Manufacturing method of a transfer-molded inductor

Abstract

Disclosed are a transfer-molded inductor and a manufacturing method thereof. The inductor comprises a magnet formed by transfer molding with a soft magnetic colloid; and a prefabricated coil assembly comprising an air-core coil and electrode sheets connected at two ends of the air-core coil. The method comprises steps of: connecting a prefabricated air-core coil and an electrode sheet by welding to form a coil assembly, and placing the coil assembly in a cavity of a mold; performing transfer molding with a soft magnetic colloid in a gelatinous state so that the coil is entirely buried in the colloid while the electrode sheets at two ends of the air-core coil are at least partially exposed outside the colloid to serve as terminal electrodes; and performing demolding after the colloid is cured to form a magnet, and finishing the terminal electrodes to obtain the inductor.

Claims

1. A manufacturing method of a transfer-molded inductor, comprising steps of: s1, connecting a prefabricated air-core coil and electrode sheets by welding to form a coil assembly, and placing the coil assembly in a cavity of a prefabricated mold; s2, performing transfer molding with a soft magnetic colloid in a gelatinous state so that the air-core coil is entirely buried in the soft magnetic colloid in the gelatinous state while the electrode sheets at two ends of the air-core coil are at least partially exposed outside the soft magnetic colloid to serve as terminal electrodes of the inductor; wherein the soft magnetic colloid contains soft magnetic powder particles, an organic adhesive, a lubricant and a curing agent, silicone resin and epoxy resin are used as the organic adhesive and solid content of the soft magnetic powder particles in the soft magnetic colloid is 95 wt % or more, wherein the soft magnetic colloid is solid at normal temperature, and is gelatinous after being heated to a preset temperature of 150˜200° C., wherein the soft magnetic colloid in the gelatinous state has a viscosity of 10,000˜20,000 cps, wherein the transfer molding is performed under a molding pressure of 10˜20 MPa; and s3, performing demolding after the soft magnetic colloid in the mold is cured to form a magnet, and finishing the terminal electrodes to obtain the transfer-molded inductor.

2. The manufacturing method of claim 1, wherein the soft magnetic powder particles include at least one of Fe—Ni system particles, Fe—Si—Al system particles, Fe—Si system particles, Fe—Si—Cr system particles and Fe system particles, and have a particle size of 5˜50 μm.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic diagram of a prefabricated air-core coil in a transfer-molded inductor according to an embodiment of the present application;

(2) FIG. 2 is a schematic diagram of a coil assembly formed by connecting a prefabricated air-core coil and electrode sheets by welding;

(3) FIG. 3 is a schematic diagram of a semi-finished product obtained after demolding during transfer molding in an embodiment;

(4) FIG. 4 is a schematic diagram of a transfer molding process according to an embodiment of the present application;

(5) FIG. 5 is a schematic diagram of a transfer-molded inductor manufactured according to the present application; and

(6) FIGS. 6a to 6c are cross-sectional views of inductors manufactured via three different processes.

DETAILED DESCRIPTION

(7) The present application will now be further described with reference to drawings and embodiments.

(8) An embodiment of the application provides a manufacturing method of a transfer-molded inductor, and a transfer molding process is adopted for integral molding of the inductor, the manufacturing method comprises the following steps of s1 to s3:

(9) s1, a prefabricated air-core coil and an electrode sheet are connected by welding to form a coil assembly, and the coil assembly is placed in a cavity of a prefabricated mold. As shown in FIG. 1, an exemplary prefabricated air-core coil 10 is formed by winding a plurality of turns of enameled wire, and is hollow and has two ends. The enameled wire can be a round wire or a flat wire, and the coil formed by winding can be circular-shaped as shown in FIG. 1 and can also be oval-shaped, racetrack-shaped, or the like, which is not restricted in the present application.

(10) In one embodiment, the electrode sheet used herein includes two separated same electrode sheets, and the two electrode sheets are respectively connected at the two ends of the air-core coil by welding to form the coil assembly. In another embodiment, the electrode sheet also can be an integral electrode sheet as shown in FIG. 3, and the integral electrode sheet has two symmetrical connecting portions to be connected respectively at the two ends of the air-core coil to form a coil assembly in another form.

(11) s2, transfer molding is performed with a soft magnetic colloid in a gelatinous state so that the air-core coil is entirely buried in the soft magnetic colloid in the gelatinous state while the electrode sheets at the two ends of the air-core coil are at least partially exposed outside the soft magnetic colloid to serve as terminal electrodes of the inductor. As shown in FIG. 4, the prefabricated coil assembly is placed in a cavity 101 of a mold 100, thereafter, the mold is closed, a cake 30′ (solid soft magnetic colloid) is put into the mold, the cake is heated (heated to a temperature of 150˜200° C.) by the mold and becomes gelatinous, and the gelatinous soft magnetic colloid has fluidity and can start to flow to be transferred into the cavity 101 under a very small pressure so as to bury the entire air-core coil and part of the electrode sheet of the coil assembly. According to the present application, the transfer molding process only requires a molding pressure of 10˜20 MPa.

(12) s3, demolding is preformed after the soft magnetic colloid in the mold is cured to form a magnet, thereby obtaining the transfer-molded inductor. As shown in FIG. 4, the gelatinous soft magnetic colloid can be cured in a few minutes after filling is completed so as to form a magnet, and at this time, a semi-finished product 40 can be demolded and taken out. In an embodiment where an integral electrode sheet is used, an obtained exemplary semi-finished product is shown in FIG. 3, in this case, a final terminal electrode 20′ can be formed by just finishing the exposed electrode sheet, such as cutting, folding or the like, and the transfer-molded inductor shown in FIG. 5 can be obtained. As shown in FIG. 5, the transfer-molded inductor comprises a magnet 30 and a coil assembly which is partially within the magnet 30, an air-core coil of the coil assembly is entirely within the magnet, while the electrode sheet has a part inside the magnet as well as the other part exposed outside the magnet to serve as terminal electrodes.

(13) The two ends of the air-core coil 10 are respectively connected with the electrode sheets by welding (e.g., laser welding) with welds inside the magnet 30. As shown in FIG. 2, in a more preferred embodiment, the part, inside the magnet, of the electrode sheet comprises a welding portion 21 which is welded to the air-core coil 10 and a reinforcing portion 22 which is not welded to the air-core coil. It is contemplated that the ends of the coil have less area and provide relatively narrow place for welding with the electrode sheets, therefore, in order to reinforce the stability of the integral connection between the electrode sheets and the magnet, the part, inside the magnet, of the electrode sheet can be designed to have a “Y” shape as shown in FIG. 2, with the welding portion 21 on one side and the reinforcing portion 22 on the other side.

(14) The soft magnetic colloid mentioned above is solid at normal temperature, and is gelatinous after being heated to a preset temperature. In one embodiment of the application, the soft magnetic colloid contains soft magnetic powder particles, an organic adhesive, a lubricant and a curing agent, and becomes gelatinous after being heated to 150˜200° C. to be used for transfer molding, and can be rapidly cured in just a few minutes.

(15) In a more preferred embodiment, the soft magnetic powder particles include at least one of Fe—Ni system particles, Fe—Si—Al system particles, Fe—Si system particles, Fe—Si—Cr system particles and Fe system particles, and have a particle size of 5˜50 μm. Moreover, in order to obtain a higher magnetic conductivity, the solid content of the soft magnetic powder particles in the soft magnetic colloid can be 95 wt % or more, and the soft magnetic colloid in the gelatinous state has a viscosity of 10,000˜20,000 cps.

(16) Specific implementation and beneficial effects of the technical solution of the present application are described below by way of a specific example.

(17) An enameled copper wire was used and wound into an air-core coil through outer-winding, and the enamel coat of two ends of the coil was removed through mechanical peeling to obtain an air-core coil 10 as shown in FIG. 1. The air-core coil and electrode sheets were connected by laser welding to form a coil assembly as shown in FIG. 2 (wherein dashed lines are used to illustrate the scope covered by the magnet). Preferably, the electrode sheet was manufactured by making a copper sheet into a desired shape and then subjecting the copper sheet to a tin fog process. Then, the coil assembly was placed in a pre-designed mold.

(18) After that, a pre-prepared soft magnetic colloid, which is already in a gelatinous state, was injected into the mold, according to a process of transfer molding as shown in FIG. 4. Wherein, the soft magnetic colloid contained magnetic powder of FeSiCr, and the raw powder was subjected to passivation and insulation treatment, the particle size of the magnetic powder being about D50=20 μm and the solid content of the magnetic powder being 95 wt % or more; preferably, silicone resin and epoxy resin were used as an organic adhesive in the soft magnetic colloid with a content of 5 wt % or less, the viscosity of the prepared soft magnetic adhesive at 170° C. is 15,000 cps, and the process of transfer molding as shown in FIG. 4 was performed under a molding pressure of 20 MPa, thereby obtaining a transfer-molded inductor sample. Several groups of samples were prepared through the method described above under a molding pressure within a range of 10-20 MPa.

(19) Conventional dry pressing and molding were performed using magnetic powder in the same configuration to manufacture inductors, and the obtained products are compared with the above-mentioned samples obtained according to the present application, as shown in the following table 1:

(20) TABLE-US-00001 TABLE 1 Solid content of Molding magnetic Technical pressure/ Deformation of powder/ Magnetic platform MPa copper wires wt % conductivity Conventional 500-800 Obvious 95% 22-28 dry pressing deformation (as shown in FIG. 6a) Molding  0-300 Non-obvious 60%  6-10 deformation (as shown in FIG. 6b) Transfer 10-25 Non-obvious 96% 25-32 molding deformation (as shown in FIG. 6c)

(21) Besides, as compared with conventional dry pressing products, the samples obtained according to the present application also have some electrical and mechanical properties greatly improved, as shown in the following table 2:

(22) TABLE-US-00002 TABLE 2 Specification Saturation Direct-current Insulation Withstand Salt fog current/A Product Inductance/μH Quality factor resistance/mΩ Resistance/MΩ voltage/V Strength/N standard/h Max Typ Conventional dry 0.82 29.6 4.85 215 190 255 24 16 19 pressing products Transfer-molded 0.82 40 4.85 1870 500 450 240 17 20 products

(23) As can be seen from the above table, compared with conventional dry pressing, the method provided by the application adopts transfer molding for manufacturing inductors, and may produce inductors with higher magnetic conductivity and some greatly improved electrical and mechanical properties under the condition of using substantially same raw materials; in addition, conventional dry pressing causes obvious deformation of copper wires (as shown in FIG. 6a) and is prone to cause copper wire damages, open circuit, short circuit and the like, while the method provided by the present application only causes non-obvious deformation of copper wires which does not influence the reliability of products. As for the molding, the molding pressure for molding process is just slightly lower than that of the conventional dry pressing, which still brings high requirements on press tonnage of a presser during molding.

(24) Therefore, according to the transfer-molded inductor and the manufacturing method thereof provided by the present application, not only is the molding pressure required greatly reduced to prevent large deformation of copper wires, but also higher magnetic conductivity may be obtained, requirements on molding equipment are not high, process conditions and product reliability may be improved, the production cost may be reduced, and batch production may be realized thereby improving the production efficiency.

(25) Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims.