CPC C22C 38/34 (2013.01) [B22F 1/102 (2022.01); B22F 1/108 (2022.01); B22F 9/082 (2013.01); C22C 1/1084 (2013.01); H01F 1/015 (2013.01); H01F 1/26 (2013.01); H01F 3/08 (2013.01); H01F 41/0246 (2013.01); B22F 2009/0828 (2013.01); B22F 2301/35 (2013.01); B22F 2304/10 (2013.01)] | 6 Claims |
1. A preparation method for a metal soft magnetic composite material inductor, comprising the following steps of:
1) mixing and smelting Fe, Si and Cr according to a following proportion: 85-95 wt % of Fe, 4-10 wt % of Si and 1-5 wt % of Cr to obtain an alloy solution;
2) making the alloy solution into alloy powder in a water atomization or gas atomization means;
3) sifting the alloy powder into a first powder of 15-45 μm, a second powder larger than 45 μm and a third powder smaller than 15 μm according to particle size;
4) mixing the first powder, the second powder and the third powder according to a following proportion: 60-80 wt % of the first powder, 5-20 wt % of the second powder, 15-35 wt % of the third powder to obtain a mixed powder, and carrying out coating insulation on the mixed powder;
5) crushing, granulating and sifting insulated powder sequentially to obtain granulation powder, and pressing the granulation powder into a material cake;
6) placing a prefabricated hollow coil assembly in a mold cavity, placing the material cake in a storage bin, liquefying the material cake into the mold cavity in a transfer molding process, and coating the coil assembly;
7) curing and demolding, and removing a runner to obtain a semi-finished product; and
8) solidifying the semi-finished product and preparing an end electrode to obtain a finished inductor,
wherein in step 4), the mixed powder is added into a resin mixed solution for coating insulation; wherein a dosage of the resin mixed solution accounts for 1-5.5 wt % of the mixed powder; the resin mixed solution is formed by mixing a solid resin with an organic solvent wherein the solid resin contains a curing agent and a release agent, and the solid resin accounts for 1-10 wt % of the resin mixed solution.
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