those of embodiment 1 except that the second soft magnetic body 20 is replaced by 4 layers, and the method for manufacturing the laminated inductor is adaptively adjusted, so that the description thereof will not be repeated here.
Comparative example 1
The present comparative example provides a laminated inductor and a method for manufacturing the same, and the laminated inductor is not described herein, except that the flat soft magnetic alloy powder in the first soft magnetic body 10 is changed to spherical soft magnetic alloy powder, and the method for manufacturing the laminated inductor is adaptively adjusted, and the other structures and conditions are the same as those of example 1.
Comparative example 2
The present comparative example provides a laminated inductor and a method for manufacturing the same, as shown in fig. 1, the laminated inductor includes 2 layers of first soft magnets 10 and 3 layers of second soft magnets 20 which are laminated, and the 3 layers of second soft magnets 20 are laminated on the interlayer part of the 2 layers of first soft magnets 10. As shown in fig. 2, the first soft magnetic body 10 is a soft magnetic body formed by casting and rolling a flat soft magnetic alloy powder, and the long axis direction of the flat soft magnetic alloy powder is perpendicular to the lamination direction of the laminated inductor, and the magnetic path direction in the laminated inductor is shown in fig. 3.
As shown in fig. 4 and 5, the second soft magnetic body 20 includes a soft magnetic powder core 21, and a first conductor 22 and a soft magnetic sheet 23 printed on the surface of the soft magnetic powder core 21 and having a nested structure. The soft magnetic powder core 21 is a soft magnetic body formed by adopting soft magnetic alloy powder through casting and rolling; the surface of the soft magnetic powder core 21 is provided with a through hole 24, and the inside of the through hole 24 is filled with a second conductor; the second conductor and the first conductor 22 communicate with each other to form a conductor coil.
In this comparative example, the flat soft magnetic alloy powder in the first soft magnetic body 10 and the soft magnetic alloy powder in the soft magnetic powder core 21 were each independently an iron-silicon alloy powder, and the soft magnetic alloy powder in the soft magnetic powder core 21 had an average particle diameter D50 of 15 μm. The soft magnetic sheet 23 is a magnetic sheet obtained by printing spherical soft magnetic alloy powder, and the spherical soft magnetic alloy powder is ferrosilicon alloy powder, and the average particle diameter D50 is 15 μm.
The preparation method provided by the comparative example comprises the following steps:
(1) Preparing 2 layers of first soft magnets 10 by adopting a casting rolling method;
(1.1) mixing flat soft magnetic alloy powder, PVB resin and n-propyl acetate to obtain first soft magnetic slurry; the mixing mass ratio of the PVB resin to the n-propyl acetate is 1.5:5, and the mass ratio of the flat soft magnetic alloy powder in the first soft magnetic slurry is 90%;
(1.2) carrying out tape casting and rolling on the first soft magnetic slurry obtained in the step (1.1) to obtain a first soft magnetic body 10;
(2) Preparing 3 layers of second soft magnets 20 by adopting a casting rolling matching printing method;
(2.1) subjecting the soft magnetic alloy powder to insulation treatment, casting rolling and processing through holes in order to obtain a soft magnetic powder core 21; the insulation treatment is specifically to perform insulation coating and drying on the soft magnetic alloy powder by utilizing phosphoric acid, wherein the mass ratio of the phosphoric acid to the soft magnetic alloy powder is 1.5:100; the casting and rolling specifically comprises the steps of mixing soft magnetic alloy powder after insulation treatment, PVB resin and n-propyl acetate to prepare second soft magnetic slurry, and carrying out casting and rolling on the second soft magnetic slurry to obtain a second soft magnet 20; the mixed mass ratio of the PVB resin to the n-propyl acetate is 1.5:5, and the mass ratio of the soft magnetic alloy powder after the insulation treatment in the second soft magnetic slurry is 90%;
(2.2) printing a first conductor on the surface of the soft magnetic powder core 21 obtained in the step (2.1) by using silver paste, and filling the through holes 24 to form a second conductor;
(2.3) mixing spherical magnetically soft alloy powder, PVB resin and n-propyl acetate to obtain soft magnetic slurry; wherein, the mixing mass ratio of the PVB resin and the n-propyl acetate is 1.5:5, and the mass ratio of the spherical soft magnetic alloy powder in the soft magnetic slurry is 90%;
(2.4) printing soft magnetic sheets 23 on the parts of the soft magnetic powder core 21 surface obtained in the step (2.2) where the first conductors 22 are not printed by using the soft magnetic slurry obtained in the step (2.3), and drying to obtain second soft magnetic bodies 20;
(3) Laminating the 3 layers of second soft magnets 20 obtained in the step (2) on the interlayer part of the 2 layers of first soft magnets 10 obtained in the step (1), so that the second conductors in the through holes 24 are mutually communicated with the first conductors 22 on the surface of the soft magnetic powder core 21 to form conductor coils, and laminating and heating to obtain laminated inductors; the heating treatment comprises a first heating treatment and a second heating treatment which are sequentially carried out, wherein the temperature of the first heating treatment is 300 ℃, the time is 60min, and the temperature of the second heating treatment is 750 ℃ and the time is 120min.
Comparative example 3
The present comparative example provides a laminated inductor and a method for manufacturing the same, in which the soft magnetic sheet 23 on the surface of the first soft magnetic body 10 is removed, only the first conductor 22 and the second conductor inside the through hole 24 are remained, and the manufacturing method is adaptively adjusted, and the other structures and conditions are the same as those of example 1, so that the description thereof will not be repeated.
Testing and results
The magnetic permeability test method comprises the following steps: an impedance analyzer Aglient E4991B (1 MHz-3 GHz) is adopted, and a clamp adopts 16454A; the test sample is a circular ring sample, and the magnetic ring has the following dimensions: the outer diameter is 6mm, the inner diameter is 3mm, and the height is the actually measured thickness of the sheet.
The method for testing the inductance value comprises the following steps: HIOKI (model IM 7581) is adopted for testing, and the electric shock sensing electrodes are arranged at two ends of the instrument, so that the testing conditions are as follows: the frequency is 100kHz, the voltage is 1V, and the inductance value can be directly read.
The first and second soft magnets obtained in examples 1 to 5 and comparative examples 1 to 3 were respectively tested for magnetic permeability and inductance value of the corresponding laminated inductor using the above test methods, and the test results are shown in table 1.
TABLE 1
As can be seen from table 1: the inductance of the laminated inductor prepared in examples 1-2 and 4-5 is higher and is greater than 606nH, the relative magnetic permeability of the first soft magnetic body is more than or equal to 163, and the relative magnetic permeability of the second soft magnetic body is more than or equal to 52; example 3 has slightly lower inductance and permeability than other examples, due to the different permeability of the different materials. In addition, the larger the particle size of the powder, the higher the magnetic permeability of the soft magnetic body, and at the same time, the larger the particle size is unfavorable for the flaking production of the soft magnetic body. Therefore, the average particle diameter D50 of the soft magnetic alloy powder is 1 to 30. Mu.m, preferably 1 to 10. Mu.m.
As can be seen from the combination of example 1 and comparative example 1: the first soft magnetic body of the flat powder is used, and the inductance of the laminated inductor can be effectively improved by utilizing the easy magnetization direction of the first soft magnetic body.
As can be seen from the combination of example 1 and comparative example 2: compared with the second soft magnetic body formed by adopting a tape casting mode, the second soft magnetic body formed by high pressure can obtain higher magnetic permeability, and the inductance of the laminated inductor is greatly improved.
As can be seen from the combination of example 1 and comparative example 3: the soft magnetic sheet in the second soft magnetic body can reasonably utilize the air gap space, reduce magnetic leakage, improve the magnetic conductivity of the material and help to further optimize the effective inductance of the laminated inductor.
Therefore, on one hand, the soft magnetic body formed by casting and rolling the flat soft magnetic alloy powder is used as the first soft magnetic body, so that the magnetic circuit is in the horizontal direction in the first soft magnetic body, and the magnetic permeability of the magnetic layers on the upper surface and the lower surface of the laminated inductor along the horizontal direction is obviously improved; on the other hand, the soft magnetic powder is adopted as the soft magnetic powder core by adopting the soft magnetic powder subjected to compression molding, and compared with the soft magnetic powder obtained by adopting the tape casting and rolling in the traditional method, a large amount of organic resin is not required to be doped in the soft magnetic powder core, so that the proportion of the soft magnetic alloy powder is obviously improved, and the magnetic conductivity of the laminated inductor is further improved. The organic combination of the first soft magnetic body and the second soft magnetic body solves the problem of low magnetic permeability of the laminated inductor in the prior art, and ensures that the laminated inductor realizes high inductance while coping with large current. In addition, the soft magnetic sheets and the first conductors are in a mutually nested structure, so that the lamination gaps between adjacent soft magnets are filled, and the magnetic permeability of the lamination inductor is further improved.
The applicant declares that the above is only a specific embodiment of the present invention, but the scope of the present invention is not limited thereto, and it should be apparent to those skilled in the art that any changes or substitutions that are easily conceivable within the technical scope of the present invention disclosed by the present invention fall within the scope of the present invention and the disclosure.
Claims (31)
1. A laminated inductor, characterized in that the laminated inductor comprises 2 layers of first soft magnets and at least 2 layers of second soft magnets which are laminated;
the at least 2 layers of second soft magnets are arranged at the interlayer part of the 2 layers of first soft magnets in a stacked manner;
the first soft magnetic body is formed by adopting flat soft magnetic alloy powder through casting and rolling, and the long axis direction of the flat soft magnetic alloy powder is mutually perpendicular to the lamination direction of the laminated inductor;
the second soft magnetic body comprises a soft magnetic powder core, a first conductor and a soft magnetic sheet, wherein the first conductor and the soft magnetic sheet are printed on the surface of the soft magnetic powder core and are in a nested structure;
the soft magnetic powder core is a soft magnetic body formed by adopting soft magnetic alloy powder through compression molding;
the relative density of the soft magnetic powder core is 85% -95%, and the relative density is specifically the ratio of the density of the soft magnetic powder core to the true density of the soft magnetic alloy powder;
The soft magnetic sheet is a magnetic sheet formed by printing spherical soft magnetic alloy powder;
the surface of the soft magnetic powder core is provided with a through hole, and the inside of the through hole is filled with a second conductor;
the second conductor and the first conductor are mutually communicated to form a conductor coil.
2. The laminated inductor as recited in claim 1, wherein the flat soft magnetic alloy powder in the first soft magnetic body and the soft magnetic alloy powder in the soft magnetic powder core each independently include any one or a combination of at least two of iron silicon, iron silicon aluminum, iron nickel molybdenum, or iron silicon chromium.
3. A laminated inductor according to claim 1, characterized in that the soft magnetic powder in the soft magnetic powder core has an average particle diameter D50 of 1-30 μm.
4. A laminated inductor according to claim 3, characterized in that the soft magnetic powder in the soft magnetic powder core has an average particle diameter D50 of 1-10 μm.
5. The laminated inductor as claimed in claim 1, wherein the spherical soft magnetic alloy powder in the soft magnetic sheet comprises any one or a combination of at least two of iron silicon, iron silicon aluminum, iron nickel molybdenum, or iron silicon chromium.
6. The laminated inductor as claimed in claim 1, wherein the spherical soft magnetic alloy powder in the soft magnetic sheet has an average particle diameter D50 of 1 to 30 μm.
7. The laminated inductor as claimed in claim 6, wherein the spherical soft magnetic alloy powder in the soft magnetic sheet has an average particle diameter D50 of 1 to 10 μm.
8. A method for manufacturing a laminated inductor according to any one of claims 1-7, characterized in that the method comprises the steps of:
(1) Preparing 2 layers of first soft magnets by adopting a tape casting rolling method;
(2) Preparing at least 2 layers of second soft magnets by adopting a compression molding and printing matching method;
(3) Laminating at least 2 layers of second soft magnetic body layers obtained in the step (2) on interlayer parts of 2 layers of first soft magnetic bodies obtained in the step (1), and performing lamination and heating treatment to obtain laminated inductors;
wherein, the step (1) and the step (2) are not in sequence.
9. The method of manufacturing according to claim 8, wherein the method of manufacturing the first soft magnetic body of step (1) specifically comprises the steps of:
(1.1) mixing flat soft magnetic alloy powder, organic resin and solvent to obtain first soft magnetic slurry;
(1.2) carrying out tape casting and rolling on the first soft magnetic slurry obtained in the step (1.1) to obtain a first soft magnetic body.
10. The method of manufacturing according to claim 9, wherein the method of manufacturing the second soft magnetic body of step (2) specifically comprises the steps of:
(2.1) sequentially performing insulation treatment, compression molding, annealing treatment and through hole processing on the soft magnetic alloy powder to obtain a soft magnetic powder core;
(2.2) printing a first conductor on the surface of the soft magnetic powder core obtained in the step (2.1) by utilizing silver paste, and filling through holes to form a second conductor;
(2.3) mixing spherical soft magnetic alloy powder, organic resin and solvent to obtain soft magnetic slurry;
and (2.4) printing a soft magnetic sheet on the part of the soft magnetic powder core surface, which is not printed with the first conductor, by using the soft magnetic slurry obtained in the step (2.3), and drying to obtain a second soft magnetic body.
11. The method of claim 10, wherein the organic resins of step (1.1) and step (2.3) each independently comprise PVB resin.
12. The method according to claim 10, wherein the solvents of step (1.1) and step (2.3) each independently comprise n-propyl acetate.
13. The method according to claim 10, wherein the mass ratio of the organic resin to the solvent in the step (1.1) and the step (2.3) is (1-2): 4-6, respectively.
14. The method according to claim 9, wherein the flat soft magnetic alloy powder in step (1.1) is present in the first soft magnetic paste in an amount of 85 to 95% by mass.
15. The method according to claim 10, wherein the spherical soft magnetic alloy powder in step (2.3) is present in the soft magnetic paste in an amount of 85 to 95% by mass.
16. The method according to claim 10, wherein the insulating treatment of step (2.1) is specifically: and (5) insulating and coating the soft magnetic alloy powder by using an insulating agent and drying.
17. The method of claim 16, wherein the insulating agent comprises any one or a combination of at least two of phosphoric acid, silicone resin, or water glass.
18. The method according to claim 16, wherein the mass ratio of the insulating agent to the soft magnetic alloy powder is (0.5-3): 100.
19. The method of claim 10, wherein the compression molding of step (2.1) is performed in a hydraulic press, a mechanical press, or a servo press.
20. The method according to claim 10, wherein the annealing treatment in step (2.1) is performed in a nitrogen atmosphere or an argon atmosphere.
21. The method of claim 10, wherein the annealing treatment in step (2.1) is performed at a temperature of 650-750 ℃.
22. The method according to claim 10, wherein the annealing treatment in step (2.1) is performed for 40 to 80 minutes.
23. The method according to claim 10, wherein the soft magnetic powder core obtained in step (2.1) has a relative density of 85% -95%, and the relative density is specifically the ratio of the density of the soft magnetic powder core to the true density of the soft magnetic alloy powder.
24. The method of manufacturing as claimed in claim 8, wherein in step (3), the second conductor inside the through hole and the first conductor on the surface of the soft magnetic powder core are connected to each other after the lamination and placement to form the conductor coil.
25. The production method according to claim 8, wherein the heat treatment in step (3) comprises a first heat treatment and a second heat treatment which are sequentially performed.
26. The method of claim 25, wherein the first heat treatment is at a temperature of 280-320 ℃.
27. The method of claim 25, wherein the first heat treatment is for a period of 40-80 minutes.
28. The method of claim 25, wherein the second heat treatment is at a temperature of 720-780 ℃.
29. The method of claim 25, wherein the second heating treatment is for a period of 100-140 minutes.
30. The preparation method according to claim 8, characterized in that the preparation method comprises the steps of:
(1) Preparing 2 layers of first soft magnets by adopting a tape casting rolling method;
(1.1) mixing flat soft magnetic alloy powder, PVB resin and n-propyl acetate to obtain first soft magnetic slurry; the mixing mass ratio of the PVB resin to the n-propyl acetate is (1-2) (4-6), and the mass ratio of the flat soft magnetic alloy powder in the first soft magnetic slurry is 85% -95%;
(1.2) carrying out tape casting rolling on the first soft magnetic slurry obtained in the step (1.1) to obtain a first soft magnetic body;
(2) Preparing at least 2 layers of second soft magnets by adopting a compression molding and printing matching method;
(2.1) sequentially performing insulation treatment, compression molding, annealing treatment and through hole processing on the soft magnetic alloy powder to obtain a soft magnetic powder core with the relative density of 85% -95%, wherein the relative density is specifically the ratio of the density of the soft magnetic powder core to the true density of the soft magnetic alloy powder; the insulation treatment is specifically to perform insulation coating and drying on the soft magnetic alloy powder by using an insulating agent, wherein the mass ratio of the insulating agent to the soft magnetic alloy powder is (0.5-3) 100, and the insulating agent comprises any one or a combination of at least two of phosphoric acid, organic silicon resin and water glass; the compression molding is carried out in a hydraulic press, a mechanical press or a servo press; the annealing treatment is carried out in nitrogen atmosphere or argon atmosphere, the temperature is 650-750 ℃ and the time is 40-80min;
(2.2) printing a first conductor on the surface of the soft magnetic powder core obtained in the step (2.1) by utilizing silver paste, and filling through holes to form a second conductor;
(2.3) mixing spherical magnetically soft alloy powder, PVB resin and n-propyl acetate to obtain soft magnetic slurry; wherein, the mixing mass ratio of the PVB resin and the n-propyl acetate is (1-2): (4-6), and the mass ratio of the spherical soft magnetic alloy powder in the soft magnetic slurry is 85% -95%;
(2.4) printing a soft magnetic sheet on the part of the soft magnetic powder core surface, which is not printed with the first conductor, by using the soft magnetic slurry obtained in the step (2.3), and drying to obtain a second soft magnetic body;
(3) Laminating at least 2 layers of second soft magnetic body layers obtained in the step (2) on interlayer parts of 2 layers of first soft magnetic bodies obtained in the step (1), enabling second conductors inside the through holes to be mutually communicated with first conductors on the surface of the soft magnetic powder core to form conductor coils, and laminating and heating to obtain laminated inductors; the heating treatment comprises a first heating treatment and a second heating treatment which are sequentially carried out, wherein the temperature of the first heating treatment is 280-320 ℃, the time is 40-80min, the temperature of the second heating treatment is 720-780 ℃, and the time is 100-140min;
wherein, the step (1) and the step (2) are not in sequence.
31. Use of a laminated inductor according to any one of claims 1-7 in a notebook computer, a digital television, a digital video recorder, a printer or a hard drive.
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