KR101759168B1 - The manufacturing method of a coil-embedded heat-radiating inductor using heat-radiating powder paste and soft-magnetic powder paste and the coil-embedded heat-radiating inductor manufactured thereby - Google Patents

Abstract

The present invention is characterized in that a coil 110 is embedded in a magnetic core formed by laminating a soft magnetic layer 130 and a heat dissipation layer 120 so that heat generated from the coil 110 and the soft magnetic layer 130 A method of manufacturing a coil-embedded heat-radiating inductor (100) having improved characteristics of efficiently discharging a ceramic powder, and a coil-embedded heat-radiating inductor (100) manufactured by the method, comprising: preparing an organic vehicle for a heat- Mixing an organic vehicle for a soft magnetic layer with an organic vehicle for a soft magnetic layer to produce a soft magnetic component paste; mixing a coil 110 , Placing the heat dissipating powder paste in the mold and hardening the heat dissipating powder paste to form the heat dissipating layer 120, Forming a soft magnetic layer (130) on the heat dissipation layer (120) by injecting a paste into the mold and curing the soft magnetic layer (130); forming the heat dissipation layer (120) The method of manufacturing a coil-embedded heat dissipation inductor (100) according to claim 1, wherein the step of forming the coil-embedded heat dissipating inductor (100) is repeated until the entire shape of the coil-embedded heat dissipating inductor (100) is completed.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a coil-embedded heat-radiating inductor using a heat-radiating powder paste and a soft-component paste, and a coil-embedded heat-radiating inductor using the heat- magnetic powder paste and the coil-embedded heat-

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a coil-embedded heat-radiating inductor using a heat-radiating powder paste and a soft-component paste, and a coil-embedded heat-radiating inductor manufactured by the method. More particularly, A coil-embedded heat dissipation having an improved characteristic of efficiently discharging heat generated in the layer including the coil and the soft magnetic material while having a high magnetic flux density by embedding a coil in a magnetic core formed by laminating layers containing a material A method of manufacturing an inductor, and a coil-embedded heat-radiating inductor manufactured by the method.

Generally, an inductor is an element that forms an inductance by winding a coil made of a metal on a magnetic core, and is widely used as an element that generates an electromagnetic wave by causing a current to flow in the coil. The inductor is a device that amplifies the signal of a specific frequency band by removing the noise in the frequency band by using the characteristic that the impedance becomes high in proportion to the frequency, or constructing the resonance circuit together with the capacitor, Or a passive element that is an important component of an electronic circuit. Particularly, as in the present invention to be described later, an inductor in which a coil is embedded in a magnetic core so as to be integrally formed can maximize its magnetic effective sectional area to obtain a high inductance, and can be usefully used in an electric circuit of an electric vehicle or the like.

The above-mentioned inductance is an index indicating the characteristics of the inductor. The inductance is determined by the length of the coil, the cross-sectional area of the coil, the winding of the coil, and the like. The magnetic permeability is defined as a magnetic field per unit magnetic field, which indicates the degree of magnetic flux generated around the magnetic core and the magnetic core when a current is applied to the coil. Since the inductance is proportional to the magnetic permeability, it is preferable to manufacture the magnetic core using a material having high magnetic permeability.

On the other hand, in the process of applying a magnetic field in a specific direction to the magnetic core, removing the magnetic field, and applying a magnetic field in the opposite direction, energy loss may occur. This loss is referred to as hysteresis loss. In addition, when a current is applied to the coil, a magnetic field is induced in the magnetic core by Ampere's law, and the induced magnetic field can cause current to flow to the magnetic core in accordance with Lenz's law. Is referred to as eddy current loss. In general, hysteresis loss is a problem in the low frequency range and eddy loss is a problem in the high frequency range. Such hysteresis loss and eddy current loss are always negative when considering various technical fields We can not, but here we look at ways to reduce these losses.

The soft magnetic material is typically a material with high magnetic permeability and low hysteresis loss. In particular, an ideal soft magnetic material has a very high saturation magnetic flux density and magnetic permeability, and a coercive force and a hysteresis loss are regarded as zero. However, since the soft magnetic material does not guarantee the reduction of the eddy current loss, the soft magnetic material is used to manufacture the inductor, the soft magnetic material is bonded to the polymer resin, or the ceramic material is coated on the end of the soft magnetic material A method of reducing the eddy current loss by imparting insulation to a magnetic core made of a soft magnetic material by manufacturing a magnetic core by a method of manufacturing a sheet by mixing a soft magnetic material with a polymer resin And a method in which these sheets are laminated so that eddy current is caused to swing only within each sheet. For example, in Korean Patent No. 10-1496626 (entitled Magnetic Part and Magnetic Particulate Metal Powder Used Therefor and Method for Manufacturing the Same, hereinafter referred to as Prior Art 1), a soft magnetic metal powder containing iron, Wherein the soft magnetic metal powder has an average particle size of 300 nm or less, a coercive force of 16 to 119 kA / m, and a saturation magnetization of 90 Am 2 / kg or more, and 1.0 g of the soft magnetic metal powder is vertically pressurized to 64 MPa (20 kN) A soft magnetic metal powder having a resistivity of 1.0 X 10? Cm or more.

However, even if an inductor is manufactured by a method of using a soft magnetic material and reducing the generation of eddy current in a predetermined manner, heat generated in the inductor is a problem. When an electric current is applied to the coil, joule heating occurs in the coil due to the current flowing through the coil. In addition, when eddy current flows in the magnetic core, joule heating occurs due to eddy current . When the above-described Joule heating occurs in the inductor, the characteristics of the inductor deteriorate and the efficiency of the system including the inductor may be deteriorated. Therefore, in order to overcome this problem, it is necessary to manufacture an inductor using a soft magnetic material, and to provide a heat dissipating means, which is disclosed in Korean Patent No. 10-0969194 (entitled: Is mounted on a display device including a liquid crystal display (LCD), an organic light emitting diode (OLED) display device, a light emitting diode (LED) display device, and a plasma display panel (PDP) And a heat-resistant heat-dissipating sheet for dissipating heat, wherein a metal sheet made of a thermally conductive material is covered and a hard heat-resistant resin is coated by coating, and the metal sheet is made of aluminum (Al) or copper (Cu) And has a thickness of 5 to 50 micrometers and is formed of an epoxy resin. The upper surface of the outer surface of the hard heat-resistant resin And a release sheet is attached to the outer surface of the adhesive layer, wherein the adhesive layer is made of a heat-dissipating silicone resin, And the heat radiation silicone is printed by any one of a screen printing method, a stencil method and a spraying method to form the adhesive layer.

Korean Patent No. 10-1496626 Korean Patent No. 10-0969194

Although the prior art 1 discloses a material having a high magnetic permeability, a low hysteresis loss and a reduced eddy current by forming an insulating film containing aluminum (Al) or the like on the soft magnetic metal powder, However, the first problem that such a technique can not reduce the joule heating generated in the coil or the magnetic core, the heat dissipation means required in the prior art 1, 2, a method of coating the heat-radiating sheet of the prior art 2 on the magnetic core formed by the prior art 1, and the like can be considered. However, the heat-radiating sheet of the prior art 2 is made of aluminum (Al) or copper (Cu) , Aluminum (Al) and copper (Cu) have a high thermal conductivity, the eddy current flowing through the magnetic core is not good due to the high electrical conductivity of aluminum (Al) or copper (Cu) When the soft magnetic metal powder is produced by vertically pressing the soft magnetic metal powder as in the prior art 1, the insulation film is broken, the resistance of the soft magnetic metal powder is lowered, and the eddy current is increased The third problem is that if the insulating film is broken as described above, the fluidity of the insulating film is lowered, and the workability and the filling property when filling the magnetic core for producing a magnetic core becomes poor, There are four problems.

According to an aspect of the present invention, there is provided a method of manufacturing a coil-embedded heat dissipation inductor having a heat dissipation structure and a portion of a coil embedded in a magnetic core, the method comprising: preparing an organic vehicle for a heat dissipation layer Preparing a heat-radiating powder paste having a density of 4 to 5 g / cc by roll mixing milling the ceramic powder with an organic vehicle for a heat-radiating layer, preparing an organic vehicle for a soft magnetic layer, And mixing and rolling the mixture to form a soft phase component paste having a density of 5 to 6 g / cc, positioning and fixing a part of the coil in a mold having a predetermined shape, A step of forming a heat dissipation layer by injecting and hardening the mixture into a mold and injecting the soft component late paste into the mold and curing the mixture, And forming a soft magnetic layer on the heat dissipation layer. The step of forming the heat dissipation layer and the step of forming the soft magnetic layer are repeated until the entire shape of the coil-embedded heat dissipation inductor is completed A method of manufacturing a coil-embedded heat dissipation inductor is provided.

According to an embodiment of the present invention, the heat-radiating powder paste may be composed of 90 to 95 wt% of the ceramic powder and 5 to 10 wt% of the organic vehicle for the heat-radiating layer.

According to an embodiment of the present invention, the ceramic powder may be a mixture of two or more kinds of ceramic powders having different average particle diameters.

According to an embodiment of the present invention, the ceramic powder may include at least one selected from the group consisting of alumina, aluminum nitride (AlN), and boron nitride (BN).

According to an embodiment of the present invention, the organic vehicle for a heat radiating layer may include at least one selected from the group consisting of a silicone resin, an epoxy resin, an acrylic resin, and a urethane resin.

According to an embodiment of the present invention, the organic vehicle for a heat dissipation layer may include at least one of a reaction initiator, a catalyst, a dispersant, and an antifoaming agent.

According to an embodiment of the present invention, the heat dissipation layer may have a thickness of 1 to 2 millimeters.

According to an embodiment of the present invention, the soft magnetic component paste may have a composition ratio of 93 to 96 wt% at the end of the soft component and 4 to 7 wt% of the soft magnetic layer organic vehicle.

According to an embodiment of the present invention, the soft magnetic material may be selected from the group consisting of pure iron, carbonyl iron, iron-silicon alloy, iron-silicon-chromium alloy, Fe-Si-Al alloy, permalloy, and molybdenum permalloy.

According to an embodiment of the present invention, the organic vehicle for a soft magnetic layer may include at least one selected from an epoxy resin, an epoxy acrylate resin, a polybutyral resin, an acrylic resin, a silicone resin, and a reactive epoxy .

According to an embodiment of the present invention, the organic vehicle for a soft magnetic layer may include at least one of a dispersant, a defoaming agent, a stabilizer, a catalyst, and a catalyst activator.

According to an embodiment of the present invention, the soft magnetic layer may have a thickness of 5 to 10 millimeters.

According to an embodiment of the present invention, the heat dissipation layer and the soft magnetic layer may have a thickness ratio of 1: 3 to 1: 5.

According to an embodiment of the present invention, the quasi-quasiparticulate ingredient may be a mixture of two or more quasi-

Also, according to an embodiment of the present invention, the soft magnetic material may be characterized in that the surface thereof is ceramic-coated.

In addition, according to an embodiment of the present invention, the quadrature component may be acidified.

A coil-embedded heat-radiating inductor manufactured by the manufacturing method of the coil-embedded heat-radiating inductor of the present invention is also provided.

According to the embodiment of the present invention, by forming the heat dissipation layer using the ceramic powder and the heat dissipation powder paste considering the average particle size and the thermal conductivity, the Joule heating generated in the soft magnetic layer and the coil in the heat dissipation layer is emitted The first effect is that it can stably exist between the soft magnetic layers and can have a strength that can not be easily broken by external physical impact. Because of the use of a quadratic component, the inductance is high and the hysteresis loss is small. The third effect is that the inductor can be downsized because it uses a high-permeability soft magnetic material. The third effect is that the space between the soft magnetic elements is filled with the edible current loss due to the filling of the organic vehicle for the soft magnetic layer. It is possible to manufacture various types of inductors because they are manufactured using a mold. A sixth effect that a manufacturing cost can be reduced by eliminating the need for a fifth effect, a high-temperature sintering process, a ceramic coating on the end of a soft component, and a pressing process for increasing the density of the magnetic core, The seventh effect that there is no fear that the film of the buried coil is deteriorated, the pressurizing step, the high temperature sintering step, the annealing step and the like can be omitted, and the eighth effect that the productivity is increased by simplifying the process .

It should be understood that the effects of the present invention are not limited to the above effects and include all effects that can be deduced from the detailed description of the present invention or the configuration of the invention described in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a perspective view showing one embodiment of a coil-embedded heat dissipation inductor of the present invention. Fig.
FIG. 2 is a cross-sectional view taken along the line AA 'of FIG. 1 showing one embodiment of a coil-embedded heat radiating inductor according to the present invention.
3 is a cross-sectional view taken along the line BB 'in FIG. 1 illustrating one embodiment of a coil-embedded heat radiating inductor according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described with reference to the accompanying drawings. The present invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. In order to clearly illustrate the present invention, parts not related to the description are omitted, and similar parts are denoted by like reference characters throughout the specification.

Throughout the specification, when a part is referred to as being "connected" (connected, connected, coupled) with another part, it is not only the case where it is "directly connected" "Is included. Also, when an element is referred to as "comprising ", it means that it can include other elements, not excluding other elements unless specifically stated otherwise.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The singular expressions include plural expressions unless the context clearly dictates otherwise. In this specification, the terms "comprises" or "having" and the like refer to the presence of stated features, integers, steps, operations, elements, components, or combinations thereof, But do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, or combinations thereof.

As shown in FIGS. 1 to 3, the coil-embedded heat dissipation inductor 100 of the present invention includes a magnetic core and a coil 110, and a part of the coil 110 is embedded in the magnetic core The magnetic coil 110 has a structure in which the heat dissipation layer 120 and the soft magnetic layer 130 are alternately stacked. The method of manufacturing the coil-embedded heat-radiating inductor 100 according to the present invention will be described in detail below.

First, an organic vehicle for a heat-radiating layer is prepared. The organic vehicle for a heat radiating layer can be produced by uniformly stirring a polymer resin for a heat radiating layer and a solvent for a predetermined heat radiating layer for a predetermined time under a predetermined temperature condition. The polymer resin for the heat radiation layer may be at least one polymer resin selected from the group consisting of a silicone resin, an epoxy resin, an acrylic resin and a urethane resin, but is not limited thereto. That is, the polymeric resin for a heat-radiating layer may be prepared by stirring two or more kinds of the polymer resin for a heat-radiating layer with a solvent for a heat-radiating layer. If one kind of polymer resin for a heat- And the polymer resin itself for the heat-radiating layer will be an organic vehicle for the heat-radiating layer. If two or more kinds of polymer resins for a heat-radiating layer are prepared at room temperature, It does not mean that the solvent for a heat-dissipating layer is not stirred with the polymer resin for a heat-dissipating layer, since the polymer resin for the heat-dissipating layer is a liquid at room temperature. The polymer resin for the heat dissipation layer functions as a binder with respect to the ceramic powder to be described later. This function is a function of a structural member that maintains the shape of the heat dissipation layer 120, a function of providing chemical resistance to various organic solvents, But are not limited to, the function of allowing the ceramic powder in the organic vehicle and the additives described below to bond and support each other to maintain a desired shape.

The solvent for the heat dissipation layer may be selected from the group consisting of methyl cellosolve, ethyl cellosolve, butyl cellosolve, butyl cellosolve acetate, aliphatic alcohol, But are not limited to, terpineol, dihydro-terpineol, ethylene glycol, ethyl carbitol, butyl carbitol, butyl carbitol acetate, The solvent may contain at least one kind selected from the group consisting of texanol, methyl ethyl ketone, ethyl acetate and cyclohexanone, But is not limited to a solvent. The solvent for the heat dissipation layer affects the viscosity of the organic vehicle for the heat dissipation layer, the viscosity of the heat dissipation powder paste, the dispersibility of the ceramic powder, the curing speed of the heat dissipation powder paste and the adhesion between the heat dissipation layer 120 and the soft magnetic layer 130 But is not limited to. If the viscosity of the organic vehicle for the heat-radiating layer is not appropriate and the viscosity of the heat-radiating powder paste is not appropriate, the thickness of the heat-dissipating layer 120 may be varied. As a result, . In addition, even when the dispersibility of the ceramic powder is low, the ceramic powder is not properly dispersed and the heat radiation function of the heat radiation layer 120 may be deteriorated. If the curing time of the heat-dissipating powder paste is prolonged because the solvent for the heat-dissipating layer is not suitable, sufficient drying of the heat-dissipating layer 120 is not performed and curing proceeds from the surface of the heat- Defects such as voids or cracks may occur in the heat dissipation layer 120 due to the solvent remaining in the interior of the heat dissipation layer 120. If voids or cracks are likely to occur, a method of manufacturing a heat-radiating layer paste using a polymer resin for a heat-radiating layer which is liquid at room temperature can be considered as described above. The adhesion between the heat dissipation layer 120 and the soft magnetic layer 130 is also important. In the heat dissipation layer 120, the ceramic powder functions as a heat dissipation function, which is a core function of the heat dissipation layer 120. In the soft magnetic layer 130, 130). However, if both layers are not in contact with each other properly, the synergy between both layers will not be exhibited properly. For this reason, a polymer resin for heat dissipation layer It is necessary to control the composition ratio of the polymer resin for the heat dissipation layer and the solvent for the heat dissipation layer so that pores and gaps do not occur between the both layers.

The organic vehicle for a heat-radiating layer is proposed to mix 60 to 70 wt% of a polymer resin for a heat-radiating layer and 30 to 40 wt% of a solvent for a heat-radiating layer. The mixing ratio of the component of the organic vehicle for the heat dissipation layer and the solvent for the heat dissipation layer to the solvent for the heat dissipation layer depends on the viscosity of the heat dissipation powder paste, the density of the heat dissipation powder paste, the adhesion between the heat dissipation layer 120 and the soft magnetic layer 130, Hardness, and strength, but it is not limited thereto. The viscosity of the heat-dissipating powder paste and the adhesiveness between the heat-dissipating layer 120 and the soft magnetic layer 130 have been described above. The density of the heat-dissipating powder paste is such that, when the proportion of the high density material increases in the heat- As the density of the paste increases and the proportion of the less dense material increases, the density of the heat-dissipating powder paste will also decrease. Details will be described later. If the heat dissipation layer 120 has a low ductility and a high degree of hardness, if the magnetic core is made very thin, there is a possibility that the magnetic core may be broken, and the strength of the heat dissipation layer 120 may be lowered between the soft magnetic layers 130 Whether or not the heat radiation layer 120 can be stably present, whether the heat radiation layer 120 is not broken in the state where the coil 110 is buried, and whether it can withstand external impacts expected depending on the use of the inductor But it is needless to say that the present invention is not limited thereto.

The organic vehicle for the heat-releasing layer may include at least one of a reaction initiator, a catalyst, a dispersant, and an antifoaming agent. When the mixing of the polymer resin for the heat dissipation layer and the solvent for the heat dissipation layer is not smooth, the reaction can be promoted by the reaction initiator or the catalyst. If the polymer resin for the heat dissipation layer is not uniformly distributed in the solvent for the heat dissipation layer, The coagulation can be prevented by injecting a dispersant, and if the bubbles are generated in the organic vehicle for the heat-radiating layer, the defoaming agent can be added to prevent the bubbles.

A process for producing an organic vehicle for a heat-radiating layer by stirring a polymer resin for a heat-radiating layer and a solvent for a heat-radiating layer (including an additive when an additive is added) is carried out for a predetermined period of time under a given rpm condition using a mechanical stirrer. Although there is no upper limit in the stirring time, it is necessary to keep in mind a minimum time for ensuring uniform stirring. This is because the kind of the polymer resin for the heat radiation layer, the kind of the solvent for the heat release layer, the polymer resin for the heat release layer, It depends on the liver composition and should be determined according to each case. After the stirring, the prepared organic vehicle for a heat-radiating layer may be selectively provided with a process of adding impurities by using a sieve and removing the internal air bubbles.

Second, the ceramic powder is kneaded by roll mixing milling with the organic vehicle for a heat-radiating layer prepared in the first step to prepare a heat-resisting powder paste. The ceramic powder includes at least one selected from the group consisting of alumina, aluminum nitride (AlN) and boron nitride (BN), but is not limited thereto and may be any ceramic powder having high thermal conductivity. Due to the above ceramic powder, the heat dissipation layer 120 receives heat generated from the soft magnetic layer 130 and the coil 110 and discharges the heat to the outside. Of course, metals generally have higher thermal conductivity than ceramics, but they are not desirable because of the high possibility of eddy currents. The ceramic powder has an average particle diameter of 2 to 100 micrometers. When the average particle diameter of the ceramic powder is more than 100 micrometers, the thermal conductivity of the heat-dissipating powder paste is lowered as the space between the ceramic powders increases. When the average particle diameter of the ceramic powder is less than 2 micrometers, the organic vehicle for the heat- The heat of the soft magnetic layer 130 is released to the outside of the soft magnetic layer 130. When the ceramic powder is too dense, the thermal conductivity is high and the thermal emissivity is low, But rather may transfer heat to the other soft magnetic layer 130.

The ceramic powder may be composed of a mixture of two or more kinds of ceramic powders having different average particle diameters. In this case, the ceramic powder having a small average particle diameter is located between the ceramic powders having a large average particle diameter, resulting in an effect of increasing the density of the heat-radiating powder paste. The density of the heat-dissipating powder paste will be described later. Mixing two or more ceramic powders having different average particle diameters proposes mixing a first ceramic powder having an average particle diameter of 2 to 5 micrometers and a second ceramic powder having an average particle diameter of 50 to 100 micrometer. This is because the ceramic powder having a small average particle diameter can be placed between the ceramic powders having a large average particle diameter.

The heat-radiating powder paste is preferably composed of 90 to 95 wt% of the ceramic powder and 5 to 10 wt% of the organic vehicle for the heat-radiating layer. When the ceramic powder exceeds 95 wt% or the organic vehicle for the heat-radiating layer is less than 5 wt%, there is a problem in the strength of the heat-radiating layer 120. When the ceramic powder is less than 90 wt% or the organic vehicle for the heat- There is a problem in the thermal conductivity of the heat-dissipating powder paste. One of the performance requirements of the heat-dissipating powder paste is the density of the heat-dissipating powder paste. The density of the heat-dissipating powder paste is directly related to the composition ratio of the organic powder for the ceramic powder and the heat-dissipating layer and the density of the ceramic powder is higher than that of the organic vehicle for the heat- The density of the heat-radiating powder paste increases as the ratio of the ceramic powder increases, which means that the thermal conductivity of the heat-radiating powder paste increases. On the contrary, the smaller the ratio of the ceramic powder, the smaller the density of the heat-dissipating powder paste. This means that the thermal conductivity of the heat-dissipating powder paste becomes smaller, but the heat radiation layer 120 is improved in thermal emissivity There is also a side. It is proposed that the density of the heat-dissipating powder paste is 4 to 5 g / cc in terms of the thermal conductivity and the thermal emissivity. In this case, generally, a high thermal conductivity can be ensured, and the heat radiation rate to the outside can be increased to some extent.

In the roll mixing milling of the ceramic powder and the organic layer for the heat-radiating layer, the ceramic powder and the organic vehicle for the heat-radiating layer are weighed and put into a kneader, and the mixture is kneaded for a predetermined time by roll mixing milling )do. There is no upper limit in the time required for the kneading process, but it is necessary to keep in mind the minimum time for ensuring roll mixing milling because the kind of ceramic powder, the composition of the organic vehicle for the heat- , The composition between the ceramic powder and the organic vehicle for the heat-dissipating layer, it should be determined according to each case.

It is possible to add one or more selected from the group consisting of a curing agent and a curing accelerator to the heat-radiating powder paste prior to the curing step of the heat-dissipating powder paste to be described later. As the curing agent, , Modified aliphatic amines, aromatic amines, modified aromatic amines, acid anhydrides, polyamides and imidazoles can be used. As curing accelerators, Lewis acids, alcohols, phenols, achylphenols, carboxylic acids, tertiary amines and imidazoles can be used , But it is not limited thereto. The time required for natural curing of the heat-dissipating powder paste can be avoided. Further, a process of mixing and defoaming a mixture of a heat radiation powder paste and a curing agent, a mixture of a heat radiation powder paste and a curing accelerator, or a mixture of a heat radiation powder paste, a curing agent and a curing accelerator may be added. In order for the curing agent or the curing accelerator to function uniformly over the entire volume of the heat-dissipating powder paste, mixing can be performed by using a rotary stirrer or a planetary stirrer, but the present invention is not limited thereto. The degassing is to remove bubbles contained in the heat-dissipating powder paste. Such bubbling can increase not only the thermal conductivity but also the strength of the heat-dissipating layer 120 to be formed later.

Third, an organic vehicle for a soft magnetic layer is prepared. The organic vehicle for a soft magnetic layer can be produced by uniformly stirring a polymer resin for a soft magnetic layer and a solvent for a predetermined soft magnetic layer for a predetermined time under a predetermined temperature condition. The polymer resin for the soft magnetic layer may be at least one polymer resin selected from the group consisting of an epoxy resin, an epoxy acrylate resin, a polybutyral resin, an acrylic resin, a silicone resin and a reactive epoxy, but is not limited thereto. That is, the polymeric resin for a soft magnetic layer may be prepared by stirring two or more kinds of the polymeric resin for a soft magnetic layer except for the polymeric resin for a soft magnetic layer. The polymer resin itself for the soft magnetic layer will be an organic vehicle for the soft magnetic layer. If two or more kinds of polymer resins for a soft magnetic layer, which are liquid at room temperature, are prepared, However, it does not mean that the polymer resin for a soft magnetic layer is a liquid at room temperature and does not mean that the solvent for a predetermined soft magnetic layer is not stirred with the polymer resin for a soft magnetic layer. The polymer resin for the soft magnetic layer functions as a binder with respect to the end of the soft magnetic material which will be described later. Such functions include the function of a structural member that maintains the shape of the soft magnetic layer 130, the function of providing chemical resistance to various organic solvents, The soft magnetic layer 130 and the soft magnetic layer 130 are filled with a space between the soft magnetic layer 130 and the soft magnetic layer 130, And reducing the eddy current loss of the soft magnetic layer 130 by increasing the resistivity of the soft magnetic layer 130. However, the present invention is not limited thereto.

The solvent for the soft magnetic layer may be selected from the group consisting of methyl cellosolve, ethyl cellosolve, butyl cellosolve, butyl cellosolve acetate, aliphatic alcohol, But are not limited to, terpineol, dihydro-terpineol, ethylene glycol, ethyl carbitol, butyl carbitol, butyl carbitol acetate, , Texanol, methyl ethyl ketone, ethyl acetate, and cyclohexanone. However, the solvent may be limited to the solvents listed above, But is not limited to organic solvents. The solvent for the soft magnetic layer is selected from the group consisting of the viscosity of the organic vehicle for the soft magnetic layer, the viscosity of the soft component late paste, the dispersibility of the soft component late dispersion, the curing speed of the soft component late paste and the adhesion between the soft magnetic layer 130 and the heat dissipation layer 120 But is not limited to. If the viscosity of the soft component paste is not appropriate because the viscosity of the organic medium for soft magnetic layer is not suitable, the thickness of the soft magnetic layer 130 may be varied. As a result, May be degraded. In addition, even when the dispersibility of the soft phase component is low, the dispersion of the soft phase component is not properly performed and the function of concentrating the magnetic field of the soft magnetic layer 130 may be degraded. If the solvent for soft magnetic layer is not suitable and the hardening time of the soft magnetic component paste is prolonged, the soft magnetic layer 130 is not sufficiently dried and hardening proceeds from the surface of the soft magnetic layer 130, Defects such as voids or cracks may occur in the soft magnetic layer 130 due to the solvent remaining in the soft magnetic layer 130. If voids or cracks are likely to occur, a method of manufacturing a paste for the soft magnetic layer 130 using a polymer resin for a soft magnetic layer, which is liquid at room temperature, can be considered as described above have. The adhesion between the soft magnetic layer 130 and the heat dissipation layer 120 is also important. In the soft magnetic layer 130, the soft magnetic layer 130 functions to concentrate magnetic lines, which is a core function of the soft magnetic layer 130. In the heat dissipation layer 120, However, if both layers are not in contact with each other properly, the synergistic effect of both layers will not be exhibited properly. For this reason, the polymer for a soft magnetic layer It is necessary not only to select the resin but also to control the composition ratio of the polymer resin for the soft magnetic layer and the solvent for the soft magnetic layer so that pores and gaps are not generated between both layers.

The organic vehicle for a soft magnetic layer is proposed to mix 50 to 60 wt% of a polymer resin for a soft magnetic layer and 40 to 50 wt% of a solvent for a soft magnetic layer. The composition ratio of the organic vehicle for the soft magnetic layer and the solvent for the soft magnetic layer and the solvent for the soft magnetic layer is such that the viscosity of the soft component late paste, the density of the soft component late paste, the adhesion of the soft magnetic layer 130 and the heat dissipation layer 120 Hardness and strength of the soft magnetic layer 130, but is not limited thereto. The viscosity of the soft component late paste and the adhesion between the soft magnetic layer 130 and the heat dissipation layer 120 have been described above and the density of the soft component late paste is such that the proportion of the high density material in the soft magnetic layer organic vehicle increases When the density of the softener component paste is increased and the density of the soft component paste is decreased when the density of the low-density component is increased, the details will be described later. If the soft magnetic layer 130 has a low ductility and a high degree of hardness, if the magnetic core is made very thin, there is a possibility that the magnetic core is broken, and the strength of the soft magnetic layer 130 is Whether or not the soft magnetic layer 130 can be stably present, whether the soft magnetic layer 130 will not break in a state where the coil 110 is buried, and whether it can withstand an external impact expected depending on the use of the inductor But it is needless to say that the present invention is not limited thereto.

The organic vehicle for a soft magnetic layer may comprise at least one of a dispersing agent, a defoaming agent, a stabilizer, a catalyst and a catalytic activator. If the polymer resin for the soft magnetic layer is not uniformly distributed in the solvent for the soft magnetic layer and there is a possibility of coagulation, such coagulation can be prevented by injecting the dispersant, and if bubbles are generated in the soft magnetic layer organic vehicle, The stabilizer can be added when it is necessary to suppress the chemical change or the state change of the organic vehicle for the soft magnetic layer and when the mixing of the polymer resin for the soft magnetic layer and the solvent for the soft magnetic layer is not smooth, The catalyst or catalyst activator may be used to promote the reaction.

The operation of producing an organic vehicle for a soft magnetic layer by agitating a polymer resin for a soft magnetic layer and a solvent for a soft magnetic layer (including an additive when an additive is added) is carried out for a predetermined time under a given rpm condition using a mechanical stirrer . There is no upper limit in the stirring time, but it is necessary to keep in mind a minimum time for ensuring uniform stirring. This is because the kind of the polymer resin for the soft magnetic layer, the kind of the solvent for the soft magnetic layer, It depends on the solvent composition for the soft magnetic layer, so it should be determined according to each case. After the agitation, the produced soft magnetic layer organic vehicle may optionally be further provided with a process of adding impurities by using a sieve and removing the inner air bubbles.

Fourth, the soft magnetic component paste is prepared by kneading (rolling mixing milling) the soft magnetic component layer with the soft magnetic layer organic vehicle prepared in the third step. Si-Al alloy, Fe-Si alloy, Fe-Si-Cr alloy, Fe-Si-Al alloy, permalloy, , And molybdenum permalloy (Mo-permalloy), but are not limited thereto. Pure iron does not refer to 100% pure iron as the term is, and is not uniformly defined in all technical fields, but iron containing about 0.2% impurities can be called pure iron. These pure iron or carbonyl iron are soft magnetic materials, but they are not used in electrical machines, except for some special applications. This is because the saturation flux density and magnetic permeability are high and the hysteresis loss is low (relatively higher than other soft magnetic materials) but the eddy current loss is large. Such a problem needs to be overcome by a vehicle with good insulation. Fe-Si alloys, Fe-Si-Cr alloys and Fe-Si-Al alloys contain silicon (Si) in common with metal alloys However, if the content of Si contained in the metal alloy increases, the resistivity of the metal alloy increases, thereby reducing the eddy current. However, if the content of Si increases, the brittleness increases, It should be noted that when the soft magnetic layer 130 is manufactured using the alloy, the soft magnetic layer 130 may have problems such as impact resistance. Molybdenum permalloy has high magnetic permeability and very low hysteresis loss. However, it should be noted that the saturation magnetic flux density is relatively low and the stability is not sufficient when the direct current superposition is applied and the frequency used is less than 1 MHz .

The softener component suggests that the average particle size is 15 to 100 micrometers. The magnetic permeability of the soft magnetic layer 130 may be lowered and the average particle diameter at the end of the soft component may be less than 15 micrometers if the average particle diameter of the soft magnetic component exceeds 100 micrometers. eddy current loss) may be a problem, and the soft magnetic layer 130 organic medium may not sufficiently fill the space between the soft magnetic layers, which may cause a problem in the strength of the soft magnetic layer 130.

The soft component term may be composed of two or more types of soft component term having different average particle diameters mixed. This results in that a quasi-continuous component having a small average particle diameter is positioned between the ends of the quasi-component having a large average particle diameter, resulting in an effect of increasing the density of the quasi-component end paste. The density of the soft component paste will be described later. It is proposed that the mixing of two or more kinds of soft component horses having different average particle diameters is carried out by mixing a first soft component end having an average particle diameter of 15 to 20 micrometers and a second soft component end having an average particle diameter of 80 to 100 micrometer. This is because it is possible to position the end of a quasi-component having a small average particle diameter between the ends of the quasi-component having a large average particle diameter. Further, the surface of the quasi-tangible component used can be treated with a ceramic coating. As described above, the polymer resin for the soft magnetic layer functions as an insulation between the ends of the soft magnetic material layer, thereby reducing the eddy current loss of the soft magnetic layer 130. In addition, If ceramic coating is applied, it will double the effect of insulation and can be treated with talc, kaolin or the like. As another method of insulating against a quasi-component, acidification can be performed, for example, phosphoric acid treatment can be performed. Such an acid treatment may also have an effect of cleaning and polishing the surface of the quartz component side-by-side.

The soft magnetic component paste is preferably composed of 93 to 96 wt% at the end of the soft component and 4 to 7 wt% of the soft magnetic layer organic vehicle. If the content of the soft magnetic material exceeds 96 wt% or the amount of the organic vehicle for the soft magnetic layer is less than 4 wt%, the eddy current loss may increase in the soft magnetic layer 130 and the strength of the soft magnetic layer 130 may also be affected , And when the content of the soft magnetic component is less than 93 wt% or the content of the soft magnetic layer organic vehicle is more than 7 wt%, there is a problem in the permeability of the soft magnetic component paste.

One of the performance requirements of the soft component late paste is the density of the soft component late paste. The density of the soft component late paste is directly related to the composition ratio of the soft component and the organic vehicle for soft magnetic layer, Is larger than the density of the organic vehicle for a soft magnetic layer, the density of the soft magnetic component paste increases as the ratio of the soft magnetic component increases, which means that the permeability of the soft magnetic component paste increases. On the contrary, the smaller the ratio of the term of the quasi-component is, the smaller the density of the quasi-component end paste is. This means that the permeability of the quasi-component end paste is smaller, but also the eddy current loss is reduced. In terms of the permeability and the eddy current loss, it is proposed that the density of the soft magnetic component paste is 5 to 6 g / cc. In this way, it is possible to secure a high magnetic permeability and at the same time to reduce the eddy current loss to some extent. And thermal shock resistance as one of component reliability as a performance requirement of other soft component paste. When an inductor or the like to which a magnetic core is applied typically generates heat at a temperature of about 130 degrees Celsius, an unusual high frequency noise or an abnormal current is generated, The polymer resin for the soft magnetic layer needs to satisfy the heat resistance since cracks, discoloration, and deterioration of adhesion with the coil 110 should not occur even if repeatedly exposed to such a temperature .

The kneading component horse and the organic vehicle for a soft magnetic layer are subjected to roll mixing milling by weighing a kneader component and an organic vehicle for a soft magnetic layer and putting them into a kneader, Roll mixing milling. There is no upper limit in the time required for the kneading process, but it is necessary to keep in mind the minimum time for ensuring the roll mixing milling. This is because the kind of the quench component, the component of the organic vehicle for the soft magnetic layer And the composition of the composition, the composition of the soft component and the composition of the organic vehicle for the soft magnetic layer.

At least one selected from the group consisting of a hardener and a hardening accelerator may be added to the soft component late paste to promote hardening of the soft component late paste before the step of hardening the soft component late paste to be described later. Aliphatic amines, aromatic aliphatic amines, aromatic amines, modified aromatic amines, acid anhydrides, polyamides and imidazoles as curing accelerators, Lewis acids, alcohols, phenols, achylphenols, carboxylic acids, tertiary amines, imidazoles But the present invention is not limited thereto. Through these uses, the time required for natural hardening of the soft component paste can be avoided. Further, a process of mixing and defoaming a mixture of a soft component late paste and a curing agent, a mixture of a soft component late paste and a curing accelerator, or a mixture of a soft component late paste, a curing agent and a curing accelerator may be added. In order for the hardener or hardening accelerator to function uniformly over the whole volume of the softener component paste, it is necessary to mix it, but a rotary stirrer or an oil stirrer can be used for this mixing, but the present invention is not limited thereto. The defoaming is to remove bubbles contained in the soft magnetic component paste. Such bubbling can increase not only the permeability but also the strength of the soft magnetic layer 130 to be formed later.

Fifth, a part of the coil 110 is positioned and fixed inside a mold having a predetermined shape. Most of the coil 110 is embedded in the magnetic core, while the remaining part of the coil 110 is exposed to the outside of the magnetic core to serve as an external terminal (electrode). Of course, it is possible to consider a configuration in which the external terminal is provided as a separate member and the member is electrically connected to the coil 110. However, in the embodiment of FIGS. 1 to 3, The coil 110 directly serves as an electrode without providing a separate member. Such an electrode basically requires two electrodes because there is a positive electrode and a negative electrode to which a voltage is applied, but an electrode may be further required depending on the circuit configuration to be implemented. The fixing position of the coil 110 may be fixed to the center of the mold at predetermined intervals on the bottom surface and both side surfaces of the mold as in the embodiment of FIGS. 1 to 3. However, no. 1 to 3, when the coil 110 is fixed, the coil 110 is fixed at an upper portion spaced apart from the mold by a predetermined distance so as not to shake the coil 110. [ However, the present invention is not limited thereto. When a part of the coil 110 is fixed to the inside of the mold, it is necessary to securely fix the coil 110 at a position to be fixed. This prevents the coil 110 from coming off from the inside of the magnetic core, In order to prevent the magnetic core from shaking in the magnetic core and not to generate a gap between the coil 110 and the magnetic core. The shape of the mold is formed according to the shape of the target magnetic core, and may be a hexahedron shape as in the embodiment of FIGS. 1 to 3, a shape obtained by chamfering the corners of the hexahedron, or a cylindrical shape, but is not limited thereto Of course.

Sixthly, the heat dissipation powder paste is injected into a mold and cured to form the heat dissipation layer 120, and the soft component paste is injected into the mold to cure the heat dissipation powder paste, 130, and repeats this until the entire shape of the coil-embedded heat-radiating inductor 100 is completed. That is, in the present invention, the soft magnetic layer 130 is formed next to the heat dissipation layer 120, the heat dissipation layer 120 is formed next, and then the soft magnetic layer 130 is formed again. 3, a soft magnetic layer 130 is formed at the bottom, a heat dissipation layer 120 is formed next, a soft magnetic layer 130 is formed next, and then a heat dissipation layer 120 is formed again Of course it is possible. As shown in FIGS. 1 to 3, the soft magnetic layer 130 may be disposed on the lowermost layer and the heat dissipation layer 120 may be disposed on the uppermost layer. However, the structure may be changed according to the user's intention. For example, in order to enhance the function of concentrating the magnetic field of the coil-embedded heat-radiating inductor 100, both the lowermost layer and the uppermost layer can be made of the soft magnetic layer 130 and the heat- Both the lowermost layer and the uppermost layer can be made of the heat dissipation layer 120.

It is proposed that the heat-radiating layer 120 has a thickness of 1 to 2 millimeters. When the thickness of the heat dissipation layer 120 exceeds 2 millimeters, the magnetic flux concentrating function of the coil-embedded heat dissipation inductor 100 may deteriorate. When the thickness of the heat dissipation layer 120 is less than 1 millimeter, 100 may be deteriorated, and breakage of the heat dissipation layer 120 may be a problem. And the soft magnetic layer 130 has a thickness of 5 to 10 millimeters. If the thickness of the soft magnetic layer 130 exceeds 10 millimeters, the heat radiation function of the coil-embedded heat radiation inductor 100 may be degraded, eddy current loss of the soft magnetic layer 130 may be a problem, If the thickness of the soft magnetic layer 130 is less than 5 millimeters, the function of concentrating the magnetic field of the coil-embedded heat radiation inductor 100 may deteriorate and the soft magnetic layer 130 may be broken. It is also proposed that the heat dissipation layer 120 and the soft magnetic layer 130 have a thickness ratio of 1: 3 to 1: 5. If the thickness ratio of the heat dissipation layer 120 and the soft magnetic layer 130 is less than 1: 3, the degree to which the coil-embedded heat dissipation inductor 100 concentrates the magnetic filament can be reduced to such an extent that it can not be used in an electric circuit, If the thickness ratio of the layer 120 and the soft magnetic layer 130 exceeds 1: 5, the degree of heat dissipation of the coil-embedded heat-dissipating inductor 100 may be such as to accelerate deterioration of the coil-embedded heat-dissipating inductor 100 It is because.

When the heat dissipation powder paste and the soft component paste are alternately injected into the mold, they should be injected so as not to generate gaps or pores between the heat dissipation layer 120 and the soft magnetic layer 130. For example, if the mold is of the type shown in FIGS. 1 to 3, the heat-radiating powder paste or the soft-component paste is to be injected while maintaining the equilibrium. The heat of the soft magnetic layer 130 is not transferred to the heat dissipation layer 120 and the heat stays only in the soft magnetic layer 130. As a result, The inductance of the coil 110 may be lower than that of the inductor of the coil 110 without the coil 120. [

Finally, the magnetic core in which the coil 110 is embedded and the heat dissipation layer 120 and the soft magnetic layer 130 are laminated is taken out from the mold.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it should be understood that various changes and modifications will be apparent to those skilled in the art. Obviously, the invention is not limited to the embodiments described above. Accordingly, the scope of protection of the present invention should be construed according to the following claims, and all technical ideas which fall within the scope of equivalence by alteration, substitution, substitution, and the like within the scope of the present invention, Range. In addition, it should be clarified that some configurations of the drawings are intended to explain the configuration more clearly and are provided in an exaggerated or reduced size than the actual configuration.

100: coil-embedded heat-radiating inductor
110: Coil
120: heat radiating layer
130: soft magnetic layer

Claims (17)

A method for manufacturing a coil-embedded heat dissipation inductor (100) having a heat dissipation structure, wherein a part of the coil (110) is embedded in a magnetic core,
(I) preparing an organic vehicle for a heat-radiating layer;
(II) ceramic powder is mixed with an organic vehicle for heat dissipation layer prepared in the step (I) by roll mixing milling to prepare a heat dissipation powder paste having a density of 4 to 5 g / cc;
(III) preparing an organic vehicle for a soft magnetic layer;
(IV) a soft magnetic component horsepaste having a density of 5 to 6 g / cc by roll mixing milling with a soft magnetic layer organic vehicle prepared in the step (III);
(V) positioning and fixing a part of the coil 110 inside a mold of a predetermined shape;
(VI) forming the heat dissipation layer 120 by injecting the heat dissipation powder paste prepared in the step (II) into the mold and curing the heat dissipation powder paste;
(VII) forming a soft magnetic layer 130 on the heat dissipation layer 120 formed in the step (VI) by injecting the soft magnetic component paste prepared in the step (IV) into the mold and curing ;
, ≪ / RTI >
Wherein the step (VI) and the step (VII) are repeated until the entire shape of the coil-embedded heat-radiating inductor (100) is completed.
The method according to claim 1,
Wherein the heat dissipation powder paste in the step (II) is composed of 90 to 95 wt% of the ceramic powder and 5 to 10 wt% of the organic vehicle for the heat dissipation layer.
The method according to claim 1,
Wherein the ceramic powder in the step (II) is a mixture of two or more kinds of ceramic powders having different average particle diameters.
The method according to claim 1,
Wherein the ceramic powder in the step (II) comprises at least one selected from the group consisting of alumina, aluminum nitride (AlN) and boron nitride (BN).
The method according to claim 1,
Wherein the organic vehicle for heat dissipation layer in step (I) comprises at least one selected from the group consisting of silicone resin, epoxy resin, acrylic resin and urethane resin.
The method according to claim 1,
Wherein the organic vehicle for a heat dissipation layer in step (I) comprises at least one of a reaction initiator, a catalyst, a dispersant, and an antifoaming agent.
The method according to claim 1,
Wherein the heat dissipation layer 120 in the step (VI) has a thickness of 1 to 2 millimeters.
The method according to claim 1,
The method of manufacturing a coil-embedded heat dissipation inductor (100) according to claim 1, wherein the soft magnetic material paste in step (IV) comprises 93 to 96 wt% of the soft magnetic material and 4 to 7 wt% of the soft magnetic layer organic vehicle.
The method according to claim 1,
The quench term in the step (IV) may be selected from the group consisting of pure iron, carbonyl iron, iron-silicon alloy, iron-silicon-chromium alloy, and at least one selected from the group consisting of alloys, alloys, permalloys, and molybdenum permalloy. The method of manufacturing a coil-embedded heat dissipation inductor (100) according to claim 1,
The method according to claim 1,
The organic vehicle for soft magnetic layer in the step (III) comprises at least one selected from the group consisting of an epoxy resin, an epoxy acrylate resin, a polybutyral resin, an acrylic resin, a silicone resin, and a reactive epoxy. A method of manufacturing an inductor (100).
The method according to claim 1,
Wherein the soft magnetic layer organic vehicle in step (III) comprises at least one of a dispersant, a defoamer, a stabilizer, a catalyst, and a catalyst activator.
The method according to claim 1,
Wherein the soft magnetic layer (130) in step (VII) has a thickness of 5 to 10 millimeters.
The method according to claim 1,
Wherein the heat dissipation layer 120 in the step (VI) and the soft magnetic layer 130 in the step (VII) have a thickness ratio of 1: 3 to 1: 5. Way.
The method according to claim 1,
The method of manufacturing a coil-embedded heat dissipation inductor (100) according to claim 1, wherein the soft magnetic material in the step (IV) is a mixture of two or more soft magnetic material materials having different average particle diameters.
The method according to claim 1,
The method of manufacturing a coil-embedded heat dissipating inductor (100) according to claim 1, wherein the soft magnetic material in the step (IV) is a ceramic coating.
The method according to claim 1,
The method of manufacturing a coil-embedded heat dissipation inductor (100) according to claim 1, wherein the quasi-
A coil-embedded heat dissipation inductor produced by any one of claims 1 to 16.

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