METHOD FOR MANUFACTURING HIGH-DENSITY INTEGRALLY-MOLDED INDUCTOR

Abstract

Provided is a method for manufacturing a high-density integrally-molded induct comprising the following steps: (1) winding an enameled wire coil to be spiral; (2) mechanically pressing first ferromagnetic powder into a magnetic core; (3) mounting the magnetic core into a. hollow cavity of the enameled wire coil; (4) mounting the enameled wire coil provided with the magnetic core into an injection mold; (5) uniformly mixing and stirring resin glue, a coupling agent and an accelerant, to obtain high-temperature resin glue; (6) uniformly stirring second ferromagnetic powder and the high-temperature resin glue, to obtain a magnetic composite material; (7) injecting the magnetic composite material into a mold cavity of the injection mold for molding, and solidifying the magnetic composite material to obtain an outer magnet; and (8) cooling and de-molding the outer magnet, to obtain a molded inductor. The inductor obtained using the above method is small in size, high in density, high in relative permeability, better in heat dissipation, and lone in service life. The inductor is simply manufactured using an integral molding method, thus reducing the production cost.

Claims

1. A method for manufacturing a high-density integrally-molded inductor, comprising: (1) winding an enameled wire coil to be spiral; (2) mechanically pressing a first ferromagnetic powder into a magnetic core with a density in a range from 6.2 to 6,9 g/cm3; (3) mounting the magnetic core into a hollow cavity of the enameled wire coil; (4) mounting the enameled wire coil provided with the magnetic core into an injection mold; (5) uniformly mixing and stirring resin glue having a concentration in a range from 70 to 80%, a coupling agent haying a concentration in a range from 5 to 10%, and an accelerant having a concentration in a range from 15 to 200% to obtain a high-temperature resin glue; (6) uniformly stirring a second ferromagnetic powder having a concentration in a range from 88 to 94% and the high-temperature resin glue having a concentration in a range from 6 to 12% to obtain a magnetic composite material; (7) injecting the magnetic composite material into a mold cavity of the injection mold for molding, and solidifying the magnetic composite material for 1.5˜2.5 hours at 125˜140 degrees Celsius to obtain an outer magnet with a density of 5.5˜6.2 g/cm3; and (8) cooling and de-molding the outer magnet to obtain a molded inductor.

2. The method for manufacturing the high-density integrally-molded inductor as claimed in claim 1, wherein a size-ratio of the second ferromagnetic powder is: −100 mesh to 200 mesh having a concentration in a range from 0 to 30%, −200 mesh to 500 mesh having a concentration in a range from 30 to 40%, and −500 mesh having a concentration in a range from 30 to 50%.

3. The method for manufacturing the high-density integrally-molded inductor as claimed in claim 1, wherein the first ferromagnetic powder is a ferrosilicon powder.

4. The method for manufacturing the high-density integrally-molded inductor as claimed in claim 1, wherein the second ferromagnetic powder is at least one of a ferrosilicon powder, ah iron powder, ferrosilicon aluminum powder, iron nickel powder, and ferrosilicochromium powder.

5. The method for manufacturing the high-density integrally-molded inductor as claimed in claim 1, wherein the resin adhesive is a modified epoxy silicone resin.

6. The method for manufacturing the high-density integrally-molded inductor as claimed in claim 1, wherein that the coupling agent is a 3-Mercaptopropylmethyldimethoxysilane.

7. The method for manufacturing the high-density integrally-molded inductor as claimed in claim 1, wherein the accelerant is an isophthalic diamine.

8. The method for manufacturing the high-density integrally-molded inductor as claimed in claim 1, after the step of (8), the manufacturing method further comprises disposing a heat dissipator outside the molded inductor.

9. The method for manufacturing the high-density integrally-molded inductor as claimed in claim 8, wherein the heat dissipator is a pure aluminum material.

Description

DETAILED DESCRIPTION

[0034] A number of embodiments are disclosed below for elaborating the disclosure. However, the embodiments of the disclosure are for detailed descriptions only, not for limiting the scope of protection of the disclosure. It is clear that the described embodiments are merely part of the embodiments of the disclosure, but not all embodiments. Based on the embodiments of the present disclosure, all other embodiments that persons skilled in the art have no creative work are within the scope of the disclosure.

Embodiment 1

[0035] A method for manufacturing a high-density integrally-molded inductor includes the steps of:

[0036] (1) By a coil winding machine, winding an enameled wire coil to be spiral;

[0037] (2) Mechanically pressing a first ferromagnetic powder into a magnetic core with a density of 6.5 g/cm3. The first ferromagnetic powder is a ferrosilicon powder;

[0038] (3) Mounting the magnetic core into a hollow cavity of the enameled wire coil;

[0039] (4) Mounting the enameled wire coil provided with the magnetic core into an injection mold;

[0040] (5) Uniformly mixing and stirring a modified epoxy silicone resin, a 3-Mercaptopropylmethyldimethoxysilane, and an isophthalic diamine to obtain a high-temperature resin glue. The weight ratio of the modified epoxy silicone resin, the 3-Mercaptopropylmethyldimethoxysilane and the isophthalic diamine are respectively 7:1:2;

[0041] (6) Uniformly stirring a second ferromagnetic powder and the high-temperature resin glue to obtain a magnetic composite material. The weight ratio of the second ferromagnetic powder and the high-temperature resin adhesive are respectively 94:6, and a size-ratio of the second ferromagnetic powder is: −100 mesh to 200 mesh, −200 mesh to 500 mesh, and −500 mesh to mix up according to the proportion of 2:3:5;

[0042] (7) Injecting the magnetic composite material into a mold cavity of the injection mold for molding, and solidifying the magnetic composite material for 2 hours at 130 degrees Celsius to obtain an outer magnet with a density of 6.2 g/cm3;

[0043] (8) Cooling and de-molding the outer magnet, to obtain a molded inductor; and

[0044] (9) Disposing a heat dissipator outside the molded inductor. The heat dissipator a pure aluminum material.

Embodiment 2

[0045] A method for manufacturing a high-density integrally-molded inductor includes the steps of:

[0046] (1) By a coil winding machine, winding an enameled wire coil to be spiral;

[0047] (2) Mechanically pressing a first ferromagnetic powder into a magnetic core with a density of 6.2 g/cm3. The first ferromagnetic powder is a ferrosilicon powder;

[0048] (3) Mounting the magnetic core into a hollow cavity of the enameled wire coil;

[0049] (4) Mounting the enameled wire coil provided with the magnetic core into an injection mold;

[0050] (5) Uniformly mixing and stirring a modified epoxy silicone resin, a 3-Mercaptopropylmethyldimethoxysilane, and an isophthalic diamine to obtain a high-temperature resin glue. The weight ratio of the modified epoxy silicone resin, the 3-Mercaptopropylmethyldimethoxysilane and the isophthalic diamine are respectively: 75:7:18;

[0051] (6) Uniformly stirring a second ferromagnetic powder and the high-temperature resin glue to obtain a magnetic composite material. The weight ratio of the second ferromagnetic powder and the high-temperature resin glue are respectively 9:1, and a size-ratio of the second ferromagnetic powder being: −100 mesh to 200 mesh −200 mesh to 500 mesh, and −500 mesh to mix up according to the proportion: 25:35:40;

[0052] (7) Injecting the mimetic composite material into a mold cavity of the injection mold for molding, and solidifying the magnetic composite material for 2.5 hours at 125 degrees Celsius to obtain an outer magnet with a density of 5.9 g/cm3;

[0053] (8) Cooling and de-molding the outer magnet to obtain a molded inductor; and

[0054] (9) Disposing a heat dissipator outside the molded inductor, the heat dissipator being a pure aluminum material.

Embodiment 3

[0055] A method for manufacturing a high-density integrally-molded inductor includes the steps of

[0056] (1) By a coil winding machine, winding an enameled wire coil to be spiral;

[0057] (2) Mechanically pressing a first ferromagnetic powder into a magnetic core with a density of 6.9 g/cm3. The first ferromagnetic powder is a ferrosilicon powder;

[0058] (3) Mounting the magnetic core into a hollow cavity of the enameled wire coil;

[0059] (4) Mounting the enameled wire coil provided with the magnetic core into an injection mold;

[0060] (5) Uniformly mixing and stirring an epoxy silicone resin, a 3-Mercaptopropylmethyldimethoxysilane, and an isophthalic diamine to obtain a high-temperature resin glue. The weight ratio of epoxy silicone resin, the 3-Mercaptopropylmethyldimethoxysilane, and the isophthalic diamine are respectively 80:5:15;

[0061] (6) Uniformly stirring a second ferromagnetic powder and the high-temperature resin glue to obtain a magnetic composite material. The weight ratio of the second ferromagnetic powder and the high-temperature resin glue are respectively 88:12, and a size-ratio of the second ferromagnetic powder being: −100 mesh to 200 mesh, −200 mesh to 500 mesh, and −500 mesh to mix up according to the proportion: 3:4:3;

[0062] (7) Injecting the magnetic composite material into a mold cavity of the injection mold for molding, and solidifying the magnetic composite material for 1.5 hours at 140 degrees Celsius to obtain an outer magnet with a density of 5.5 g/cm3;

[0063] (8) Cooling and de-molding the outer magnet to obtain a molded inductor; and

[0064] (9) Disposing a heat dissipator outside the molded inductor. The heat dissipator is a pure aluminum material.

Embodiment 4

[0065] A method for manufacturing a high-density integrally-molded inductor includes the steps of:

[0066] (1) By a coil winding machine, winding an enameled wire coil to be spiral;

[0067] (2) Mechanically pressing a first ferromagnetic powder into a magnetic core with a density of 6.9 g/cm3. The first ferromagnetic powder is a ferrosilicon powder;

[0068] (3) Mounting the magnetic core into a hollow cavity of the enameled wire coil;

[0069] (4) Mounting the enameled wire coil provided with the magnetic core into an injection mold;

[0070] (5) Uniformly mixing and stirring a modified epoxy silicone resin, a 3-Mercaptopropylmethyldimethoxysilane, and an isophthalic diamine to obtain a high-temperature resin glue. The weight ratio of the modified epoxy silicone resin, the 3-Mercaptopropylmethyldimethoxysilane, and the isophthalic diamine are respectively 7:1:2;

[0071] (6) Uniformly stirring a second ferromagnetic powder and the high-temperature resin glue to obtain a magnetic composite material. The weight ratio of the second ferromagnetic powder and the high-temperature resin glue are respectively 9:1, and a size-ratio of the second ferromagnetic powder being: −100 mesh to 200 mesh, −200 mesh to 500 mesh, and −500 mesh to mix up according to the proportion: 2:3:5;

[0072] (7) Injecting the magnetic composite material into a mold cavity of the injection mold for molding, and solidifying the magnetic composite material for 2 hours at 130 degrees Celsius to obtain an outer magnet with a density of 6.0 g/cm3;

[0073] (8) Cooling and de-molding the outer magnet to obtain a molded inductor; and

[0074] (9) Disposing a heat dissipator outside the molded inductor, the heat dissipator being a pure aluminum material.

[0075] The inductors are manufactured to the same condition according the embodiments 1 to 4, and the inductors are tested by the electrical performance comparison test with the traditional inductor. The data are shown as below:

TABLE-US-00001 The traditional The The The The inductor embodiment 1 embodiment 2 embodiment 3 embodiment 4 Coil number 30 30 30 30 30 The length of 15.8 15.8 15.8 15.8 15.8 effective magnetic circuit 1 (cm) Initial 201.54 269.62 268.64 269.32 269.87 inductance L@0A The 180.26 266.69 265.51 265.84 266.95 inductance in the 5A L@5A

[0076] For the skilled in the art, it is clear that he disclosure is not limited to the details of an exemplary embodiment. And without departing from the spirit or essential characteristics of the present disclosure, it is possible to realize the disclosure with other specific forms. Therefore, no matter with any points, it should be seen as an exemplary embodiment, but not limiting, the scope of the present disclosure is defined by the appended claims rather than the foregoing description define, and therefore intended to fall claim All changes which come within the meaning and range of equivalents of the elements to include in the present invention