CN118136396A - Injection molding inductor manufacturing method and injection molding inductor - Google Patents
Injection molding inductor manufacturing method and injection molding inductor Download PDFInfo
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- CN118136396A CN118136396A CN202410307416.1A CN202410307416A CN118136396A CN 118136396 A CN118136396 A CN 118136396A CN 202410307416 A CN202410307416 A CN 202410307416A CN 118136396 A CN118136396 A CN 118136396A
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- 238000001746 injection moulding Methods 0.000 title claims abstract description 60
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 58
- 239000002002 slurry Substances 0.000 claims abstract description 63
- 238000010438 heat treatment Methods 0.000 claims abstract description 35
- 238000000034 method Methods 0.000 claims abstract description 27
- 239000000843 powder Substances 0.000 claims description 33
- 239000006247 magnetic powder Substances 0.000 claims description 32
- 229910045601 alloy Inorganic materials 0.000 claims description 20
- 239000000956 alloy Substances 0.000 claims description 20
- 229910000519 Ferrosilicon Inorganic materials 0.000 claims description 9
- 238000003825 pressing Methods 0.000 claims description 7
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 6
- 239000003292 glue Substances 0.000 claims description 6
- 229910052751 metal Inorganic materials 0.000 claims description 6
- 239000002184 metal Substances 0.000 claims description 6
- 239000011248 coating agent Substances 0.000 claims description 4
- 238000000576 coating method Methods 0.000 claims description 4
- 229910000838 Al alloy Inorganic materials 0.000 claims description 3
- 229910000599 Cr alloy Inorganic materials 0.000 claims description 3
- 239000004593 Epoxy Substances 0.000 claims description 3
- 229910000863 Ferronickel Inorganic materials 0.000 claims description 3
- 239000004677 Nylon Substances 0.000 claims description 3
- 239000000853 adhesive Substances 0.000 claims description 3
- 230000001070 adhesive effect Effects 0.000 claims description 3
- 229910000808 amorphous metal alloy Inorganic materials 0.000 claims description 3
- 239000000788 chromium alloy Substances 0.000 claims description 3
- 238000009413 insulation Methods 0.000 claims description 3
- 229920001778 nylon Polymers 0.000 claims description 3
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 claims description 3
- 239000002694 phosphate binding agent Substances 0.000 claims description 3
- 239000004033 plastic Substances 0.000 claims description 3
- 229920001296 polysiloxane Polymers 0.000 claims description 3
- 235000019353 potassium silicate Nutrition 0.000 claims description 3
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 3
- 238000005253 cladding Methods 0.000 claims description 2
- 238000002347 injection Methods 0.000 claims 9
- 239000007924 injection Substances 0.000 claims 9
- 239000000696 magnetic material Substances 0.000 abstract description 21
- 230000008569 process Effects 0.000 abstract description 15
- 230000009471 action Effects 0.000 abstract description 5
- 239000011162 core material Substances 0.000 description 12
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 8
- 239000007789 gas Substances 0.000 description 7
- 239000000463 material Substances 0.000 description 6
- 239000000243 solution Substances 0.000 description 5
- 229910052757 nitrogen Inorganic materials 0.000 description 4
- 230000002093 peripheral effect Effects 0.000 description 4
- 238000004804 winding Methods 0.000 description 4
- 239000000203 mixture Substances 0.000 description 3
- 238000005086 pumping Methods 0.000 description 3
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 2
- 238000000280 densification Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 239000001257 hydrogen Substances 0.000 description 2
- 229910052739 hydrogen Inorganic materials 0.000 description 2
- 230000006698 induction Effects 0.000 description 2
- 230000035699 permeability Effects 0.000 description 2
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- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
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- 238000005516 engineering process Methods 0.000 description 1
- 230000017525 heat dissipation Effects 0.000 description 1
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- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 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
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F17/00—Fixed inductances of the signal type
- H01F17/04—Fixed inductances of the signal type with magnetic core
- H01F17/045—Fixed inductances of the signal type with magnetic core with core of cylindric geometry and coil wound along its longitudinal axis, i.e. rod or drum core
-
- 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
- H01F27/02—Casings
- H01F27/022—Encapsulation
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/005—Impregnating or encapsulating
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Manufacturing Cores, Coils, And Magnets (AREA)
Abstract
The invention relates to the technical field of inductors, and provides an injection molding inductor manufacturing method and an injection molding inductor, wherein the method comprises the following steps: placing a coil or a combination of the coil and a magnetic column in a preset shell; injecting magnetic slurry into the preset shell; and heating the preset shell after the magnetic slurry is injected in a vacuum environment to form the injection molding inductor. In the manufacturing method, the magnetic material-containing slurry (namely, the magnetic slurry) is adopted for the periphery of the coil to be molded in the preset shell at one time, and the shell is heated in a vacuum environment, so that the magnetic slurry is filled uniformly and has no gap under the action of atmospheric pressure, and therefore, the high-density magnetic material is formed on the periphery of the coil, and compared with the prior art, a mold cavity for manufacturing the high-density magnetic material in advance is not required, the high-density magnetic material on the periphery of the coil can be ensured, and meanwhile, the manufacturing procedures are fewer and the process is simple.
Description
Technical Field
The invention relates to the technical field of inductors, in particular to a manufacturing method of an injection molding inductor and the injection molding inductor.
Background
At present, the inductance industry is mainly divided into two inductance manufacturing modes:
In the first mode, a magnetic core winding mode is adopted, and after the magnetic core is manufactured, the magnetic core is wound outside, and the coil inductance is improved by utilizing the characteristic that the magnetic permeability of the magnetic core is far higher than that of air. Although the manufacturing method can manufacture a large-sized inductor, the problems of low utilization rate of the inductor space, complicated process, electromagnetic compatibility (Electromagnetic Compatibility, EMC) caused by the exposed coil and the like exist.
In a second mode, an integrated molded inductor is adopted, the coil is pre-buried in the magnetic powder and directly pressed into a required shape, and the main working procedures are as follows: magnetic powder manufacturing, coil winding, integral pressing, baking, curing and the like. The manufacturing method can improve the space utilization rate of the device and shorten the process from magnetic powder to the device. However, due to the limitations of magnetic powder materials and technology, only small-sized inductors can be manufactured, the size is concentrated within 1-30 mm, and the requirement of high power cannot be met.
In the prior art, in order to solve the technical problems existing in the two modes, an injection molding mode is adopted to manufacture the inductor, and the procedures are as follows: manufacturing magnetic slurry containing magnetic substances, and pressing the magnetic slurry into a die cavity with high-density magnetic materials by using a press; and then transferring the coil or the coil and magnetic core assembly into a mold cavity, and finally injecting magnetic liquid into the mold cavity to fill the gap. In the manufacturing mode, in order to enable the magnetic material on the periphery of the coil to reach higher density, a die cavity of the high-density magnetic material needs to be manufactured first, and the manufacturing steps of the die cavity involve the processes of pressurization, baking, assembly and the like, so that the process is complex, and the manufacturing process of the whole injection molding inductor is long and the process is complex.
Disclosure of Invention
The invention provides a manufacturing method of an injection molding inductor and the injection molding inductor, which are used for solving the problems of long manufacturing procedure and complex process of the injection molding inductor in the prior art.
The invention provides a manufacturing method of an injection molding inductor, which comprises the following steps:
placing a coil or a combination of the coil and a magnetic column in a preset shell;
Injecting magnetic slurry into the preset shell;
and heating the preset shell after the magnetic slurry is injected in a vacuum environment to form the injection molding inductor.
According to the injection molding inductor manufacturing method provided by the invention, the preset shell body after the magnetic slurry is injected is placed in a vacuum environment for heating, and the injection molding inductor manufacturing method comprises the following steps:
placing the preset shell after the magnetic slurry is injected into a heatable vacuumizing container, and vacuumizing the heatable vacuumizing container;
And after the vacuumizing reaches the first preset duration, heating is started, and meanwhile, the vacuum state of the heatable vacuumizing container is maintained until the magnetic slurry is solidified.
According to the manufacturing method of the injection molding inductor provided by the invention, the heating temperature in a vacuum environment is 50-300 ℃.
According to the injection molding inductor manufacturing method provided by the invention, the preset shell body after the magnetic slurry is injected is heated in a vacuum environment, and the injection molding inductor manufacturing method comprises the following steps:
Placing the preset shell after the magnetic slurry is injected into a heatable vacuum vessel, vacuumizing the heatable vacuum vessel, and heating at a first temperature;
And after the vacuumizing reaches a second preset time, heating is started at a second temperature, and meanwhile, the vacuum state of the heatable vacuumizing container is maintained until the magnetic slurry is solidified, wherein the second temperature is higher than the first temperature.
According to the injection molding inductor manufacturing method provided by the invention, the range of the first temperature is [50 ℃,100 ℃, and the range of the second temperature is [100 ℃,300 ℃).
According to the injection molding inductance manufacturing method provided by the invention, before the combination body of the coil and the magnetic column is arranged in the preset shell, the injection molding inductance manufacturing method further comprises the following steps:
Coating and insulating the magnetic powder;
pressing the magnetic powder subjected to the cladding insulation treatment into a magnetic powder core with a designed shape;
carrying out heat treatment on the pressed magnetic powder core for 1-5 hours at the temperature of 600-850 ℃ to obtain the magnetic column;
And sleeving the coil on the outer surface of the magnetic column.
According to the injection molding inductor manufacturing method provided by the invention, the magnetic powder comprises the following components: at least one of FeSiB amorphous alloy powder, feSi alloy powder, feNi alloy powder, feSiAl alloy powder, feSiCr alloy powder and carbonyl iron powder.
According to the manufacturing method of the injection molding inductor provided by the invention, the preset shell is a metal shell or a plastic shell.
According to the manufacturing method of the injection molding inductor provided by the invention, the magnetic slurry comprises the following components: magnetic powder and insulating curing glue;
The magnetic powder comprises: at least one of amorphous powder, nanocrystalline powder, carbonyl iron powder, ferrosilicon aluminum alloy powder, ferrosilicon alloy powder, ferronickel alloy powder and ferrosilicon chromium alloy powder;
The insulating and curing adhesive comprises the following components: at least one of water glass, phosphate binder, silicone, epoxy, phenolic and nylon.
The invention also provides an injection molding inductor, which is manufactured by the manufacturing method of the injection molding inductor.
According to the injection molding inductor manufacturing method and the injection molding inductor, the coil or the combination of the coil and the magnetic column is arranged in the preset shell; injecting magnetic slurry into the preset shell; and heating the preset shell after the magnetic slurry is injected in a vacuum environment to form the injection molding inductor. Because the process of vacuumizing, baking and solidifying the magnetic slurry is adopted in the manufacturing process, the process ensures that the magnetic slurry is uniformly filled in the shell without gaps under the action of atmospheric pressure on one hand, and the magnetic slurry is thoroughly volatilized in the heating process on the other hand, so that gaps are not generated in the cavity, and the magnetic material is compactly filled; and the peripheral materials of the coil are all made of the slurry containing the magnetic material (namely the magnetic slurry) by one-time injection molding in the preset shell, so that compared with the prior art, the method does not need to manufacture a die cavity of the high-density magnetic material in advance, and has the advantages of less manufacturing procedures and simple process while ensuring that the peripheral magnetic material of the coil can reach higher density.
Drawings
In order to more clearly illustrate the invention or the technical solutions of the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described, and it is obvious that the drawings in the description below are some embodiments of the invention, and other drawings can be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic flow chart of a method for manufacturing an injection molding inductor according to the present invention;
Fig. 2 is a schematic diagram of an injection molding inductor manufactured by the manufacturing method of the injection molding inductor;
fig. 3 is a schematic diagram of a magnetic induction loop of an injection molding inductor manufactured by the manufacturing method of the injection molding inductor.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the present invention more apparent, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings, and it is apparent that the described embodiments are some embodiments of the present invention, not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
The method for manufacturing the injection molding inductor according to the embodiment of the invention, as shown in fig. 1, comprises the following steps:
step S110: the coil or the combination of the coil and the magnetic column is arranged in a preset shell, the shell can be cuboid or cylindrical, the size of the shell can be set according to practical conditions, and if a large-sized inductor is to be manufactured, the size range can be 3 cm-200 cm, for example: the square has a side length of 200cm. The magnetic column can be a cylinder, an elliptic cylinder or a square cylinder and the like. Of course, after the coil or the combination of the coil and the magnetic column is placed in the preset shell, the pin wire of the coil extends out of the through hole on the preset shell, and sealing treatment is carried out at the through hole.
Step S120: and injecting magnetic slurry into the preset shell, and filling the space around the coil or the combination of the coil and the magnetic column in the preset shell after the magnetic slurry is injected into the preset shell. The coil can be completely covered by the magnetic slurry, preferably, the coil or the combination of the coil and the magnetic column is coated in the middle of the preset shell by the magnetic slurry, and the surface of the magnetic slurry is flush with the opening of the preset shell, so that the manufactured injection molding inductor has better performance.
Step S130: and heating the preset shell after the magnetic slurry is injected in a vacuum environment to form the injection molding inductor. Specifically, the preset shell body after the magnetic slurry is injected is placed in a heatable vacuumizing container, the heatable vacuumizing container is vacuumized, and after vacuumizing, the preset shell body is uniformly filled with the magnetic slurry under the action of atmospheric pressure without gaps, namely bubbles in the magnetic slurry can be extruded out, so that the magnetic material on the periphery of the coil is densified, and higher density is achieved. In addition, in the process of heating and curing the magnetic slurry, certain volatile gases in the magnetic slurry can be rapidly removed due to the vacuumizing effect, and the volatile gases can not be left in the preset shell to generate gaps.
According to the manufacturing method of the injection molding inductor, the manufacturing steps are adopted, and the process of vacuumizing, baking and solidifying the magnetic slurry is adopted in the manufacturing process, so that on one hand, residual bubbles in the magnetic slurry are extruded under the action of atmospheric pressure, the magnetic slurry is uniformly filled in the shell without gaps, on the other hand, the magnetic slurry is volatilized thoroughly in the heating process, the gaps are not generated in the cavity, and the magnetic material is filled compactly; and the peripheral materials of the coil are all made of the slurry containing the magnetic material (namely the magnetic slurry) by one-time injection molding in the preset shell, so that compared with the prior art, the method does not need to manufacture a die cavity of the high-density magnetic material in advance, and has the advantages of less manufacturing procedures and simple process while ensuring that the peripheral magnetic material of the coil can reach higher density.
In some embodiments, step S130 specifically includes:
and placing the preset shell after the magnetic slurry is injected into a heatable vacuum-pumping container, vacuumizing the heatable vacuum-pumping container, and discharging the gas in the magnetic slurry in a vacuum atmosphere in the vacuumizing process.
And after the vacuumizing reaches the first preset duration, heating is started, and meanwhile, the vacuum state of the heatable vacuumizing container is maintained until the magnetic slurry is solidified. In this embodiment, the vacuum is first pumped, and heating is started after the vacuum pumping reaches the first preset duration, so that the situation that the magnetic slurry is solidified faster due to the fact that the magnetic slurry is solidified after the air bubbles come out and is not discharged is avoided, and the magnetic material on the periphery of the coil of the injection molding inductor is made to be denser and higher in density.
Specifically, the first preset time period is 10 minutes to 1 hour, the magnetic slurry mixture material and the proportion are different according to the size of the injection molding inductor, the heating temperature in the vacuum environment is 50 ℃ to 300 ℃, the specific temperature is different according to the size of the injection molding inductor, the heating time is 0.5 to 5 hours, and the specific temperature is different according to the size of the injection molding inductor.
In some embodiments, step S130 specifically includes:
And placing the preset shell after the magnetic slurry is injected into a heatable vacuum vessel, vacuumizing the heatable vacuum vessel, and heating at a first temperature.
And after the vacuumizing reaches a second preset time, heating is started at a second temperature, and meanwhile, the vacuum state of the heatable vacuumizing container is maintained until the magnetic slurry is solidified, wherein the second temperature is higher than the first temperature.
In this embodiment, heating and vacuumizing are performed simultaneously, and the first temperature with a lower temperature is used for heating at the beginning, so that the magnetic slurry is not solidified faster due to the lower temperature, and bubbles in the magnetic slurry can be completely discharged in a vacuum atmosphere. In the first temperature heating process, when the magnetic slurry containing volatile materials is heated at a lower first temperature, volatile gases can volatilize rapidly under the action of atmospheric pressure before the magnetic slurry is solidified, and the volatile gases cannot remain in the magnetic slurry to form gaps, so that the densification degree of the magnetic materials around the coil of the injection molding inductor is improved.
Specifically, the first temperature is in the range of [50 ℃,100 ℃) and may be 60 ℃, 70 ℃, 75 ℃, 80 ℃, 85 ℃, 90, preferably 75 ℃; the heating time (i.e., the second preset time period) is 0.2 to 3 hours, preferably 0.5 hours.
The second temperature is in the range of [100 ℃,300 ℃ ], which may be 120 ℃, 150 ℃, 180 ℃,200 ℃, 220 ℃, 230 ℃, 250 ℃, 280 ℃, preferably 230 ℃, for a heating time of 0.3-2 hours, preferably 1 hour.
The first temperature, the second preset time length and the heating time corresponding to the second temperature are different according to different materials and proportions of the magnetic slurry mixture.
In some embodiments, if the combination of the coil and the magnetic pillar is placed in the preset housing, the step S110 further includes a step of manufacturing the magnetic pillar, where the step of manufacturing the magnetic pillar specifically includes:
and coating insulating treatment is carried out on the magnetic powder, namely, insulating substances are coated on the surface of the magnetic powder so as to facilitate mutual insulation between the subsequent magnetic powder and the magnetic slurry.
The magnetic powder after the pressing and coating insulating treatment is a magnetic powder core with a designed shape, in particular, the magnetic powder can be pressed into a cylinder or an elliptic square structure, the pressing pressure is in the range of 10-23t/cm 2, and the pressure is determined according to the size of the injection molding inductor.
The pressed magnetic powder core is subjected to heat treatment at 600-850 ℃, preferably at 750 ℃ for 1-5 hours in nitrogen or a mixed gas atmosphere of hydrogen and nitrogen, so as to obtain the magnetic column. The heat treatment in nitrogen or the mixed gas atmosphere of hydrogen and nitrogen can avoid the oxidation of metal in the magnetic powder core.
And sleeving the coil on the outer surface of the magnetic column, and particularly winding on the surface of the magnetic column to form the coil sleeved on the outer surface of the magnetic column, wherein the winding can be single-layer or multi-layer.
In this embodiment, the magnetic powder core material after high-density pressing and high-temperature heat treatment has the characteristics of high saturation magnetic induction strength (Bs), low loss and high magnetic permeability, and the manufactured injection molding inductor can generate high inductance and low loss.
The magnetic powder core includes: at least one of FeSiB amorphous alloy powder, feSi alloy powder, feNi alloy powder, feSiAl alloy powder, feSiCr alloy powder and carbonyl iron powder.
In some embodiments, the preset shell is a metal shell (such as an aluminum shell) or a plastic shell, and the thickness of the preset shell is between 0.1 and 1 mm.
In some embodiments, the magnetic slurry comprises: the weight ratio of the magnetic powder is more than or equal to 80% and less than or equal to 95%, and the insulating and curing glue can be inorganic glue or organic glue.
Specifically, the magnetic powder includes: amorphous powder, nanocrystalline powder, carbonyl iron powder, ferrosilicon aluminum alloy powder, ferrosilicon alloy powder, ferronickel alloy powder and ferrosilicon chromium alloy powder.
The insulating and curing adhesive comprises the following components: at least one of water glass, phosphate binder, silicone, epoxy, phenolic and nylon.
The periphery is the mixture of magnetic powder and insulating curing glue, so that the inductor forms a magnetic loop and prevents the magnetic field from leaking out, and the EMC meets the requirements. Preferably, the magnetic powder is a metal or alloy magnetic material, and the metal or alloy magnetic material has high thermal coefficient and good heat dissipation of the device, thereby being beneficial to reducing the inductance temperature during the injection molding inductance work.
The invention also provides an injection molding inductor, which is manufactured by the manufacturing method of the injection molding inductor in any embodiment. As shown in fig. 2 and 3, the structure of the injection molding inductor manufactured by the method includes: a housing 201, a magnetic post 202, a coil 203, a cured magnetic paste 204, and an outgoing line 205. The magnetic column 202 is positioned inside the shell 201, the gap between the magnetic column 202 and the inner wall of the shell 201 is filled with solidified magnetic slurry 204, the coil 203 is wound on the outer surface of the magnetic column 202, and two ends of the coil 203 are led out of the shell 201 through lead-out wires 205. The injection molding inductor is manufactured by adopting the method of the embodiment, has few manufacturing procedures and simple process, and the densification degree of the magnetic material at the periphery of the coil is high, namely, the density is high, and as can be seen from fig. 3, a magnetic loop (shown by a dotted line in fig. 3) formed by the injection molding inductor is completely in the structure of the whole inductor, and no magnetic field leakage exists.
Finally, it should be noted that: the above embodiments are only for illustrating the technical solution of the present invention, and are not limiting; although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit and scope of the technical solutions of the embodiments of the present invention.
Claims (10)
1. A method for manufacturing an injection molding inductor, comprising the steps of:
placing a coil or a combination of the coil and a magnetic column in a preset shell;
Injecting magnetic slurry into the preset shell;
and heating the preset shell after the magnetic slurry is injected in a vacuum environment to form the injection molding inductor.
2. The method of manufacturing an injection molded inductor according to claim 1, wherein the step of heating the pre-set housing after the injection of the magnetic paste in a vacuum environment comprises:
placing the preset shell after the magnetic slurry is injected into a heatable vacuumizing container, and vacuumizing the heatable vacuumizing container;
And after the vacuumizing reaches the first preset duration, heating is started, and meanwhile, the vacuum state of the heatable vacuumizing container is maintained until the magnetic slurry is solidified.
3. The method for manufacturing the injection molding inductor according to claim 2, wherein the heating temperature in the vacuum environment is 50 ℃ to 300 ℃.
4. The method of manufacturing an injection molded inductor according to claim 1, wherein the pre-set housing after the injection of the magnetic paste is heated in a vacuum environment, comprising:
Placing the preset shell after the magnetic slurry is injected into a heatable vacuum vessel, vacuumizing the heatable vacuum vessel, and heating at a first temperature;
And after the vacuumizing reaches a second preset time, heating is started at a second temperature, and meanwhile, the vacuum state of the heatable vacuumizing container is maintained until the magnetic slurry is solidified, wherein the second temperature is higher than the first temperature.
5. The method of manufacturing an injection molded inductor according to claim 4, wherein the first temperature is in a range of [50 ℃,100 ℃ and the second temperature is in a range of [100 ℃,300 ℃.
6. The method of manufacturing an injection molded inductor according to claim 1, further comprising, before placing the combination of the coil and the magnetic pillar in the pre-set housing:
Coating and insulating the magnetic powder;
pressing the magnetic powder subjected to the cladding insulation treatment into a magnetic powder core with a designed shape;
carrying out heat treatment on the pressed magnetic powder core for 1-5 hours at the temperature of 600-850 ℃ to obtain the magnetic column;
And sleeving the coil on the outer surface of the magnetic column.
7. The method of manufacturing an injection molded inductor according to claim 6, wherein the magnetic powder comprises: at least one of FeSiB amorphous alloy powder, feSi alloy powder, feNi alloy powder, feSiAl alloy powder, feSiCr alloy powder and carbonyl iron powder.
8. The method of any one of claims 1 to 7, wherein the pre-set housing is a metal or plastic shell.
9. The injection molding inductor manufacturing method according to any one of claims 1 to 7, wherein the magnetic paste comprises: magnetic powder and insulating curing glue;
The magnetic powder comprises: at least one of amorphous powder, nanocrystalline powder, carbonyl iron powder, ferrosilicon aluminum alloy powder, ferrosilicon alloy powder, ferronickel alloy powder and ferrosilicon chromium alloy powder;
The insulating and curing adhesive comprises the following components: at least one of water glass, phosphate binder, silicone, epoxy, phenolic and nylon.
10. Injection molded inductor, characterized in that it is manufactured by the injection molded inductor manufacturing method according to any one of claims 1 to 9.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202410307416.1A CN118136396A (en) | 2024-03-18 | 2024-03-18 | Injection molding inductor manufacturing method and injection molding inductor |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202410307416.1A CN118136396A (en) | 2024-03-18 | 2024-03-18 | Injection molding inductor manufacturing method and injection molding inductor |
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| CN118136396A true CN118136396A (en) | 2024-06-04 |
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| CN202410307416.1A Pending CN118136396A (en) | 2024-03-18 | 2024-03-18 | Injection molding inductor manufacturing method and injection molding inductor |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN119982902A (en) * | 2025-01-17 | 2025-05-13 | 清华大学 | Magnetic powder liquid injection method and system for magnetic powder sealing device |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN119982902A (en) * | 2025-01-17 | 2025-05-13 | 清华大学 | Magnetic powder liquid injection method and system for magnetic powder sealing device |
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