Integrally molded inductor structure with terminal electrode led out from bottom and manufacturing process thereof
Technical Field
The invention relates to the technical field of die casting inductor preparation, in particular to an integrally formed die casting inductor structure with a terminal electrode led out from the bottom and a manufacturing process thereof.
Background
The inductor is applied to most of electronic products, and equipment damage caused by current problems can not easily occur when the electronic products are used after the inductor is installed; with the development of the inductor industry, the improvement of the manufacturing technology and the research and development technology, the inductor products are continuously upgraded and updated, and the integrally molded die casting inductor is a new product after the updating and updating, so that the application range is wider.
Fig. 1 shows an integrally molded inductor structure formed by die casting, which includes an inductor body, the inductor body is mainly formed by pressing metal powder in a die casting manner, the specific manufacturing method is well known to those skilled in the art, and will not be described herein, a coil is wound inside the inductor body, the end edges of the two ends of the coil are exposed on the surface of the inductor body, then external end electrodes are respectively formed on the outer surfaces of the two end edges, the end electrodes are led out from the inductor body from the side edges, and then the bottom of the end electrodes is bent to facilitate the subsequent SMT surface mounting technology.
The integrally molded inductor with the above structure is generally only suitable for the situation that the length and width of the PCB are not limited, and the size of the PCB is gradually reduced along with the trend of gradually reducing the size of the electronic product, so the mold inductor, which is indispensable in the circuit application, also faces the challenge of gradually reducing the size. The integrally molded die casting inductor structure is mainly characterized in that the end electrode is led out from the inductor body from the side edge, and then the end electrode is bent at the bottom to facilitate the subsequent SMT surface mounting technology; because the terminal electrode is made of conductive materials, a certain space needs to be reserved beside the inductance terminal electrode during circuit layout, and the phenomenon that other components contact the inductance terminal electrode in the SMT process to cause short circuit and influence circuit operation is avoided; taking the power-on design of a mobile phone and a notebook computer as an example, the usage amount of inductors is several to tens of inductors, and each inductor needs to reserve a certain space, so that the sum of the inductors and the reserved space on the circuit layout cannot be ignored, and further miniaturization of the PCB can be restrained.
Disclosure of Invention
The invention mainly solves the technical problem of providing an integrally formed die casting inductance structure with a terminal electrode led out from the bottom and a manufacturing process thereof, wherein the periphery of a bottom electrode integrally formed die casting inductance component is not provided with conductors, and peripheral components can be further close to each other during circuit layout, so that the size of a PCB is effectively saved, a substantial step is promoted for a PCB miniaturization technology, and the integrally formed die casting inductance structure has good practical value.
In order to solve the technical problems, the invention adopts a technical scheme that: the utility model provides an one-piece shaping die casting inductance structure that termination electrode bottom was drawn forth, includes the enameled wire book, the enameled wire book is stereotyped through the winding tool winding, and the initiating terminal and the ending terminal of the enameled wire book after the design are acute angle contained angle, the bottom of enameled wire book is filled and is provided with first magnetism powder layer, the top of first magnetism powder layer is provided with second magnetism powder layer, first magnetism powder layer and second magnetism powder layer are rectangle an organic whole and set up, the initiating terminal and the ending terminal of enameled wire book extend to the upper surface both ends of second magnetism powder layer, the surface of first magnetism powder layer and second magnetism powder layer is provided with the coating layer, the both sides of coating layer upper surface are provided with the vacancy district respectively, the initiating terminal and the ending terminal of enameled wire book expose respectively in corresponding vacancy district department, the surface in vacancy district is provided with the copper layer, and the surface of the electroplated copper layer is sequentially provided with an electroplated nickel layer and an electroplated tin layer.
Preferably, the first magnetic powder layer is composed of metal powder, a binder and an additive, the metal powder is soft magnetic powder, the binder is any one of epoxy resin, acryl resin, phenolic resin and silicone resin, the additive is stearic acid, and the first magnetic powder layer and the second magnetic powder layer have the same composition structure.
Preferably, the soft magnetic powder is at least one of carbon-based iron powder, reduced iron powder, iron nickel powder, iron silicon aluminum powder, iron silicon chromium powder and iron silicon powder, and the stearic acid is any one of fatty acid or graphite fluoride.
Preferably, the addition ratio of the binder is 0.5 wt% to 10 wt%.
Preferably, the cross-sectional shape of the enameled wire coil is any one of a circle, a rectangle, a square and a polygon.
Preferably, the coating layer is any one of an epoxy resin layer, an acryl resin layer, a phenol resin layer and a silicon resin layer.
Preferably, the thickness range of the coating layer is 1-100 um.
Preferably, the thickness of the electroplated copper layer is 0.5-20 um, the thickness of the electroplated nickel layer is 0.5-20 um, and the thickness of the electroplated tin layer is 0.5-20 um.
The invention also provides a manufacturing process of the integrally molded die casting inductor structure with the bottom of the terminal electrode led out, which comprises the following steps,
(A) winding the enameled wire coil on a winding jig, wherein the starting end and the ending end of the wound enameled wire coil form an acute included angle;
(B) filling a first magnetic powder layer into a forming die of a die-casting forming machine, turning the formed enameled wire coil for 180 degrees, and implanting the enameled wire coil into the first magnetic powder layer in the forming die;
(C) filling a second magnetic powder layer into the forming die, and then pressing and forming under the pressure of 1-10 ton/cm2The starting end and the ending end of the enameled wire coil are arranged at two ends of the upper surface of the second magnetic powder layer in an extending mode;
(D) putting the semi-finished product after the compression molding into an oven for baking to cure the binder, wherein the baking temperature is between 60 and 260 ℃, and the baking time is between 0.5 and 24 hours;
(E) arranging a coating layer on the surface of the product obtained in the step (D), and then putting the product into an oven for baking at the baking temperature of 60-260 ℃ for 0.5-24 h;
(F) grinding the two sides of the upper surface of the coating layer of the product obtained in the step (E) in a grinding mode, wherein the positions after grinding are vacant areas, and the starting end and the ending end of the enameled wire coil are respectively exposed at the corresponding vacant areas;
(G) applying an electroplated copper layer on the vacant areas obtained in the step (F), wherein the electroplated copper layer is deposited on the vacant areas without the coating layer;
(H) and (G) continuously applying the product obtained in the step (G) as an electroplated nickel layer and an electroplated tin layer, thereby obtaining the integrally formed die casting inductance structure product with the bottom of the terminal electrode led out.
Preferably, the coating layer in the step (E) is provided by any one of dipping, rolling spraying and arranging spraying.
The invention has the beneficial effects that: according to the integrally-formed die-casting inductance structure with the end electrode led out from the bottom and the manufacturing process thereof, the integrally-formed die-casting inductance component with the bottom electrode is obtained through a plurality of structural procedures such as winding, die-casting forming, grinding and electroplating of an enameled wire coil, no conductor exists around the integrally-formed die-casting inductance component, and peripheral components can be further close to each other during circuit layout, so that the size of a PCB is effectively saved, a substantial step is promoted for a PCB miniaturization technology, and the integrally-formed die-casting inductance structure with the end electrode led out from the bottom has good practical value and.
Drawings
Fig. 1 is a diagram of an integrally molded inductor structure of the prior art related to the background of the invention;
FIG. 2 is a schematic side view of the enameled wire coil wound and shaped on the winding jig of the present invention;
FIG. 3 is a top view of the enameled wire coil wound and shaped on the winding fixture in the present invention;
fig. 4 is a schematic structural view of the forming die of the present invention filled with a first magnetic powder layer;
FIG. 5 is a schematic structural view of the shaped enameled wire coil turned 180 degrees and then placed in the first magnetic powder layer of the forming mold;
fig. 6 is a schematic view of the structure after the filling of the second magnetic powder layer is continued on the basis of fig. 5;
FIG. 7 is a schematic view of the product shaping structure after the forming mold is removed from the base of FIG. 4;
FIG. 8 is a schematic view of the structure of FIG. 7 after a coating layer is disposed thereon;
FIG. 9 is a schematic structural view of a region with two sides of the upper surface ground to obtain voids on the basis of FIG. 8;
FIG. 10 is a schematic view of a structure of applying an electroplated copper layer at the vacant areas on the basis of FIG. 9;
FIG. 11 is a schematic structural view of the nickel electroplating layer and the tin electroplating layer which are continuously applied on the basis of FIG. 10;
FIG. 12 is the schematic view of FIG. 11 after being turned over to embody the final product structure;
the parts in the drawings are numbered as follows:
1. enamelling the wire coil; 2. winding a wire tool; 3. a first magnetic powder layer; 4. a second magnetic powder layer; 5. a coating layer; 6. an empty area; 7. electroplating a copper layer; 8. electroplating a nickel layer; 9. electroplating a tin layer; 10. and (5) forming a die.
Detailed Description
The following detailed description of the preferred embodiments of the present invention, taken in conjunction with the accompanying drawings, will make the advantages and features of the invention easier to understand by those skilled in the art, and thus will clearly and clearly define the scope of the invention.
Example (b):
as shown in fig. 2 and 3, an integrally molded die casting inductance structure with a terminal electrode led out from the bottom comprises an enameled wire coil 1, wherein the enameled wire coil 1 is wound and shaped by a winding jig 2, the starting end and the finishing end of the shaped enameled wire coil 1 form an acute included angle, the cross section of the enameled wire coil 1 is in a shape of any one of a circle, a rectangle, a square or a polygon, and the cross section of the enameled wire coil 1 embodied in the embodiment is in a shape of a circle.
As shown in fig. 4, 5 and 6, a first magnetic powder layer 3 is filled at the bottom end of the enameled wire roll 1, a second magnetic powder layer 4 is arranged above the first magnetic powder layer 3, the first magnetic powder layer 3 and the second magnetic powder layer 4 are integrally arranged in a rectangular shape, the starting end and the ending end of the enameled wire roll 1 are arranged at two ends of the upper surface of the second magnetic powder layer 4 in an extending manner, and the first magnetic powder layer 3 and the second magnetic powder layer 4 have the same composition structure.
As shown in fig. 4, 5 and 6, the first magnetic powder layer 3 is composed of metal powder, a binder and an additive, wherein the metal powder is soft magnetic powder, and the soft magnetic powder is at least one of carbon-based iron powder, reduced iron powder, iron nickel powder, iron silicon aluminum powder, iron silicon chromium powder and iron silicon powder. The adhesive is any one of epoxy resin, acrylic resin, phenolic resin and silicon resin, and the addition proportion of the adhesive is 0.5-10 wt%, so that better molding density and magnetic property can be achieved. The additive is stearic acid, and the stearic acid is any one of fatty acid or graphite fluoride.
As shown in fig. 7, 8 and 9, a coating layer 5 is disposed on the outer surfaces of the first magnetic powder layer 3 and the second magnetic powder layer 4, the coating layer 5 is any one of an epoxy resin layer, an acryl resin layer, a phenolic resin layer and a silicone resin layer, the thickness of the coating layer 5 is preferably in a range of 1 to 100um, the thickness range provides enough thickness to protect the magnetic powder, and then the two sides of the upper surface of the coating layer 5 are respectively provided with a vacant area 6 by grinding, so that the start end and the end of the enameled wire coil 1 are respectively exposed at the corresponding vacant areas 6.
As shown in fig. 10, 11 and 12, an electroplated copper layer 7 is formed on the surface of the obtained void region 6, and an electroplated nickel layer 8 and an electroplated tin layer 9 are sequentially arranged on the surface of the electroplated copper layer 7, wherein the thickness of the electroplated copper layer 7 is 0.5 to 20um, and the copper layer has better bonding property and conductivity with the magnetic core, in addition, the preferred thickness of the electroplated nickel layer 8 is 0.5 to 20um, and the preferred thickness of the electroplated tin layer 9 is 0.5 to 20um, so that each electroplated layer has better bonding property and better conductivity.
The invention also provides a manufacturing process of the integrally formed die casting inductance structure with the end electrode led out from the bottom, which comprises the following steps,
(A) winding the enameled wire coil 1 on a winding jig 2, wherein the starting end and the ending end of the wound enameled wire coil 1 form an acute included angle;
(B) filling a first magnetic powder layer 3 into a forming die 10 of a die-casting forming machine, turning the formed enameled wire coil 1 by 180 degrees, and implanting the enameled wire coil into the first magnetic powder layer 3 in the forming die 10;
(C) filling a second magnetic powder layer 4 into a forming die 10, and then performing compression forming under the pressure of 1-10 ton/cm2The starting end and the ending end of the enameled wire coil 1 are arranged at two ends of the upper surface of the second magnetic powder layer 4 in an extending manner;
(D) putting the semi-finished product after the compression molding into an oven for baking to cure the binder, wherein the baking temperature is between 60 and 260 ℃, and the baking time is between 0.5 and 24 hours;
(E) arranging a coating layer 5 on the surface of the product obtained in the step (D), wherein the coating layer 5 is arranged in any one of impregnation, rolling spraying and arrangement spraying, and then placing the product into an oven for baking at the baking temperature of 60-260 ℃ for 0.5-24 h;
(F) grinding the two sides of the upper surface of the coating layer 5 of the product obtained in the step (E) in a grinding mode, wherein the positions after grinding are vacant areas 6, and the starting end and the ending end of the enameled wire coil 1 are respectively exposed at the corresponding vacant areas 6;
(G) applying an electroplated copper layer 7 on the vacant areas 6 obtained in the step (F), and depositing the electroplated copper layer 7 on the vacant areas 6 without the coating layer;
(H) and (G) continuously applying the product obtained in the step (G) as an electroplated nickel layer 8 and an electroplated tin layer 9, thereby obtaining the integrally formed die casting inductance structure product with the bottom of the terminal electrode led out.
The above description is only an embodiment of the present invention, and not intended to limit the scope of the present invention, and all modifications of equivalent structures and equivalent processes performed by the present specification and drawings, or directly or indirectly applied to other related technical fields, are included in the scope of the present invention.