Constant-flux inductors (CFIs) are designed to have a more uniform flux density in the core for efficient use of the magnetic material and higher inductance density. However, these inductors generally require unique winding structures that are difficult to manufacture by conventional means. In this article, we applied a paste-extrusion 3-D printer to fabricate spiral windings with varying turn-by-turn widths to make a pot-core CFI. The printing speed and extrusion rate of the printer were optimized for a commercial silver paste to form the windings. The printed windings were sintered at 850 °C to get electrical conductivity approaching that of bulk silver. To form the magnetic core, a custom-made curable magnetic composite paste was used to encase the windings. After curing at 200 °C, the permeability of the magnetic material can reach over 35 with low core-loss density. A 1-μH pot-core CFI of 5 mm x 5 mm x 2 mm was designed, fabricated, and characterized for its inductance and quality factor versus frequency and inductance versus dc current.

中文翻译：

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罐芯恒通量电感器螺旋绕组的增材制造

恒定磁通电感器（CFI）设计为在磁芯中具有更均匀的磁通密度，以有效利用磁性材料和更高的电感密度。然而，这些电感器通常需要独特的绕组结构，这些绕组结构难以通过常规手段来制造。在本文中，我们应用了糊料挤出3-D打印机来制造具有不同匝间宽度的螺旋绕组，以制造罐芯CFI。打印机的印刷速度和挤出速度已针对商用银浆进行优化，以形成绕组。印刷绕组在850°C下烧结，电导率接近散装银。为了形成磁芯，使用了定制的可固化磁性复合膏来包裹绕组。在200°C固化后，磁性材料的磁导率可以达到35以上，且铁损密度低。设计，制造了一个5μx 5 mm x 2 mm的1-μH罐芯CFI，其电感，品质因数与频率，电感与直流电流有关。