阅读说明：本技术 一种无需二次填粉的薄型电感及其加工工艺 (Thin inductor without secondary powder filling and processing technology thereof ) 是由 谢明谚 罗宜春 于 2020-12-30 设计创作，主要内容包括：本发明公开了一种无需二次填粉的薄型电感及其加工工艺,该薄型电感加工工艺包括：调配好的铁粉放入成型模具成型出工形铁芯,将铁芯放入烤箱或隧道炉中烘烤；将漆包线沿工形铁芯中柱绕制并将引出线拉出,折入工字形铁芯预留的凹槽中形成组装线圈；将绕制完成的组装线圈放入热压模具中直接压制成型,无需再填粉,热压温度：165±15°；将折入凹槽的漆包线经过激光去漆、印银、电镀或浸锡等操作形成端子。该一种无需二次填粉的薄型电感及其加工工艺,在成型过程中,铁芯与端子之间因压力关系,结合紧密,无需其他操作固定端子,故比原有的磁封胶式电感性能更佳,而且简化了制程,提升产品品质。(The invention discloses a thin inductor without secondary powder filling and a processing technology thereof, wherein the processing technology of the thin inductor comprises the following steps: placing the prepared iron powder into a forming die to form an I-shaped iron core, and placing the iron core into an oven or a tunnel furnace to be baked; winding the enameled wire along the center column of the I-shaped iron core, pulling out the outgoing line, and folding the enameled wire into a reserved groove of the I-shaped iron core to form an assembly coil; the assembly coil finished by winding is directly pressed and formed in a hot-pressing die without powder filling, and the hot-pressing temperature is as follows: 165 +/-15 degrees; and carrying out operations such as laser depainting, silver printing, electroplating or tin dipping on the enameled wire folded into the groove to form the terminal. According to the thin inductor without secondary powder filling and the processing technology thereof, in the forming process, due to the pressure relation between the iron core and the terminals, the iron core and the terminals are tightly combined, and other operations for fixing the terminals are not needed, so that the thin inductor has better performance than the original magnetic sealing glue type inductor, the manufacturing process is simplified, and the product quality is improved.)

1. The process for manufacturing the thin inductor without secondary powder filling according to claim 1, wherein the process comprises the following steps: the processing technology comprises the following steps:

step one, forming and baking an I-shaped iron core: placing the prepared iron powder into a forming die to form an I-shaped iron core, and placing the iron core into an oven or a tunnel furnace to be baked;

step two, winding: winding the enameled wire along the center column of the I-shaped iron core, pulling out the outgoing line, and folding the enameled wire into a reserved groove of the I-shaped iron core to form an assembly coil;

step three, hot-press forming: the assembly coil finished by winding is directly pressed and formed in a hot-pressing die without powder filling, and the hot-pressing temperature is as follows: 165 +/-15 degrees;

step four, terminal processing: and carrying out operations such as laser depainting, silver printing, electroplating or tin dipping on the enameled wire folded into the groove to form the terminal.

2. The thin inductor without secondary powder filling and the processing technology thereof as claimed in claim 1, wherein: and the depth of the groove in the second step is required to be lower than the height of the enameled wire.

3. The thin inductor without secondary powder filling and the processing technology thereof as claimed in claim 1, wherein: the iron powder is stainless steel alloy iron powder.

4. The thin inductor without secondary powder filling and the processing technology thereof as claimed in claim 1, wherein: the temperature of the hot-pressing die in the third step is 165 +/-15 ℃.

5. The thin inductor without secondary powder filling and the processing technology thereof as claimed in claim 1, wherein: the lead wire can be fixed by dispensing in a lead wire groove reserved on the iron core, or the tail end of the lead wire is folded into a groove at the other end for fixing.

Technical Field

The invention relates to the technical field of thin inductors, in particular to a thin inductor without secondary powder filling and a processing technology thereof.

Background

An inductor is a component that can convert electrical energy into magnetic energy for storage. The inductor is similar in structure to a transformer, but has only one winding. The inductor has an inductance that only impedes the change in current. If the inductor is in a state where no current is passing, it will try to block the current from flowing through it when the circuit is on; if the inductor is in a current passing state, the inductor will try to keep the current unchanged when the circuit is opened. Inductors are also known as chokes, reactors, dynamic reactors.

Most of the conventional thin chip inductors are sealed rubber inductors: the technology is that the I-shaped iron core is wound, glue is coated in a groove in the middle of the upper hem and the lower hem of the I-shaped iron core to protect a product, and the terminal treatment is spot welding or soldering after electroplating on the I-shaped iron core. When winding, the upper and lower pendulums are broken due to high strength during product winding (the thickness of the upper and lower pendulums is small), and if the thickness of the upper and lower pendulums is too thick, the space of middle winding is insufficient, so that the inductance performance is limited, and therefore, the thin inductor without secondary powder filling and the processing technology thereof are provided.

Disclosure of Invention

Aiming at the defects of the prior art, the invention provides a thin inductor without secondary powder filling and a processing technology thereof, and solves the problems that in the existing gluing inductor technology, a product is easy to break in the winding process due to the fact that an upper pendulum and a lower pendulum are thin, and the performance cannot be improved due to the fact that the winding space is small due to the fact that the upper pendulum and the lower pendulum are thick.

The invention provides the following technical scheme: a thin inductor without secondary powder filling and a processing technology thereof are disclosed, the processing technology comprises the following steps:

step one, forming and baking an I-shaped iron core: placing the prepared iron powder into a forming die to form an I-shaped iron core, and placing the iron core into an oven or a tunnel furnace to be baked;

step two, winding: winding the enameled wire along the center column of the I-shaped iron core, pulling out the outgoing line, and folding the enameled wire into a reserved groove of the I-shaped iron core to form an assembly coil;

step three, hot-press forming: the assembly coil finished by winding is directly pressed and formed in a hot-pressing die without powder filling, and the hot-pressing temperature is as follows: 165 +/-15 degrees;

step four, terminal processing: and carrying out operations such as laser depainting, silver printing, electroplating or tin dipping on the enameled wire folded into the groove to form the terminal.

Preferably, the depth of the groove in the second step is lower than the height of the enameled wire.

Preferably, the iron powder is stainless steel alloy iron powder.

Preferably, the temperature of the hot-pressing die in the third step is 165 +/-15 ℃.

Preferably, the lead wire can be dispensed and fixed in a lead wire groove reserved on the iron core, or the tail end of the lead wire is folded into a groove at the other end for fixing.

Compared with the prior art, the invention has the following beneficial effects: according to the thin inductor without secondary powder filling and the processing technology thereof, the performance is improved: because of hot press molding, the product density is higher than that of magnetic seal glue type and laminated inductor, and more magnetic powder particles are in each unit volume, so that the inductor has better performance than the original magnetic seal glue type inductor; the process is simplified: in the original magnetic sealing glue type inductor, an iron core needs to be plated in a groove firstly, and then a lead and the iron core are fixed in a welding mode; the yield is improved: the original magnetic seal glue inductor has the defects of poor iron core damage, limited winding center pillar height and poor winding easily caused by thinner upper and lower pendulums in the winding process. The size of the existing H-shaped iron core is higher than that of a final product, the thickness of the upper pendulum and the lower pendulum and the height of the middle column are increased, the winding difficulty is reduced, and the yield of the manufacturing process can be improved.

Drawings

FIG. 1 is a schematic structural diagram of the I-shaped iron core of the present invention after molding;

FIG. 2 is a schematic diagram of the assembled coil after winding according to the present invention;

FIG. 3 is a schematic structural diagram of the hot press molded product of the present invention;

FIG. 4 is a schematic of the final structure of the present invention;

FIG. 5 is a schematic structural view of the upper and lower swings and the center pillar of the forming mold of the present invention.

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.

Referring to fig. 1-5, the invention discloses a thin inductor without secondary powder filling and a processing technology thereof, wherein the processing technology comprises the following steps:

step one, forming and baking an I-shaped iron core: placing the prepared iron powder into a forming die to form an I-shaped iron core, and placing the iron core into an oven or a tunnel furnace to be baked;

step two, winding: winding the enameled wire along the center column of the I-shaped iron core, pulling out the outgoing line, and folding the enameled wire into a reserved groove of the I-shaped iron core to form an assembly coil;

step three, hot-press forming: the assembly coil finished by winding is directly pressed and formed in a hot-pressing die without powder filling, and the hot-pressing temperature is as follows: 165 +/-15 degrees;

step four, terminal processing: and carrying out operations such as laser depainting, silver printing, electroplating or tin dipping on the enameled wire folded into the groove to form the terminal.

And the depth of the groove in the second step is required to be lower than the height of the enameled wire.

The iron powder is stainless steel alloy iron powder.

The temperature of the hot pressing die in the third step is 165 +/-15 ℃.

The lead wire can be fixed by dispensing in a lead wire groove reserved on the iron core, or the tail end of the lead wire is folded into a groove at the other end for fixing.

Examples

The thin inductor is formed by placing prepared iron powder into a forming die, and the size of an iron core formed by placing the iron powder into the forming die is as follows: 3.0 × 2.3 × 1.8mm, the height of the iron core is 1.3-1.5 times of the height of the finished product, the central column is 1.6 × 1.3 × 0.8mm, the thickness of the lower hem (with a groove) of the forming die is 0.55mm, and the thickness of the upper hem is 0.45 mm.

When the thin inductor is processed, firstly, forming an I-shaped iron core: placing the prepared iron powder into a forming die for forming, wherein the iron powder is stainless steel alloy iron powder, winding the enameled wire along the center column of the I-shaped iron core, pulling out the outgoing line, and folding the enameled wire into a reserved groove of the I-shaped iron core, wherein the depth of the groove is lower than the height of the enameled wire; the glue can be dispensed in a lead slot reserved on the iron core to fix the lead, and the tail end of the lead can also be folded into a groove at the other end to be fixed. Hot-press molding: the hot pressing die temperature is 165 +/-15 ℃, the semi-finished product wound by the H-shaped iron core is placed into the hot pressing die, the iron powder can be softened when meeting high temperature, the iron powder does not need to be additionally added into the die during molding, the iron core swings up and down and meets high pressure, and a product is extruded and molded in the middle of the iron core, and a terminal is treated: the molded terminal is subjected to tin immersion or electroplating treatment, the molded product terminal needs to be ground flat, foreign matters on the terminal (enameled wire) are removed, and then the ground flat terminal is subjected to tin immersion or electroplating.

In the steps, iron powder of the I-shaped iron core can be softened and easily molded at a high temperature of 165 +/-15 ℃ without damaging a coating layer of the enameled wire. The size of the hot-pressing die is 0.2 +/-0.1 mm larger than that of the H-shaped iron core, the hot-pressing die can be conveniently placed into the die without deviating too much, powder does not need to be filled in the hot-pressing forming process, the hot-pressing die is vertically arranged to be close to the middle of the hot-pressing die, and the height of a product is lower than that of the H-shaped iron core.

Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.