阅读说明：本技术 一种高散热一体成型电感及其制备方法 (High-heat-dissipation integrally-formed inductor and preparation method thereof ) 是由 徐可心 孙洪波 钱江华 林涛 马飞 王伟 吴长和 王劲 于 2021-09-30 设计创作，主要内容包括：本发明提供一种高散热一体成型电感及其制备方法,磁柱上绕制线圈；在绕有线圈的磁芯各表面进行导热材料的第一次涂覆,形成连续的第一导热层；加入磁粉热压成型并烧结固化,在磁柱外围形成磁粉层,获得电感半成品；在电感半成品的外表面进行导热材料的第二次涂覆,形成连续的第二导热层；制作电极,形成一体成型电感。极大提高产品的散热能力,在电感工作过程中及时将热量运输到产品表面,防止内部过热导致电感性能下降。(The invention provides a high heat dissipation integrally formed inductor and a preparation method thereof.A coil is wound on a magnetic pole; performing first coating of heat conducting materials on all surfaces of the magnetic core wound with the coil to form a continuous first heat conducting layer; adding magnetic powder, hot-pressing, molding, sintering and curing to form a magnetic powder layer on the periphery of the magnetic column to obtain a semi-finished inductor product; coating the outer surface of the semi-finished inductor product with a heat conducting material for the second time to form a continuous second heat conducting layer; and manufacturing electrodes to form the integrally formed inductor. The heat dissipation capacity of the product is greatly improved, heat is timely transported to the surface of the product in the working process of the inductor, and the phenomenon that the performance of the inductor is reduced due to internal overheating is prevented.)

1. A preparation method of a high-heat-dissipation integrally-formed inductor is characterized by comprising the following steps:

step A1, preparing and forming a magnetic core comprising a leaf pendulum and a magnetic column, wherein the magnetic column is connected with the upper surface of the leaf pendulum, and a coil is wound on the magnetic column;

step A2, performing first coating of heat conducting material on each surface of the magnetic core wound with the coil to form a continuous first heat conducting layer;

step A3, adding magnetic powder into the magnetic core to perform hot press molding, sintering and curing to form a magnetic powder layer on the periphery of the magnetic column, thereby obtaining an inductance semi-finished product;

step A4, performing second coating of heat conducting materials on the outer surface of the semi-finished inductor to form a continuous second heat conducting layer;

step a5, preparing and forming electrodes on the inductor semi-finished product formed with the second heat conduction layer, so as to form the integrated inductor.

2. The method according to claim 1, wherein the first and second heat conducting layers are made of one of graphene, heat conducting silica gel and heat conducting silicone grease.

3. The method for manufacturing a high heat dissipation integrally formed inductor as recited in claim 1, wherein the magnetic core is T-shaped;

the continuous first heat conduction layer covers the upper surface of the vane pendulum, the lower surface of the vane pendulum, four side surfaces of the vane pendulum, the winding cylindrical surface of the magnetic pillar and the top surface of the magnetic pillar;

the second heat conduction layer which is coated continuously covers the upper surface and four side surfaces of the magnetic powder layer.

4. The method according to claim 3, wherein the top surface of the magnetic pillar protrudes above the top surface of the magnetic powder layer.

5. The method for manufacturing an integrally formed inductor with high heat dissipation according to claim 1, wherein the magnetic core is i-shaped;

the blade pendulum comprises a first blade pendulum and a second blade pendulum;

the upper surface of the magnetic column is connected with the lower surface of the first vane pendulum, the lower surface of the magnetic column is connected with the upper surface of the second vane pendulum, and the magnetic powder layer is arranged on the periphery of the magnetic column;

the continuous first heat conduction layer covers the winding cylindrical surface of the magnetic column, the upper surface of the first vane pendulum, the lower surface of the first vane pendulum, the four side surfaces of the first vane pendulum, the upper surface of the second vane pendulum, the lower surface of the second vane pendulum and the four side surfaces of the second vane pendulum;

the second heat conduction layer which is coated continuously covers four side faces of the magnetic powder layer.

6. The method for manufacturing a high heat dissipation integrally formed inductor as claimed in claim 1, wherein the magnetic core is formed by cold press molding and curing.

7. A high heat dissipation integrally formed inductor, which is manufactured by the method for manufacturing a high heat dissipation integrally formed inductor according to any one of claims 1 to 6, and comprises:

the magnetic core comprises a leaf pendulum and a magnetic column, and a coil is wound on the magnetic column;

the surfaces of the magnetic core wound with the coils are respectively coated with a first heat conduction layer;

the periphery of the magnetic column is formed with a magnetic powder layer which is formed by hot press molding of magnetic powder and sintering and solidifying, and the outer surfaces of the magnetic powder layer are coated with second heat conduction layers.

8. The inductor as claimed in claim 7, wherein the first and second heat conducting layers are made of one of graphene, heat conducting silicone, and heat conducting silicone grease.

9. The high heat dissipation integrally formed inductor as claimed in claim 7, wherein the magnetic core is T-shaped;

the continuously coated first heat conduction layer covers the upper surface of the vane pendulum, the lower surface of the vane pendulum, four side surfaces of the vane pendulum, the winding cylindrical surface of the magnetic pillar and the top surface of the magnetic pillar;

the second heat conduction layer which is coated continuously covers the upper surface and four side surfaces of the magnetic powder layer;

the top surface of the magnetic pillar protrudes out of the upper surface of the magnetic powder layer.

10. The high heat dissipation integrally formed inductor as claimed in claim 7, wherein the magnetic core is i-shaped;

the blade pendulum comprises a first blade pendulum and a second blade pendulum; the upper surface of the magnetic column is connected with the lower surface of the first blade pendulum, and the lower surface of the magnetic column is connected with the upper surface of the second blade pendulum;

the magnetic powder layer is arranged on the periphery of the magnetic column;

the first heat conduction layer which is coated continuously covers the winding cylindrical surface of the magnetic column, the upper surface of the first blade pendulum, the lower surface of the first blade pendulum, the four side surfaces of the first blade pendulum, the upper surface of the second blade pendulum, the lower surface of the second blade pendulum and the four side surfaces of the second blade pendulum;

the second heat conduction layer which is coated continuously covers four side faces of the magnetic powder layer.

Technical Field

The invention relates to the technical field of inductors, in particular to a high-heat-dissipation integrally-formed inductor and a preparation method thereof.

Background

Inductance is a property of a closed loop and is a physical quantity. When current passes through the coil, magnetic field induction is formed in the coil, and the induced magnetic field can generate induction current to resist the current passing through the coil. It is a parameter of the circuit that describes the induced electromotive force effect induced in the present coil or in another coil due to the change in the coil current. Inductance is a generic term for self-inductance and mutual inductance. The device providing the inductance is called an inductor. The integrated inductor (molded inductor) comprises a seat body and a winding body, wherein the seat body is formed by embedding the winding body into metal magnetic powder through die casting, and SMD pins are lead-out pins of the winding body and are directly formed on the surface of the seat body. The integrated into one piece inductance generates heat easily at the course of the work, because integrated into one piece inductance coils is buried inside the inductance, and the soft magnetic powder heat conduction effect that has the resin is very poor, and the inductance during operation heat can't in time be derived and lead to producing the property ability to descend and even have the danger of catching fire and exploding.

Disclosure of Invention

Based on the problems, the invention provides a high-heat-dissipation integrally-formed inductor and a preparation method thereof, and aims to solve the technical problems that the inductor is not easy to dissipate heat and the performance of the inductor is influenced in the prior art.

A preparation method of a high-heat-dissipation integrally-formed inductor comprises the following steps:

step A1, preparing and forming a magnetic core comprising a leaf pendulum and a magnetic column, wherein the magnetic column is connected with the upper surface of the leaf pendulum, and a coil is wound on the magnetic column;

step A2, performing first coating of heat conducting material on each surface of the magnetic core wound with the coil to form a continuous first heat conducting layer;

step A3, adding magnetic powder into the magnetic core to perform hot press molding, sintering and curing to form a magnetic powder layer on the periphery of the magnetic column, thereby obtaining an inductance semi-finished product;

step A4, performing secondary coating of heat conducting materials on the outer surface of the semi-finished inductor to form a continuous second heat conducting layer;

step a5, preparing and forming electrodes on the inductor semi-finished product formed with the second heat conduction layer, thereby forming the integrated inductor.

Furthermore, the first heat conduction layer and the second heat conduction layer are made of one of graphene materials, heat conduction silica gel and heat conduction silicone grease.

Furthermore, the magnetic core is T-shaped;

the continuous first heat conduction layer covers the upper surface of the leaf pendulum, the lower surface of the leaf pendulum, four side surfaces of the leaf pendulum, the winding cylindrical surface of the magnetic column and the top surface of the magnetic column;

the second heat conduction layer coated continuously covers the upper surface and four side surfaces of the magnetic powder layer.

Further, the top surface of the magnetic pillar protrudes out of the upper surface of the magnetic powder layer.

Further, the magnetic core is I-shaped;

the leaf pendulum comprises a first leaf pendulum and a second leaf pendulum;

the upper surface of the magnetic column is connected with the lower surface of the first pendulum, the lower surface of the magnetic column is connected with the upper surface of the second pendulum, and the magnetic powder layer is arranged on the periphery of the magnetic column;

the continuous first heat conduction layer covers the winding cylindrical surface of the magnetic column, the upper surface of the first leaf pendulum, the lower surface of the first leaf pendulum, the four side surfaces of the first leaf pendulum, the upper surface of the second leaf pendulum, the lower surface of the second leaf pendulum and the four side surfaces of the second leaf pendulum;

the second heat conduction layer coated continuously covers four sides of the magnetic powder layer.

Further, the magnetic core is formed by cold press molding and curing.

The high-heat-dissipation integrally-formed inductor is characterized by being prepared by the preparation method of the high-heat-dissipation integrally-formed inductor, and comprises the following steps:

the magnetic core comprises a leaf pendulum and a magnetic column, and a coil is wound on the magnetic column;

the surfaces of the magnetic core wound with the coil are respectively coated with a first heat conduction layer;

and a magnetic powder layer formed by hot-press molding and sintering and curing of magnetic powder is formed on the periphery of the magnetic column, and a second heat conduction layer is coated on each outer surface of the magnetic powder layer.

Furthermore, the first heat conduction layer and the second heat conduction layer are made of one of graphene materials, heat conduction silica gel and heat conduction silicone grease.

Furthermore, the magnetic core is T-shaped;

the continuously coated first heat conduction layer covers the upper surface of the leaf pendulum, the lower surface of the leaf pendulum, four side surfaces of the leaf pendulum, the winding cylindrical surface of the magnetic column and the top surface of the magnetic column;

the second heat conduction layer coated continuously covers the upper surface and four side surfaces of the magnetic powder layer.

The top surface of the magnetic pillar protrudes out of the upper surface of the magnetic powder layer.

Further, the magnetic core is I-shaped;

the leaf pendulum comprises a first leaf pendulum and a second leaf pendulum; the upper surface of the magnetic column is connected with the lower surface of the first vane pendulum, and the lower surface of the magnetic column is connected with the upper surface of the second vane pendulum;

the magnetic powder layer is arranged on the periphery of the magnetic column;

the continuously coated first heat conduction layer covers the winding cylindrical surface of the magnetic column, the upper surface of the first vane pendulum, the lower surface of the first vane pendulum, the four side surfaces of the first vane pendulum, the upper surface of the second vane pendulum, the lower surface of the second vane pendulum and the four side surfaces of the second vane pendulum;

the second heat conduction layer coated continuously covers four sides of the magnetic powder layer.

The beneficial technical effects of the invention are as follows: the invention provides a high-heat-dissipation integrally-formed inductor and a preparation method thereof. The heat dissipation capacity of the product is greatly improved, heat is timely transported to the surface of the product in the working process of the inductor, and the phenomenon that the performance of the inductor is reduced due to internal overheating is prevented.

Drawings

Fig. 1 is a schematic diagram of a T-shaped structure of a high-heat-dissipation integrally-formed inductor according to the present invention;

FIG. 2 is a schematic diagram of an I-shaped structure of a high heat dissipation integrally formed inductor according to the present invention;

fig. 3 is a flowchart illustrating steps of a method for manufacturing a high heat dissipation integrated inductor according to the present invention.

Wherein the content of the first and second substances,

1-a magnetic core;

2-a coil;

3-a first thermally conductive layer;

4-a magnetic powder layer;

5-a second thermally conductive layer;

11-leaf pendulum;

12-a magnetic column;

11 a-first leaf pendulum;

11 b-second leaf pendulum.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

It should be noted that the embodiments and features of the embodiments may be combined with each other without conflict.

The invention is further described with reference to the following drawings and specific examples, which are not intended to be limiting.

Referring to fig. 3, a method for manufacturing a high heat dissipation integrally formed inductor includes the following steps:

step A1, preparing and forming a magnetic core comprising a leaf pendulum and a magnetic column, wherein the magnetic column is connected with the upper surface of the leaf pendulum, and a coil is wound on the magnetic column;

step A2, performing first coating of heat conducting material on each surface of the magnetic core wound with the coil to form a continuous first heat conducting layer;

step A3, adding magnetic powder into the magnetic core to perform hot press molding, sintering and curing to form a magnetic powder layer on the periphery of the magnetic column, thereby obtaining an inductance semi-finished product;

step A4, performing secondary coating of heat conducting materials on the outer surface of the semi-finished inductor product to form a continuous second heat conducting layer, wherein the second heat conducting layer is in contact with the first heat conducting layer;

step a5, preparing and forming electrodes on the inductor semi-finished product formed with the second heat conduction layer, thereby forming the integrated inductor.

Furthermore, the first heat conduction layer and the second heat conduction layer are made of one of graphene materials, heat conduction silica gel and heat conduction silicone grease.

Specifically, in step a5, the battery is laser printed and electroplated to form an integrally formed inductor.

The surface of the semi-finished product after winding and hot pressing is coated with graphene or other heat conducting materials, so that the heat dissipation capacity of the product is greatly improved, heat is timely transported to the surface of the product in the inductor working process, the phenomenon that the inductance performance is reduced due to internal overheating is prevented, and the performance cannot be reduced too much when the inductor works under higher current.

Table 1 is a table comparing the performance of the inductor of the present invention with that of the conventional inductor.

	Existing integrally formed inductor	The invention discloses an integrally formed inductor
			Number of turns of coil	5.5	5.5
Initial inductance	1.07μH	1.04μH
			Inductance/product temperature at 3A	0.94μH/29.6℃	0.96μH/27.4℃
Inductance/product temperature at 5A	0.88μH/32.2℃	0.91μH/29.1℃
			Inductance/product temperature at 7A	0.82μH/35.5℃	0.87μH/32.9℃

Referring to fig. 1, further, the magnetic core is T-shaped;

the continuous first heat conduction layer covers the upper surface of the leaf pendulum, the lower surface of the leaf pendulum, four side surfaces of the leaf pendulum, the winding cylindrical surface of the magnetic column and the top surface of the magnetic column;

the second heat conduction layer coated continuously covers the upper surface and four side surfaces of the magnetic powder layer.

Further, the top surface of the magnetic pillar protrudes out of the upper surface of the magnetic powder layer.

The top surface of the magnetic pillar protrudes to enable the first heat conduction layer and the second heat conduction layer to be in better contact, and heat inside the inductor is dissipated.

Referring to fig. 2, further, the magnetic core is i-shaped;

the leaf pendulum comprises a first leaf pendulum and a second leaf pendulum;

the upper surface of the magnetic column is connected with the lower surface of the first pendulum, the lower surface of the magnetic column is connected with the upper surface of the second pendulum, and the magnetic powder layer is arranged on the periphery of the magnetic column;

the continuous first heat conduction layer covers the winding cylindrical surface of the magnetic column, the upper surface of the first leaf pendulum, the lower surface of the first leaf pendulum, the four side surfaces of the first leaf pendulum, the upper surface of the second leaf pendulum, the lower surface of the second leaf pendulum and the four side surfaces of the second leaf pendulum;

the second heat conduction layer coated continuously covers four sides of the magnetic powder layer.

Referring to fig. 1, further, the magnetic core is formed by cold press molding and curing.

A high-heat-dissipation integrally-formed inductor is manufactured by the manufacturing method of the high-heat-dissipation integrally-formed inductor, and comprises the following steps:

the magnetic core (1) comprises a leaf pendulum (11) and a magnetic column (12), and a coil (2) is wound on the magnetic column (12);

the surfaces of the magnetic core (1) wound with the coil (2) are coated with a first heat conduction layer (3);

a magnetic powder layer (4) formed by hot-pressing and sintering and solidifying magnetic powder is formed on the periphery of the magnetic column (12), and a second heat conduction layer (5) is coated on each outer surface of the magnetic powder layer;

the second heat conducting layer (3) is in contact with the first heat conducting layer (5).

Furthermore, the first heat conduction layer (3) and the second heat conduction layer (5) are made of one of graphene materials, heat conduction silica gel and heat conduction silicone grease.

Furthermore, the magnetic core is T-shaped;

the continuously coated first heat conduction layer (3) covers the upper surface of the leaf pendulum (11), the lower surface of the leaf pendulum (11), the four side surfaces of the leaf pendulum (11), the winding cylindrical surface of the magnetic column (12) and the top surface of the magnetic column (12);

the second heat conducting layer (5) coated continuously covers the upper surface and four side surfaces of the magnetic powder layer (4).

The top surface of the magnetic column (12) protrudes out of the upper surface of the magnetic powder layer (4).

Further, the magnetic core (1) is I-shaped;

the magnetic core (1) comprises a first blade pendulum (11a), a second blade pendulum (11b) and a magnetic column (12); the upper surface of the magnetic column (12) is connected with the lower surface of the first pendulum blade (11a), and the lower surface of the magnetic column (12) is connected with the upper surface of the second pendulum blade (11 b);

the magnetic powder layer (4) is arranged at the periphery of the magnetic column (12);

the continuously coated first heat conduction layer (3) covers the winding cylindrical surface of the magnetic column (12), the upper surface of the first blade pendulum (11a), the lower surface of the first blade pendulum (11a), the four side surfaces of the first blade pendulum (11a), the upper surface of the second blade pendulum (11b), the lower surface of the second blade pendulum (11b) and the four side surfaces of the second blade pendulum (11 b);

the second heat conducting layer (5) coated continuously covers the four sides of the magnetic powder layer (4).

While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention.