US 11,685,980 B2
Metal soft magnetic composite material inductor and preparation method thereof
Xinshu Yu, Guangdong (CN); Shengcheng Xia, Guangdong (CN); Youyun Li, Guangdong (CN); and Xin Che, Guangdong (CN)
Assigned to Shenzhen Sunlord Electronics Co., Ltd., Guangdong (CN)
Filed by Shenzhen Sunlord Electronics Co., Ltd., Guangdong (CN)
Filed on Mar. 24, 2021, as Appl. No. 17/211,775.
Application 17/211,775 is a continuation of application No. PCT/CN2019/113772, filed on Oct. 28, 2019.
Claims priority of application No. 201910376481.9 (CN), filed on May 7, 2019; and application No. 201910380702.X (CN), filed on May 8, 2019.
Prior Publication US 2021/0210261 A1, Jul. 8, 2021
Int. Cl. C22C 38/34 (2006.01); B22F 9/08 (2006.01); H01F 1/01 (2006.01); H01F 1/26 (2006.01); H01F 41/02 (2006.01); B22F 1/102 (2022.01); H01F 3/08 (2006.01); B22F 1/10 (2022.01); C22C 1/10 (2023.01)
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
OG exemplary drawing
 
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.