阅读说明：本技术 一种超低电阻的热压非耦合双电感及其制造方法 (Ultra-low-resistance hot-pressing non-coupling double inductor and manufacturing method thereof ) 是由 饶金火 林伙利 王俊文 于 2021-07-13 设计创作，主要内容包括：本发明揭示了一种超低电阻的热压非耦合双电感及其相对应的制造方法,电感包含一组电感功能器件以包覆绝缘体,电感功能器件由线圈部分及磁芯部分共同构成,线圈部分包括两个完全相同的成型铜框,磁芯部分为一块超合金中柱,超合金中柱的外周侧设置有多处凸台结构,两个成型铜框套设于超合金中柱外部,热压成型状态下,电感功能器件在包覆绝缘体内部置中,两个成型铜框各自的端头作为电感器件的引脚、凸出于包覆绝缘体的一侧端面。本发明使用成型铜框替代了现有技术中的普通线圈,不仅使成型过程转变为前段加工、方便了后续的装配作业,而且增加了电感中线圈部分的厚度,显著地降低了成型后电感成品的DCR。(The invention discloses a hot-pressing non-coupling double inductor with ultra-low resistance and a corresponding manufacturing method thereof, wherein the inductor comprises a group of inductor functional devices for coating an insulator, each inductor functional device is composed of a coil part and a magnetic core part, the coil part comprises two identical formed copper frames, the magnetic core part is a piece of superalloy center pillar, a plurality of boss structures are arranged on the outer peripheral side of the superalloy center pillar, the two formed copper frames are sleeved outside the superalloy center pillar, in a hot-pressing forming state, the inductor functional devices are arranged in the coated insulator, and the respective ends of the two formed copper frames are used as pins of the inductor and protrude out of one side end face of the coated insulator. The invention uses the formed copper frame to replace the common coil in the prior art, not only converts the forming process into front-section processing and facilitates subsequent assembly operation, but also increases the thickness of the coil part in the inductor and obviously reduces the DCR of the formed inductor finished product.)

1. The utility model provides an ultra-low resistance hot pressing non-coupling double inductance, contains a set of inductance function device and wholly wraps in the outside cladding insulator (1) of inductance function device, inductance function device comprises coil part and magnetic core part jointly, its characterized in that: the coil part comprises two formed copper frames (2) with the same structure and size, wherein the formed copper frames (2) are formed by bending strip copper materials and are integrally in a C-shaped structure with right-angle turns; the magnetic core part is a superalloy center pillar (3), a plurality of boss structures are arranged on the outer peripheral side of the superalloy center pillar (3), two formed copper frames (2) are sleeved outside the superalloy center pillar (3), and the two formed copper frames (2) are symmetrically and parallelly arranged outside the superalloy center pillar (3) through the boss structures on the outer peripheral side of the superalloy center pillar (3); in the hot press molding state of the inductance functional device and the cladding insulator (1), the inductance functional device is arranged in the cladding insulator (1), and the respective ends (21) of the two molding copper frames (2) are used as pins of the inductance device and protrude out of one side end face of the cladding insulator (1).

2. The ultra-low resistance thermocompression uncoupled dual inductor of claim 1, further comprising: the forming copper frame (2) is formed by bending and processing a strip-shaped copper material, the cross section of the strip-shaped copper material is rectangular, the length of the cross section of the strip-shaped copper material is 2.5-3 mm, and the width of the cross section of the strip-shaped copper material is 0.5-1 mm.

3. The ultra-low resistance thermocompression uncoupled double inductor of claim 2, wherein: each formed copper frame (2) can be divided into an end head (21) and a central part, the central part is composed of a horizontal section (22) and two vertical sections (23), the number of integral equivalent turns is 3/4, the two vertical sections (23) are respectively connected to one side of the horizontal section (22) and are perpendicular to the horizontal section (22), the three parts form a C-shaped structure with a right-angle turn together, the end part of each vertical section (23) is connected with an end head (21), the arrangement direction of the end head (21) is perpendicular to the vertical section (23) and is parallel to the horizontal section (22), two central shafts of the end head (21) in the horizontal direction on the same formed copper frame (2) are overlapped, and a gap exists between the two end heads (21).

4. The ultra-low resistance thermocompression uncoupled dual inductor of claim 3, further comprising: the superalloy center pillar (3) is integrally of a cubic structure, a connecting boss (31) is arranged on the lower end face of the superalloy center pillar (3) along the central line of the lower end face, the height of the connecting boss (31) is smaller than the section width of the strip copper material, and the width of the connecting boss (31) is equal to the gap between the two end heads (21); in the combined state of the formed copper frame (2) and the superalloy center pillar (3), the end face of the inner periphery side of the formed copper frame (2) is in contact with the end face of the outer periphery side of the superalloy center pillar (3), and the two end heads (21) are in contact with the end faces of the two sides of the connecting boss (31) respectively.

5. The ultra-low resistance thermocompression uncoupled double inductor of claim 4, wherein: the outer peripheral side of the superalloy center post (3) is further provided with a positioning hole (32) for integrally positioning the superalloy center post (3) in the assembling process, and the positioning hole (32) is formed in the center position of the connecting boss (31) and the lower end face of the superalloy center post (3).

6. The ultra-low resistance thermocompression uncoupled double inductor of claim 4, wherein: two side end faces of the superalloy center pillar (3) are respectively provided with a separation boss (33) along the central line thereof, the two separation bosses (33) have the same structure and size, and the central lines of the two separation bosses (33) are parallel and are perpendicular to the central line of the connecting boss (31); under the combined state of the forming copper frame (2) and the superalloy center pillar (3), the end faces of the opposite sides of the forming copper frame (2) are respectively in contact with the end faces of the corresponding sides of the two separation bosses (33).

7. A manufacturing method of an ultra-low resistance hot-pressing non-coupling double inductor, which is used for processing the ultra-low resistance hot-pressing non-coupling double inductor as claimed in any one of claims 1 to 6, and is characterized by comprising the following steps:

s1, processing parts, selecting magnetic powder, obtaining a superalloy center pillar (3) with a corresponding material through cold press molding, selecting two sections of strip copper materials, and obtaining two molded copper frames (2) through bending molding;

s2, assembling and processing an inductance functional device, namely respectively sleeving the two formed copper frames (2) on the outer peripheral sides of the superalloy center pillars (3) to enable the two formed copper frames (2) to be symmetrically and parallelly arranged on the superalloy center pillars (3), so that a complete inductance functional device is obtained;

s3, blending and processing the coating powder, namely mixing the metal powder, the insulating powder, the adhesive, the lubricant and the curing agent to obtain the coating powder for pressing;

s4, hot press molding, namely, placing the inductance functional device in a processing die with the shape consistent with that of a final inductance finished product, using a positioning hole on the superalloy center pillar (3) to center the inductance functional device, then injecting preheated pressing coating powder to enable the inductance functional device to be approximately buried in the pressing coating powder, exposing the end heads (21) of the two molding copper frames (2) outside the pressing coating powder, and then integrating the inductance functional device and the pressing coating powder into a whole through hot press molding to obtain an inductance processing intermediate piece;

s5, performing paint spraying processing, namely performing full-coverage spraying on the end face of one side, exposed out of the end head (21), of the inductance processing intermediate piece by using an insulating material to form a dense insulating coating on the end face of the side of the inductance processing intermediate piece;

s6, performing laser paint stripping processing, namely performing laser paint stripping processing on the end head (21) on the outer periphery side of the inductance processing intermediate piece to enable the insulating coating on the surface of the end head (21) to be completely stripped, and the end head (21) to be exposed and protrude out of the end face of the inductance processing intermediate piece;

and S7, electroplating, namely electroplating the end socket (21) on the inductance processing intermediate piece to form a dense electroplated layer on the exposed surface of the end socket (21) to obtain the inductance finished product.

8. The method for manufacturing an ultra-low resistance thermocompression non-coupled dual inductor as claimed in claim 7, wherein in S1: the selection range of the magnetic powder comprises one or more of FeSiCr, FeSiAl, FeSi, FeSiCrB and Fe-based alloy; the density of the superalloy center post (3) after cold press molding is 6g/cm³～6.5g/cm³。

9. The method for manufacturing an ultra-low resistance thermocompression non-coupled dual inductor as claimed in claim 7, wherein in S3: the material selection range of the metal powder comprises any one or more of FeSiCr, FeSiCrB, FeSi and Fe-based alloy; the material range of the insulating powder comprises any one or more of epoxy resin, bakelite resin and silicone resin.

10. The method for manufacturing an ultra-low resistance thermocompression non-coupled dual inductor as claimed in claim 7, wherein in S4: the preheating temperature of the coating powder for pressing is 55-90 ℃, and the preheating time is 4-7 sec; in the hot-press molding process, the inductance functional component and the coating powder are heated at the temperature of 150-180 ℃ and the temperature is 1.0t/6.6 x 6.6mm²～2.5t/6.6*6.6mm²The pressure is maintained for 60-120 sec under the pressure condition.

Technical Field

The invention relates to a double-inductor device, in particular to an ultralow-resistance hot-pressing non-coupling double inductor and a corresponding manufacturing method thereof, and belongs to the technical field of inductor processing.

Background

In recent years, along with the continuous development of computer communication, artificial intelligence and other technologies, various hardware devices are layered endlessly, and update iterations are increasingly frequent. The hardware development level of the existing stage is reflected by large-scale data processing equipment such as data centers and cloud servers on the national and enterprise level and unmanned vehicles on the personal level.

Under such a trend, the design and manufacture of various hardware devices are also developing toward integration and high efficiency, and in order to fully utilize the internal space of the devices and ensure the continuous and efficient operation of the devices, not only the arrangement relationship among the internal elements becomes more compact, but also the efficiency of each element itself is significantly improved.

Taking an inductance device in an electronic device as an example, the inductance device is widely applied to various circuits to realize the functions of filtering, energy storage, matching and resonance. Considering the requirements of the external size and the internal structure of the device, the internal space of the device should be considered to be fully utilized at the beginning of its design, and therefore the performance requirements of the inductive device used therein are also very strict.

At present, a common inductor formed by hot pressing in the market is generally formed by pressing an internal magnetic core, a coil and an external coating material. In a specific manufacturing process, the general flow includes: forming a magnetic core, bending a coil, flattening and trimming the coil, performing hot press forming, and performing subsequent curing and ending. The inductor is limited by the existing coil structure and processing flow, so that the reliability of the inductor finished product obtained by processing is relatively poor, the Direct Current Resistance (DCR) and the electromagnetic Interference (EMI) are high, and the inductor has the problems of low bearable maximum Current, high alternating Current loss, high product energy consumption and the like in practical use.

In addition, the hot press molding inductor in the prior art is basically connected with the PCB board by virtue of the independent pins protruding from the surface of the inductor, and obvious contact resistance exists between the inductor and the PCB board, so that the efficiency of the inductor is influenced, the overall layout of a circuit is severely restricted, and the simplified design of the circuit is influenced.

In summary, how to provide a brand-new thermal pressing non-coupling dual inductor with ultra-low resistance and adapted to various high-end electronic devices and a corresponding manufacturing method thereof based on various prior arts, which not only ensures that the dual inductor is applicable to various application scenarios with higher requirements and has higher reliability, but also can further improve the manufacturing process of devices, and realize the automatic and mass industrial production of inductor devices, which becomes a problem to be solved by technical personnel in the field at present.

Disclosure of Invention

In view of the above-mentioned drawbacks of the prior art, an object of the present invention is to provide an ultra-low resistance thermocompression non-coupled dual inductor and a corresponding manufacturing method thereof, which are described in detail below.

A hot-pressing non-coupling double inductor with ultra-low resistance comprises a group of inductance functional devices and a cladding insulator integrally coated outside the inductance functional devices, wherein each inductance functional device is formed by a coil part and a magnetic core part together, the coil part comprises two formed copper frames with the same structure and size, and the formed copper frames are formed by bending strip-shaped copper materials and are integrally in a C-shaped structure with right-angle turns; the magnetic core part is a superalloy center pillar, a plurality of boss structures are arranged on the outer peripheral side of the superalloy center pillar, two formed copper frames are sleeved outside the superalloy center pillar, and the two formed copper frames are symmetrically and parallelly arranged outside the superalloy center pillar through the boss structures on the outer peripheral side of the superalloy center pillar; and under the hot press molding state of the inductance functional device and the cladding insulator, the inductance functional device is arranged in the cladding insulator, and the respective ends of the two molded copper frames are used as pins of the inductance device and protrude out of one side end face of the cladding insulator.

Preferably, the shaping copper frame is formed by strip copper product bending process, the cross-section of strip copper product is the rectangle, the cross-sectional length of strip copper product is 2.5mm ~ 3mm, the cross-sectional width of strip copper product is 0.5mm ~ 1 mm.

Preferably, each of the formed copper frames may be divided into an end head and a central portion, the central portion is composed of a horizontal segment and two vertical segments, the number of the integral equivalent turns is 3/4, the two vertical segments are respectively connected to one side of the horizontal segment and are perpendicular to the horizontal segment, the two vertical segments and the horizontal segment form a C-shaped structure with a right-angle turn, the end of each vertical segment is connected with an end head, the direction of the end head is perpendicular to the vertical segment and parallel to the horizontal segment, the central axes of the two end heads on the same formed copper frame in the horizontal direction are overlapped, and a gap exists between the two end heads.

Preferably, the superalloy center pillar is integrally of a cubic structure, a connecting boss is arranged on the lower end face of the superalloy center pillar along the center line of the lower end face of the superalloy center pillar, the height of the connecting boss is smaller than the width of the cross section of the strip copper material, and the width of the connecting boss is equal to the gap between the two ends; under the combined state of the formed copper frame and the superalloy center pillar, the end face on the inner peripheral side of the formed copper frame is in contact with the end face on the outer peripheral side of the superalloy center pillar, and the two ends are in contact with the end faces on the two sides of the connecting boss respectively.

Preferably, the outer peripheral side of the superalloy center pillar is further provided with a positioning hole for positioning the entire superalloy center pillar in the assembling process, and the positioning hole is formed in the lower end face of the superalloy center pillar and the center position of the connecting boss.

Preferably, two side end faces of the superalloy center pillar are respectively provided with a separation boss along a central line thereof, the two separation bosses are completely the same in structure and size, and the central lines of the two separation bosses are parallel and are perpendicular to the central line of the connection boss; and under the combined state of the formed copper frames and the superalloy center pillars, the end faces of the opposite sides of the two formed copper frames are respectively in contact with the end faces of the corresponding sides of the two separation bosses.

A manufacturing method of the ultra-low resistance hot-pressing non-coupling double inductor is used for processing the ultra-low resistance hot-pressing non-coupling double inductor, and comprises the following steps:

s1, processing parts, namely selecting magnetic powder, obtaining a superalloy center pillar with a corresponding material through cold press molding, selecting two sections of strip copper materials, and obtaining two molded copper frames through bending molding;

s2, assembling and processing an inductance functional device, namely sleeving the two formed copper frames on the outer peripheral side of the superalloy center pillar respectively, and arranging the two formed copper frames on the superalloy center pillar symmetrically and in parallel to obtain a complete inductance functional device;

s3, blending and processing the coating powder, namely mixing the metal powder, the insulating powder, the adhesive, the lubricant and the curing agent to obtain the coating powder for pressing;

s4, hot press molding, namely, placing the inductance functional device in a processing die with the shape consistent with that of a final inductance finished product, utilizing a positioning hole on the superalloy center pillar to enable the inductance functional device to be positioned in the inductance functional device, then injecting preheated pressing coating powder, enabling the inductance functional device to be approximately buried in the pressing coating powder, exposing the end heads of the two molded copper frames outside the pressing coating powder, and then integrating the inductance functional device and the pressing coating powder through hot press molding to obtain an inductance processing intermediate piece;

s5, performing paint spraying processing, namely performing full-coverage spraying on the end face of one side, exposed out of the end head, of the inductance processing intermediate piece by using an insulating material to form a dense insulating coating on the end face of the side of the inductance processing intermediate piece;

s6, performing laser paint stripping processing, namely performing laser paint stripping processing on the end head on the outer periphery side of the inductance processing intermediate piece to enable the insulating coating on the surface of the end head to be completely stripped, and the end head to be exposed and protrude out of the end face of the inductance processing intermediate piece;

and S7, electroplating, namely, electroplating the end head on the inductor processing intermediate piece to form a dense electroplated layer on the exposed surface of the end head to obtain an inductor finished product.

Preferably, in S1: the selection range of the magnetic powder comprises one or more of FeSiCr, FeSiAl, FeSi, FeSiCrB and Fe-based alloy; the density of the superalloy center post after cold press forming is 6g/cm³～6.5g/cm³。

Preferably, in S3: the material selection range of the metal powder comprises any one or more of FeSiCr, FeSiCrB, FeSi and Fe-based alloy; the material range of the insulating powder comprises any one or more of epoxy resin, bakelite resin and silicone resin.

Preferably, in S4: the preheating temperature of the coating powder for pressing is 55-90 ℃, and the preheating time is 4-7 sec; in the hot-press molding process, the inductance functional component and the coating powder are heated at the temperature of 150-180 ℃ and the temperature is 1.0t/6.6 x 6.6mm²～2.5t/6.6*6.6mm²The pressure is maintained for 60-120 sec under the pressure condition.

The advantages of the invention are mainly embodied in the following aspects:

according to the ultra-low-resistance hot-pressing non-coupling double inductor, the formed copper frame is used for replacing a common coil used in the prior art, the thickness of the coil part in the inductor is increased, the DCR of a formed inductor finished product is remarkably reduced, and tests show that the resistance of the inductor finished product can be controlled below 0.2m omega. In the assembly process of the inductance device, the lower end face of the finished inductance product is welded on the PCB in a whole, so that no contact resistance exists between the finished inductance product and the PCB, the inductance efficiency is further improved, more possibilities are provided for the arrangement of the finished inductance product, and the finished inductance product can be better applied to high-precision application scenes such as a data center, a cloud server, an unmanned vehicle and the like.

In addition, in the inductance structure, the magnetic core part is provided with the positioning hole and the plurality of bosses matched with the coil part, and the magnetic core part and the coil part are centered in the inductance device by virtue of the limiting action of the positioning hole and the bosses, so that the shielding performance of an inductance finished product is greatly improved, the electromagnetic interference among electrical elements in a use scene is avoided as much as possible, the EMI (electro-magnetic interference) of the inductance finished product is reduced, and the use stability of the inductance finished product is ensured. The inductor device has higher inductance value, can bear higher maximum current, has low alternating current loss in the actual application process, and improves the integral energy-saving effect of the inductor device to the maximum extent.

Corresponding to the inductor device, in the manufacturing method of the ultralow-impedance hot press molding inductor disclosed by the invention, the processing of the coil part is front-stage processing, the processing process is simple and direct, and convenience is provided for production and subsequent assembly molding operation. The manufacturing method of the invention also fully considers the development level of the related technology and considers the process difficulty of product manufacturing, wherein most steps can be completed by using an automatic means, thereby realizing the standardization and the flow of the inductance production and greatly improving the production efficiency of inductance production enterprises.

Finally, the invention also provides reference basis for other related schemes in the same field, can be expanded and extended, applies similar structures and manufacturing methods to other technical schemes of inductance devices, and has very wide application prospect.

The following detailed description of the embodiments of the present invention is provided in connection with the accompanying drawings for the purpose of facilitating understanding and understanding of the technical solutions of the present invention.

Drawings

FIG. 1 is a schematic structural diagram of an inductor functional device according to the present invention in an unassembled state;

FIG. 2 is a schematic view of the overall structure of the intermediate part for inductor processing after hot press molding in the present invention;

fig. 3 is a schematic view of the overall structure of the inductor product according to the present invention.

Wherein: 1. coating an insulator; 2. forming a copper frame; 21. a tip; 22. a horizontal segment; 23. a vertical section; 3. a superalloy center pillar; 31. connecting the bosses; 32. positioning holes; 33. separating the bosses.

Detailed Description

The invention provides a hot-pressing non-coupling double inductor with ultra-low resistance and a corresponding manufacturing method thereof, and the specific scheme is as follows.

A hot-pressing non-coupling double inductor with ultra-low resistance comprises a group of inductance functional devices and a coating insulator 1 which is wholly coated outside the inductance functional devices, wherein the inductance functional devices are formed by a coil part and a magnetic core part together, and the structure of the inductance functional devices is shown in figure 1 (for convenience of display, the upper end face and the lower end face of the inductance functional devices are inverted).

The coil part comprises two formed copper frames 2 with the same structure and size, and the formed copper frames 2 are formed by bending strip-shaped copper materials and are integrally in a C-shaped structure with right-angle turns; the magnetic core part is divided into a superalloy center pillar 3, a plurality of boss structures are arranged on the outer peripheral side of the superalloy center pillar 3, two formed copper frames 2 are sleeved outside the superalloy center pillar 3, and the two formed copper frames 2 are symmetrically and parallelly arranged outside the superalloy center pillar 3 through the boss structures on the outer peripheral side of the superalloy center pillar 3; in the hot press molding state of the inductance functional device and the cladding insulator 1, the inductance functional device is arranged in the cladding insulator 1, and the respective ends 21 of the two molded copper frames 2 are used as pins of the inductance device and protrude out of one side end face of the cladding insulator 1.

The forming copper frame 2 is formed by bending a strip-shaped copper material, the section of the strip-shaped copper material is rectangular, the length of the section of the strip-shaped copper material is 2.5-3 mm, and the width of the section of the strip-shaped copper material is 0.5-1 mm. In this embodiment, it is preferable that the sectional length of the strip-shaped copper material is 2.6mm, and the sectional width of the strip-shaped copper material is 0.9 mm.

Each formed copper frame 2 can be divided into an end head 21 and a central part, the central part is composed of a horizontal section 22 and two vertical sections 23, the number of integral equivalent turns is 3/4, the two vertical sections 23 are respectively connected to one side of the horizontal section 22 and are perpendicular to the horizontal section 22, the three parts jointly form a C-shaped structure with right-angle turns, the end part of each vertical section 23 is connected with one end head 21, the arrangement direction of the end heads 21 is perpendicular to the vertical section 23 and is parallel to the horizontal section 22, the central axes of the two end heads 21 on the same formed copper frame 2 in the horizontal direction are overlapped, and a gap exists between the two end heads 21.

The superalloy center pillar 3 is integrally of a cubic structure, a connecting boss 31 is arranged on the lower end face of the superalloy center pillar 3 along the central line of the lower end face, the height of the connecting boss 31 is smaller than the section width of the strip copper material, and the width of the connecting boss 31 is equal to the gap between the two end heads 21; in the combined state of the formed copper frame 2 and the superalloy center pillar 3, the end surface on the inner circumferential side of the formed copper frame 2 is in contact with the end surface on the outer circumferential side of the superalloy center pillar 3, and the two ends 21 are in contact with the end surfaces on both sides of the connecting boss 31.

In addition to the above structure, the outer peripheral side of the superalloy center pillar 3 is further provided with a positioning hole 32 for integrally positioning the superalloy center pillar 3 in the assembling process, and the positioning hole 32 is formed in the center of the connection boss 31 and the lower end surface of the superalloy center pillar 3.

The end surfaces of the two sides of the superalloy center pillar 3 are respectively provided with a separation boss 33 along the central line thereof, the two separation bosses 33 have the same structure and size, and the central lines of the two separation bosses 33 are parallel and are perpendicular to the central line of the connecting boss 31; under the combined state of the formed copper frame 2 and the superalloy center pillar 3, the end surfaces of the two opposite sides of the formed copper frame 2 are respectively in contact with the end surfaces of the two corresponding sides of the two separation bosses 33.

In summary, the ultra-low resistance hot-pressing non-coupling double inductor uses the formed copper frame to replace a common coil used in the prior art, increases the thickness of the coil part in the inductor, and obviously reduces the DCR of the formed inductor finished product, and tests show that the resistance of the inductor finished product can be controlled below 0.2m omega. In the assembly process of the inductance device, the lower end face of the finished inductance product is welded on the PCB in a whole, so that no contact resistance exists between the finished inductance product and the PCB, the inductance efficiency is further improved, more possibilities are provided for the arrangement of the finished inductance product, and the finished inductance product can be better applied to high-precision application scenes such as a data center, a cloud server, an unmanned vehicle and the like.

In addition, in the inductance structure, the magnetic core part is provided with the positioning hole and the plurality of bosses matched with the coil part, and the magnetic core part and the coil part are centered in the inductance device by virtue of the limiting action of the positioning hole and the bosses, so that the shielding performance of an inductance finished product is greatly improved, the electromagnetic interference among electrical elements in a use scene is avoided as much as possible, the EMI (electro-magnetic interference) of the inductance finished product is reduced, and the use stability of the inductance finished product is ensured. The inductor device has higher inductance value, can bear higher maximum current, has low alternating current loss in the actual application process, and improves the integral energy-saving effect of the inductor device to the maximum extent.

Corresponding to the product structure, the invention also discloses a manufacturing method of the ultra-low resistance hot-pressing non-coupling double inductor, which is used for processing the ultra-low resistance hot-pressing non-coupling double inductor and comprises the following steps:

and S1, processing parts, selecting magnetic powder, obtaining the superalloy center pillar 3 with corresponding material through cold press molding, selecting two sections of strip copper materials, and obtaining two molded copper frames 2 through bending molding.

In this step, the magnetic powder is selected from a range including any one or more of fesicrcr, fesai, FeSi, fesirb, and Fe-based alloys. And the density of the superalloy center post 3 after cold press forming is 6g/cm³～6.5g/cm³。

And S2, assembling and processing the inductance functional device, respectively sleeving the two formed copper frames 2 on the outer peripheral side of the superalloy center pillar 3, and symmetrically and parallelly arranging the two formed copper frames 2 on the superalloy center pillar 3 to obtain the complete inductance functional device.

S3, blending the coating powder, mixing the metal powder, the insulating powder, the binder, the lubricant, and the curing agent to obtain the coating powder for pressing.

In this step, the range of the material selected for the metal powder includes any one or more of fesicrib, fesirb, FeSi, and Fe-based alloy; the material range of the insulating powder comprises any one or more of epoxy resin, bakelite resin and silicone resin.

S4, performing hot press molding, namely, placing the inductance functional device in a processing mold with the same shape as the final inductance finished product, using the positioning hole on the superalloy center pillar 3 to center the inductance functional device, then injecting the preheated pressing coating powder, so that the inductance functional device is substantially buried in the pressing coating powder, the end 21 of each of the two molded copper frames 2 is exposed outside the pressing coating powder, and then integrating the inductance functional device and the pressing coating powder through hot press molding to obtain the inductance processing intermediate part shown in fig. 2.

In this step, it is noted that the preheating temperature of the coating powder for pressing is 55 to 90 ℃ and the preheating time period is 4 to 7 sec; in the hot-press molding process, the inductance functional component and the coating powder are heated at the temperature of 150-180 ℃ and the temperature is 1.0t/6.6 x 6.6mm²～2.5t/6.6*6.6mm²The pressure is maintained for 60-120 sec under the pressure condition.

S5, performing paint spraying processing, namely performing full-coverage type spraying on the end face of one side, exposed out of the end head 21, of the inductance processing intermediate piece by using an insulating material to form a dense insulating coating on the end face of the side of the inductance processing intermediate piece;

s6, performing laser paint stripping processing on the end socket 21 on the outer periphery side of the inductance processing intermediate piece, so that the insulating coating on the surface of the end socket 21 is completely stripped, and the end socket 21 is exposed and protrudes out of the end face of the inductance processing intermediate piece;

and S7, electroplating, namely, electroplating the end head 21 on the inductance processing intermediate piece to form a dense electroplated layer on the exposed surface of the end head 21, so as to obtain the inductance finished product shown in the figure 3.

The manufacturing method of the ultralow-impedance hot-press molding inductor is different from the prior art, the processing of the molded copper frame 2 serving as the coil part is front-section processing, the processing process is simple and direct, and convenience is provided for production and subsequent assembly molding operation. The manufacturing method of the invention also fully considers the development level of the related technology and considers the process difficulty of product manufacturing, wherein most steps can be completed by using an automatic means, thereby realizing the standardization and the flow of the inductance production and greatly improving the production efficiency of inductance production enterprises.

The invention also provides reference basis for other related schemes in the same field, can be expanded and extended, applies similar structures and manufacturing methods to other technical schemes of inductance devices, and has very wide application prospect.

It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein, and any reference signs in the claims are not intended to be construed as limiting the claim concerned.

Finally, it should be understood that although the present description refers to embodiments, not every embodiment contains only a single technical solution, and such description is for clarity only, and those skilled in the art should integrate the description, and the technical solutions in the embodiments can be appropriately combined to form other embodiments understood by those skilled in the art.