CN101944429A - Electronic component - Google Patents
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- CN101944429A CN101944429A CN 201010226985 CN201010226985A CN101944429A CN 101944429 A CN101944429 A CN 101944429A CN 201010226985 CN201010226985 CN 201010226985 CN 201010226985 A CN201010226985 A CN 201010226985A CN 101944429 A CN101944429 A CN 101944429A
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- overlay film
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Abstract
Electronic component of the present invention (1), have part main body (2) and be formed at described part main body (2) lip-deep by overlay film (3), it is characterized in that, described had at least by overlay film (3) be present in describedly by the top layer (3b) of the face side of overlay film (3) be present in the la m (3a) of this inboard, top layer, the softening point ratio that is contained in the skin glass composition on described top layer (3b) is contained in the softening point height of the la m glass ingredient of described la m (3a).Can comprise its fusing point crystalline material higher in top layer (3b) again than the softening point of the glass ingredient of la m.If employing the present invention then can provide to have as described belowly by the electronic component of overlay film, and when forming, can effectively prevent by the defective of overlay film and thickness deviation and foreign matter by the generation of situations such as adhering on the overlay film by overlay film.
Description
Technical field
The present invention relates to electronic components such as coil component, in more detail, relate to have prevent effectively part be mutually adhered together or be attached to form under the situation of sintering furnace by the electronic component of overlay film.
Background technology
Along with miniaturization,, existing Ni-Zn magnetic core is studied to the use of Mn-Zn magnetic core in order to obtain needed characteristic as the coil component of an example of electronic component.But the Mn-Zn magnetic core can not directly be provided with electrode because its insulating properties is low on the surface of magnetic core, therefore is necessary on the surface of magnetic core dielectric film to be set.Dielectric film can adopt for example glass or resin etc.
Such dielectric film for example uses sleeve coating (barrel coating) method to form, and promptly forms glass coating film (with reference to TOHKEMY 2001-237135 communique) on the magnetic core surface, and the glass coating film that forms is fired into.At this moment, glass coating film burns till with the above temperature of its softening point usually.Therefore glass coating film is softening in the process of burning till, and might take place to be mutually adhered together between the part or is attached to firing furnace and causes the defective of glass coating film or the thickness deviation takes place.And also has foreign matter attached to the problem on the softening glass coating film.
Even there is not the electronic component such as FERRITE CORE, piezo-resistance of conductivity,, also have to form in its surface by the situation of overlay film as diaphragm for the performance that improves its tenable environment condition and insulation property etc.Therefore require to obtain having on the whole surface of part, form by overlay film, do not had defective etc. by overlay film, and the electronic component that thickness deviation and foreign matter adhere to do not take place.
Summary of the invention
The present invention makes in view of such actual conditions, and its purpose is, the generation that can effectively prevent by the defective of overlay film and thickness deviation is provided, and prevents the electronic component that situations such as foreign matter adheres on by overlay film take place simultaneously.
To achieve these goals, the electronic component of the 1st form of the present invention, be have the part main body and be formed on the described part body surfaces by the electronic component of overlay film, it is characterized in that, described had at least by overlay film be present in describedly by the top layer of the face side of overlay film be present in the la m of this inboard, top layer, the softening point of skin glass composition that is contained in described top layer is than the softening point height of the la m glass ingredient that is contained in described la m.
In the 1st form, preferably at the softening point height than described la m glass ingredient, and the temperature lower than the softening point of described skin glass composition forms described by overlay film.
If adopt the 1st form of the present invention, then can think and form by the stage of overlay film, the near surface whole or skin glass composition at least of skin glass composition does not soften, or only reaches softening initial stage (the low state of viscosity of the glass ingredient of near surface).Therefore can effectively prevent and be mutually adhered together or be attached to firing furnace between the part and cause by the situation of overlay film defective and thickness deviation and take place.And can prevent effectively that foreign matter from adhering on by overlay film.
And the glass ingredient generation vitrifying of la m when forming by overlay film, the whole surface of cap piece main body, and can guarantee to be close to the part main body.
And the skin glass composition on top layer also with than its same vitrifying of la m glass ingredient in the inner part also solidifies.That is to say that also there is the function of diaphragm on the top layer.
Thereby, by implementing aforesaid technical scheme, can solve the existing problems when being formed by overlay film, can give different characteristics to la m and top layer according to desirable characteristic.
In the 1st form, the content of the ornamental equivalent in the preferably described skin glass composition is littler than the content of the ornamental equivalent in the described la m glass ingredient.Ornamental equivalent in the glass ingredient, for example alkali metal oxide etc., the tendency that has the softening point that makes glass ingredient to reduce.Thereby,, can improve the softening point of skin glass composition by implementing aforesaid technical scheme.Consequently, the top layer is not easy to be invaded (anti-plating) by plating bath.So, the constituent that the inner glass composition also can select plating bath to invade easily, so the composition of inner glass composition is not defined.
In the 1st form, the softening point of preferably described skin glass composition is higher 30～100 ℃ than the softening point of described la m glass ingredient.By setting such temperature difference, can promote effect of the present invention.
In the 1st form, preferably the thickness on described top layer described by 1/8～1/2 scope of the gross thickness of overlay film in.By being set at such skin depth, can promote effect of the present invention.
Again, to achieve these goals, the electronic component of the 2nd form of the present invention, be have the part main body and be formed on the described part body surfaces by the electronic component of overlay film, it is characterized in that, described had at least by overlay film be present in describedly by the top layer of the face side of overlay film be present in the la m of this inboard, top layer, the fusing point of crystalline material that is contained in described top layer is than the softening point height of the la m glass ingredient that is contained in described la m.
In the 2nd form,, and form described by overlay film than the low-melting temperature of described crystalline material preferably at softening point height than described la m glass ingredient.
If adopt the 2nd form of the present invention, then can think and form by the stage of overlay film, the near surface whole or crystalline material at least of the crystalline material that comprises in the top layer does not melt (the most surperficial hardness of crystalline material is constant), or only reaches the initial stage (the most surperficial hardness of crystalline material has some reductions) of fusing.Therefore can effectively prevent and be mutually adhered together or be attached to firing furnace between the part and cause by the situation of overlay film defective and thickness deviation.And can prevent effectively that foreign matter from adhering on by overlay film.
Thereby, by implementing aforesaid technical scheme, can solve the existing problems when being formed by overlay film, can give different characteristics to la m and top layer corresponding to desirable characteristic.
In the 2nd form, preferably described crystalline material is select in pottery, metal and this group material of alloy at least a.By selecting above-mentioned material, can increase above-mentioned effect, obtain desirable characteristic.
In the 2nd form, preferably the fusing point of described crystalline material is higher more than 30 ℃ than the softening point of described la m glass ingredient.By such temperature difference is set, can promote effect of the present invention.
In the 2nd form, preferably the particle diameter of described crystalline material be described by 1/8～1/2 scope of the gross thickness of overlay film in.By particle diameter being arranged in the above-mentioned scope, can promote effect of the present invention.
Description of drawings
The profile of the coil component of Fig. 1 the present invention one example.Fig. 2 is the general profile of the sleeve arrangement that uses when making of the coil component of the present invention's one example.Fig. 3 is the profile of the coil component behind the coiling coil.Fig. 4 be expression the present invention one example coil component by near the general profile the overlay film.Fig. 5 is the profile of the coil component of another example of the present invention.
Embodiment
The present invention will be described for example shown in reference to the accompanying drawings below.
The 1st example Coil componentThe shape of the coil component of the present invention's one example is not particularly limited, and for example can be shapes such as tabular, bar-shaped, tubular.In this example, coil component 1 as shown in Figure 1, forms cylindric core shapes, and the whole surface with part main body 2 forms by the structure of overlay film 3.
The part main bodyPart main body 2 has the wireline reel 4 of cylinder or polygon prism shape and along the direction of principal axis of this wireline reel 4 a pair of blade of a sword portion 5 in both sides formation in aggregates.Blade of a sword portion 5 outer through bigger than the external diameter of wireline reel 4 forms the recess 6 that is centered on by blade of a sword portion 5 on the periphery of wireline reel 4.And shown in Figure 3 as the back, coiling lead 30 in this recess 6.
The size of part main body 2 is not particularly limited, in this example, the external diameter of wireline reel 4 is 0.6～1.2mm, the axial width of wireline reel 4 is 0.3～1.0mm, the external diameter of blade of a sword portion 5 is 2.0～3.0mm, the thickness of blade of a sword portion 5 is 0.2～0.3mm, and the degree of depth from the outer surface of blade of a sword portion 5 to the outer surface of wireline reel 4 is 0.5～1.0mm.Again, the shape of blade of a sword portion 5 also can be shapes such as quadrangle, octangle except circle.
The material of part main body 2 is not particularly limited, and in this example, is made of conductivity magnetic materials such as soft magnetic metals such as Mn-Zn ferrite, permalloy, metal dust stampings.
CoatingIn this example, as shown in Figure 1, coating 3 has and is positioned at by the top layer 3b of overlay film face side with than the structure of this top layer la m 3a in the inner part at the film thickness direction superimposed layer.In Fig. 1, constituted by 2 layers by overlay film, but also can form structure more than 3 layers, for example also can between la m 3a and top layer 3b, form different layers.
La m 3a and top layer 3b comprise glass ingredient, as described below, film in the inboard and face side is filmed forms by heat treatment, as glass component, so long as with morphogenetic material of amorphous or the material that forms as sintered glass ceramics, being not particularly limited, for example, also can be the silicon boron glass.Specifically, can be for example lead borosilicate glass, borosilicic acid bismuth glass, zinc borosilicate glass etc.
Again, in this example, the softening point of the glass ingredient that comprises among the 3b of top layer (skin glass composition) is than the softening point height of the glass ingredient that comprises among the la m 3a (la m glass ingredient).By doing like this, filmed in the inboard and face side is filmed in the operation of heat-treating, can effectively prevent being mutually adhered together between the part or being attached to firing furnace and causing the defective of filming or the thickness deviation takes place.But also can prevent effectively that foreign matter from taking place attached to the situation on filming.The softening point of glass ingredient utilizes for example differential thermal analysis method to measure.
And by overlay film (la m 3a and top layer 3b) since vitrifying after the heat treatment can work as the diaphragm of part main body.Also have, in this example, so-called vitrifying is defined as continuous non-crystalline solids film, has the state with the rigidity of crystallization same degree.
Again, the glass ingredient that comprises in by overlay film has under the situation of insulating properties, works as dielectric film, can prevent to be short-circuited between the lead of part main body and coiling.
The softening point of la m glass ingredient preferably more than 300 ℃, below 800 ℃.Again, the softening point of skin glass composition preferably more than 300 ℃, below 920 ℃.Again, the basis of the regulation more than 300 ℃ is that the softening point of most glass ingredients is more than 300 ℃.
Again, the softening point of skin glass composition is advisable for high 30～100 ℃ with the softening point than la m glass ingredient, high 50～80 ℃ then better.This is because if the difference of softening point is too small, then when heat treatment, the glass powder that comprises during face side is filmed (glass ingredient) is excessively softening, and the tendency that is difficult to obtain effect of the present invention is arranged.Otherwise,,, must surpass the heating of the inboard needs of filming then in order to make the face side coated glassization if difference is excessive.
Again, the content that preferably makes ornamental equivalent in the skin glass composition lacks than the content of the ornamental equivalent in the la m glass ingredient.By doing like this, can make the softening point of skin glass composition keep higher temperature, the top layer is composed with anti-plating.As the la m glass ingredient, also can select easily by the material of plating bath etch, so the composition of the glass ingredient of la m is unrestricted, can select only glass ingredient according to the part main body.
Here, so-called ornamental equivalent is the composition in conjunction with reduction that makes the detailed outline structure that is present in the glass structure, if the content of this composition is many, then forms the low tendency of softening point by glass.As ornamental equivalent, in this example, enumerate for example alkali metal oxide (Na
2O, K
2O), alkaline earth oxide (CaO, MgO) etc.
Be advisable with 1～30 micron by the thickness t 3 of overlay film 3,3～20 microns then better.Again, the thickness t 2 of top layer 3b is to be advisable by 1/8～1/2 of overlay film gross thickness (thickness t 2 on the thickness t 1+ top layer of la m), and 1/5～1/3 of its gross thickness is better.Be in the above-mentioned scope by the thickness on the top layer of overlay film by making by overlay film and constituting, can improve above-mentioned effect.
An example to the manufacture method of the coil component of this example describes below.
At first prepare the raw material of the material of constituent part main body 2.As raw material, the material of constituent part main body is under the ferritic situation, as long as use oxides such as iron oxide, zinc oxide.Or also can adopt all cpds that obtains oxide after burning till.
Then the raw material that will prepare and adhesive resin etc. are mixed, and this mixture are shaped to the shape of regulation with known forming method.In this example, be shaped to cylinder type magnetic core shape, obtain the formed body of magnetic core portion 2.Also have, also calcining raw materials as required in order to form the form that is suitable for moulding, also can carry out granulation etc. with raw material pulverizing.Can remove processing of adhesive etc. as required to this formed body again.Then the formed body that obtains is burnt till, obtain sintered body (part main body 2).
In described in the above, to the part main body is that the method that obtains the part main body under the ferritic situation is illustrated, even but the part main body is under the situation of for example permalloy etc., as long as use known raw material, utilizes known method to obtain the part main body and gets final product.
Then use sleeve shown in Figure 2 (barrel) device 100 to form on the surface of the part main body 2 that obtains that film in the inboards that are made of glass ingredient, adhesive resin etc. and face side is filmed.
Sleeve arrangement 100 shown in Figure 2 has cylindrical sleeve 100a cylindric or the polygon prism shape, Kong inside therein, and receiving sleeve container 102, and make it direction (or it is reverse) in arrow A go up rotation freely around its axle center.
Form inlet tube 103 and outlet 104 on the cylindrical sleeve 100a respectively.Can make oven dry enter the inside of cylindrical sleeve 100a from inlet tube 103, discharge the air of cylindrical sleeve inside from outlet 104 with gas.
On the axle core position of the inside of sleeved container 102,, can spray slurries 106 to a plurality of part main bodys 2 that the inside of sleeved container 102 stores from nozzle 105 along direction of principal axis configuration rose 105.Sleeved container 102 rotates on the arrow A direction, so part main body 2 exists with state shown in Figure 2, utilizes the rotation of sleeved container 102 to stir.
Nozzle 105 can be to the group injection slurries 106 of part main body 2.Can freely change the direction of spraying slurries again from nozzle 105.Also have, cylindrical sleeve 100a goes up and connects diagram abridged discharge line, can discharge remaining slurries 106.
Form a plurality of holes that are communicated with outside and inside on the wall of sleeved container 102, the slurries 106 that the below of cylindrical sleeve 100a stores are also invaded the inside of sleeved container 102, part main body 2 can be impregnated in these slurries 106.Again, in oven dry with gas from inlet tube 103 by cylindrical sleeve 100a during, also to the internal flow of sleeved container 102 to outlet 104 circulations.
At first, many part main bodys 2 are contained in the inside of sleeved container shown in Figure 2 102.Make sleeved container 102 rotations then, Yi Bian stir the set of part main body 2, Yi Bian spray (coating) slurries 106 from nozzle 25, film in the formation inboard and face side is filmed.Remaining slurries 106 are discharged by not shown discharge pipe.
Slurries 106 contain as the glass powder of the raw material of above-mentioned glass ingredient, adhesive resin and solvent.The additive that can also contain other.Glass powder will be so long as will constitute the oxide raw material of this glass ingredient or raw materials such as non-oxidized substance such as halide are mixed, fusion, chilling form the amorphous state powder and get final product.As glass powder, also can use sintered glass ceramics again.In this example, glass powder uses pyrex.The average grain diameter of glass powder (medium particle diameter) does not limit especially, preferably more than 0.1 μ m, in the following scope of 10 μ m.
The adhesive resin that contains in the slurries 106 preferably uses the mixture of polyvinyl alcohol (PVA), polyvinyl alcohol resin sex change body or these resins.By such operation, particularly film in the inboard, the close property excellence of itself and part main body 2.
Again, with respect to the glass powder in this slurries 106, the content of adhesive resin is advisable with 10～40 weight %, and 15～25 weight % are then desirable more.
Solvent is preferably moisture.Solvent also can be a water, when but the contact angle of the surface of glass powder and water is big, by with certain proportion mixed ethanol, isopropyl alcohol (IPA), isobutanol water-soluble alcohols such as (IBA), can suppress the aggegation and the sedimentation of glass powder, be desirable method.
In this example, spraying during slurries 106 on part main body 2 in the early stage and latter stage, changes the glass powder that comprises in the slurries 106.Specifically, add the glass powder that should comprise in inboard the filming in the slurries in the early stage,, then in slurries 106, add the glass powder that face side should comprise in filming in latter stage.That is to say, change glass powder, so that the softening point of the glass powder that face side comprises in filming is higher than the softening point of the glass powder that comprises in inboard the filming.
By doing like this, can on the surface of part main body 2, form the inboard that comprises the different glass powder of softening point film and face side film.
Also have, the different glass powder of softening point also can change the kind of glass powder to be made.The diverse situation of glass powder has the different situation of the such glass of lead glass and bismuth glass itself, and the amount or the diverse situation of additive (for example ornamental equivalent) also arranged.
From the qualification especially of processing time of nozzle 105 spraying slurries 106, for example can be about 30～180 minutes.Also have, the time of replacing the glass powder in the slurries gets final product according to the la m 3a of formation and the thickness decision of top layer 3b.
Again, the temperature of slurries 106 also has relation with solvent composition during spraying, preferably more than 40 ℃ below 100 ℃.Under the situation of using low-boiling solvent, preferably in the said temperature scope, adopt lower temperature.
Then, simultaneously film (film in the inboard and face side is filmed) dried processing while spray slurries 106.During oven dry is handled, make oven dry, discharge from outlet 104 with the inside of gas from inlet tube 103 inflow cylindrical sleeve 100a.Oven dry gas that this oven dry is used in handling is the air of 50～100 ℃ of temperature for example.Can carry out for example 5～30 minutes oven dry again after spray treatment again handles.
Adopt said method once on the surface of a large amount of part main bodys 2, roughly to be formed uniformly by overlay film.
After oven dry is handled, the part main body 2 that formation is filmed is taken out from sleeved container 102, heat-treat.The decisions such as softening point of the glass powder that contains during heat-treat condition is filmed according to the inboard and face side is filmed.In this example, with the softening point height of the glass powder (la m glass ingredient) that comprises in filming than the inboard, and the low temperature of softening point of the glass powder (skin glass composition) that comprises in filming of specific surface side is heat-treated.Specifically, preferably 600～800 ℃ of heat treatment temperatures, heat treatment time is 5～30 minutes.
Can think that by doing like this, it is whole or the face side surface of filming is not softening at least that face side is filmed, or only reach softening initial stage (state that the viscosity of filming is lower).Consequently, can effectively prevent and be mutually adhered together between the part or be attached to firing furnace and cause the defective of filming or the thickness deviation takes place.But also can prevent effectively that foreign matter from taking place attached to the situation on filming.
And,, can confirm also the same vitrifying with the inner glass composition and the curing after heat treatment of skin glass composition though its reason may not be clear.This is considered to because be subjected to the vitrified influence of la m.
Heat treatment is preferably burnt till under the nitrogen atmosphere of partial pressure of oxygen below 0.1%.This is because by reducing partial pressure of oxygen, under the situation that for example the part main body is made of the Mn-Zn based ferrite, can prevent the oxidation of part main body.In case the oxidation of Mn-Zn based ferrite just forms di-iron trioxide (hematite), causes deterioration in characteristics.Again, the Ni-Zn based ferrite is also because there is the problem of oxidation in the relation of forming.
After the heat treatment, form vitrifiedly on the surface of part main body 2, obtain the cylindrical shape magnetic core by overlay film 3 (la m 3a and top layer 3b).
As shown in Figure 3, on the end face of a blade of a sword portion 5 of each part main body 2 with methods such as printing, duplicating, dipping, sputter, platings form the pair of terminal electrode 12 that by silver, titanium, nickel, chromium, copper etc. constitute thereafter.Even part main body 2 has conductivity, terminal electrode 12 is also owing to being insulated by the existence of overlay film 3.
, around wireline reel 4 coiling leads 30, the two ends of this lead with welding methods such as thermo-compressed, ultrasonic bonding, laser welding, method for welding etc. respectively be connected in terminal electrode 12, finish the making of the coil component of the present invention's one example thereafter.
The 2nd exampleIn this example, except replacing the skin glass composition, the top layer contain fusing point than the high crystalline material of the softening point of inner glass composition outside, identical with the 1st example, repeat specification is omitted.
By doing like this, can think that in heat treatment step the surface whole or particle of crystalline material at least of the particle of the crystalline material that comprises during face side is filmed is not melted, or only reach the state of the initial stage (hardness of particle has some to reduce) of fusing.Consequently, can effectively prevent and be mutually adhered together between the part or be attached to firing furnace and cause the defective of filming or the thickness deviation takes place.But also can prevent effectively that foreign matter from taking place attached to the situation on filming.
Again, the fusing point of crystalline material preferably is set at higher more than 30 ℃ than the softening point of inner glass composition.If because the difference of softening point is too small, then the fusing of crystalline material is excessive.
As such crystalline material, as long as have the fusing point higher, be not particularly limited, but preferably described crystalline material is select in pottery, metal and this group material of alloy at least a than the softening point of inner glass composition.
As ceramic material, for example aluminium oxide, zirconia, magnesium oxide, mullite etc. are arranged.Crystalline material comprises under the situation of pottery, can also improve insulating properties and abrasion performance except above-mentioned effect, can make the ion migration be not easy to take place simultaneously.
As metal, can enumerate for example gold, platinum, silver, copper, nickel etc.Can enumerate for example molybdenum alloy, nickel alloy, copper alloy etc. as alloy.Make the part main body have insulating properties, crystalline material comprises under the situation of metal or alloy, except having above-mentioned effect, can also prevent the generation of static.
The crystalline material that comprises in the top layer also can form the solid film on the whole surface that covers la m 3a, but in this example, as shown in Figure 4, the particle of crystalline material is present in as point on the surface of la m 3a, forms top layer 3c.
That is to say that in the top layer, the particle of crystalline material needn't have no to exist with gap, as long as shown in Figure 4, there is the formation top layer in the crystalline material particle in the mode of point, just can access effect of the present invention.And can be as shown in Figure 4, the particle of crystalline material exists highlightedly from la m 3a.
Also have, the particle of crystalline material and la m can clearly be distinguished and come in Fig. 4, and for example still also can have all there are the indefinite situation in its border in particle and la m with transparent state.
The same by the thickness of overlay film 3 with the 1st example, be advisable with 1～30 micron, 3～20 microns are then desirable more.Again, the particle diameter of the crystalline material that comprises in the top layer is to be advisable by 1/8～1/2 of the gross thickness of overlay film (particle diameter of the thickness+crystalline material of la m), and 1/5～1/3 better.The particle diameter that makes crystalline material can improve above-mentioned effect in above-mentioned scope.
In this example, can use the method identical with the 1st example, on the surface of part main body, form by overlay film (la m and top layer).
That is to say, as long as replace the glass powder that comprises in the top layer in the 1st example, in slurries, add the particle of above-mentioned crystalline material, make heat treatment temperature, and make it fusing point than crystalline material is low and get final product than the softening point height of the glass component that comprises in the la m.Owing to do like this, the particle of crystalline material does not melt in heat treatment step, and therefore crystalline material exists with graininess in the top layer.
Specifically, preferably heat treatment temperature is 500～850 ℃, and heat treatment time is 5～30 minutes.
Can think that owing to do like this, does not melt on the surface whole or crystalline material particle at least of crystalline material particle, or just reach the initial stage (state that the hardness of particle is low slightly) of fusion.Consequently, can effectively prevent and be mutually adhered together between the part or be attached to firing furnace and cause the defective of filming or the situation of thickness deviation takes place.But also can prevent effectively that foreign matter from taking place attached to the situation on filming.
The 3rd exampleIn above-mentioned example, by overlay film with 2 layers of formation, but also can be as shown in Figure 5, with formation more than 3 layers.In this example, la m constitutes with 2 layers (the 1st la m 3a and the 2nd la m 3b), except formation is filmed, the mechanical strength that the mechanical strength of filming in the 2nd inboard that makes the 1st inboard film go up to form is filmed than the 1st inboard that is formed on the part body surfaces greatly outside, the same with the 1st example or the 2nd example, repeat specification is omitted.
Like this, on by the film thickness direction of overlay film, intensity difference is set, make face side the layer strength ratio part main body one side the layer intensity little, with this make face side the layer (the 2nd a la m 3b) work as sacrifice layer.So, even under the situation that part is in contact with one another, there is defective in the 2nd la m 3b (and top layer 3c), also owing to there is high-intensity the 1st la m 3a to stay, can access effect of the present invention.
And if there is the 1st la m to stay, in heat treatment step, the 2nd la m around the defect part or top layer are softening, are obtained repairing by the thin part of overlay film, solidify, and can access more uniformly by overlay film.
As the means that aforesaid intensity difference is set, can enumerate the softening point method higher that for example makes the glass ingredient that comprises in the 2nd la m than the softening point of the glass ingredient that comprises in the 1st la m.That is to say, make the relation of the 1st la m and the 2nd la m, with the la m in the 1st example and identical the getting final product of relation on top layer.
Can when spraying slurries, change the content of adhesive resin again for the formation la m.That is to say that forming the content that increases adhesive resin when film in the 1st inboard, the content that reduces adhesive resin when filming in formation the 2nd inboard gets final product.
Again can be in the kind that changes adhesive resin midway of spraying slurries.For example reduce the molecular weight of the adhesive resin in the 1st la m, the molecular weight that strengthens the adhesive resin in the 2nd la m gets final product.
Again can be at the particle diameter that changes glass powder midway of spraying slurries.Glass powder adopts the powder of specified particle diameter, can control debinding dosage.
Implement means as mentioned above, film in the 1st inboard and the 2nd inboard produces intensity difference between filming, therefore in heat treatment step, film and work as expendable film in the 2nd inboard.
Again, preferably the film ratio of the intensity of filming with the 1st inboard of the 2nd inboard is more than 2 times.By being set at more than 2 times, can improving the 2nd inboard and film as the effect of expendable film.Also have, intensity difference can utilize for example following test determination that grasps.
Grasp test and be will be linked to blade (the replacement blade that the HA-F30 that design cutter (design knife)/コ Network ヨ makes uses) on the force cell) each inboard of vertically forming on the surface by the part main body that is pressed in test usefulness film with and/or on face side films, grasp test, utilize the power of force cell mensuration till expose on the surface of part main body.
Also have, the invention is not restricted to above-mentioned example, within the scope of the invention various changes can be arranged.
For example in above-mentioned example, each border on la m and top layer is clear and definite, but again can be necessarily clear and definite.Slowly change at the composition that makes slurries, form by under the situations such as overlay film, these borders may not be clear and definite.Thereby, as long as by high than part main body one side of the softening point of the face side of overlay film or fusing point by the softening point of overlay film.
Again, as the part main body of utilizing method of the present invention to handle, being not limited to the part main body 2 of coil component, also can be the magnetic core of inductance component such as transformer.Again, the material of magnetic core is not particularly limited, and also can be that for example ferrite, aluminium oxide, iron etc. constitute.And also can be that ceramic laminated chip element, the Nd-Fe of piezo-resistance, thermistor, capacitor, coil etc. is metal magnet etc. with the part that method of the present invention is handled.Example
Further the present invention will be described according to detailed embodiment below.But the invention is not restricted to these embodiment.
In this material powder, add PVA as adhesive resin, granulation forms particle.With this particle extrusion forming, obtain cylindric form forming magnetic core body.
Then, this formed body is burnt till in air and nitrogen atmosphere, obtain part main body as sintered body.Part main body 2, the diameter of its blade of a sword are 3mm, and the thickness of the blade of a sword is 0.25mm, to part main body 2 formation as described below that obtain by overlay film.
At first make the silica-based glass powder of 1.5 microns of 740 ℃ of average grain diameters of softening point, with the regulation weight ratio with this glass powder and PVA mixed with resin.Again the solid state component that obtains (glass powder with PVA mixture) is mixed with the weight ratio of regulation with solvent, carry out 16 hours ball milling mixing, prepare the 1st slurries.Solvent employing water and ethanol are with the solution of 8: 2 mixed.With respect to the glass powder in the 1st slurries, the content of adhesive resin is 17 weight %.The softening point of filming that utilizes the 1st slurries to form is 740 ℃.
Again, except with respect to glass powder, the content of adhesive resin is outside the 8 weight %, makes the 2nd slurries with the 1st slurries the samely.The softening point of filming that utilizes the 2nd slurries to form is 740 ℃.
Also make the silica-based glass powder of 780 ℃ of softening points, 1.0 microns of average grain diameters, except with respect to glass powder, the content of adhesive resin is outside the 10 weight %, makes the top layer slurries with the 1st slurries the samely.Utilizing the top layer is 780 ℃ with the softening point of filming that slurries form, and compares highly 40 ℃ with the 2nd slurries with the 1st slurries, confirms high 30～100 ℃.
Then using sleeve (barrel) device, carry out spray treatment on the surface of part main body 2 with above-mentioned the 1st slurries, films in the 1st inboard that forms 10 microns of thickness.Then use the 2nd slurries to carry out spray treatment, forming thickness with this is to film in 10 microns the 2nd inboard.Then utilize the top layer to carry out spray treatment with slurries again, the formation thickness is that 5 microns face side is filmed.That is to say that the gross thickness of filming is 25 microns.
To 1000 part main bodys 2, there is the number of the part main body 2 of the defective (matrix visual defects) that can see on the surface that utilizes visual means to investigate part main body 2.The incidence that the part main body 2 of matrix visual defects is arranged is 0.0%.Utilize again grasp the 1st inboard that test obtains film the ratio of the film-strength (before the heat treatment) of filming with respect to the 2nd inboard be 2.0 times, more than 2 times.
760 ℃ part main bodys 2 that formation filmed carry out 1 hour heat treatment thereafter.Its treatment temperature is than inboard softening point (740 ℃) height of filming, and the temperature of the softening point that the specific surface side is filmed (780 ℃) is low.
Again to the part main body 2 of similar number measure after the heat treatments by the thickness deviation of overlay film, with respect to 10 microns of average film thickness, the standard deviation of expression thickness deviation is 0.90, confirms that the deviation of thickness is also little.
Again to the part main body 2 of same number measure after the heat treatments by the adhering to of foreign matters such as dust on the overlay film, the ratio that is observed the part that foreign matter adheres to is 0.1%, it is few to confirm that foreign matter adheres to.
Embodiment 2Except making, use the top layer slurries, make the softening point that utilizes the top layer to film with the face side of slurries formation is outside 850 ℃, the same with embodiment 1, forms on a plurality of part main bodys 2 and films, the incidence of investigation matrix visual defects.The incidence that the part main body 2 of matrix visual defects is arranged is 0.0%.With embodiment 1 the same part main body that formation filmed heat-treat thereafter.
Also have, have the softening point different with embodiment 1 in order to make it, the top layer is with slurries manufacturing as described below.Promptly, reduce the addition of the ornamental equivalent (alkali metal oxide or alkaline earth oxide) in the glass ingredient, the slurries that obtain are like this used with slurries as the top layer the 2nd slurries.
Again to part main body 2 measure after the heat treatments by the thickness deviation of overlay film, with respect to 10 microns of average film thickness, the standard deviation of expression thickness deviation is 0.93, confirms that the deviation of thickness is little.
Again to part main body 2 measure after the heat treatments by the adhering to of foreign matters such as dust on the overlay film, the ratio that is observed the part that foreign matter adheres to is 0.1%, it is few to confirm that foreign matter adheres to.
Comparative example 1Do not use the top layer with slurries and the 2nd slurries, only with the 1st slurries, only form the 1st inboard and film on the surface of part main body 2, the same with embodiment 1 in addition, the incidence of investigation matrix visual defects is then with embodiment 1 the same heat-treating.The incidence that the part main body 2 of matrix visual defects is arranged is 2.2%.
Utilize under the state before heat treatment again and grasp the coating strength of filming in pilot survey the 1st inboard, the result is 28N.Utilize after heat treatment again and grasp the film-strength of filming in pilot survey the 1st inboard, the result is 32N.
Again to part main body 2 measure after the heat treatments by the thickness deviation of overlay film, with respect to 10 microns of average film thickness, the standard deviation of expression thickness deviation is 2.8, confirms that the thickness deviation is big.
Again to part main body 2 measure after the heat treatments by the adhering to of foreign matters such as dust on the overlay film, the ratio that is observed the part that foreign matter adheres to is 70%, confirms that foreign matter adheres to many.
Comparative example 2Do not use the top layer with slurries and the 1st slurries, only with the 2nd slurries, form the 2nd inboard on the surface of part main body 2 and film, the same with embodiment 1 in addition, the incidence of investigation matrix visual defects is then with embodiment 1 the same heat-treating.The incidence that the part main body 2 of matrix visual defects is arranged is 20.7%.
Utilize under the state before heat treatment again and grasp the coating strength of filming in pilot survey the 2nd inboard, the result is 14N.Utilize after heat treatment again and grasp the film-strength of filming in pilot survey the 2nd inboard, the result is 35N.
The thickness deviation of being filmed in the 2nd inboard after the 2 mensuration heat treatments of part main body with respect to 10 microns of average film thickness, represents that the standard deviation of thickness deviation is 2.2 again, confirms that the deviation of thickness is big.
Again part main body 2 is measured the 2nd inboard after the heat treatments and film and go up adhering to of foreign matters such as dust, the ratio that is observed the part that foreign matter adheres to is 70%, confirms that foreign matter adheres to many.
Comparative example 3Except making, use the top layer slurries, making the softening point that utilizes the top layer to film with the face side of slurries formation is outside 680 ℃, the same with embodiment 1, forms on the part main body and films, the incidence of investigation matrix visual defects is then with embodiment 1 the same heat-treating.The incidence that the part main body 2 of matrix visual defects is arranged is 92%.
Utilize under the state before heat treatment again and grasp pilot survey by the coating strength of overlay film, the result is 28N.Utilize after burning till again and grasp pilot survey by the coating strength of overlay film, the result is 22N.
Again to part main body 2 measure after the heat treatments by the thickness deviation of overlay film, with respect to 10 microns of average film thickness, the standard deviation of expression thickness deviation is 5.8, confirms that the deviation of thickness is big.
Again to part main body 2 measure after the heat treatments by the adhering to of foreign matters such as dust on the overlay film, the ratio that is observed the part that foreign matter adheres to is 100%, confirms that foreign matter adheres to many.
Embodiment 3Replace the top layer with the silica-based glass powder that comprises in the slurries, use alumina powder, change the following stated condition as crystalline material, the same with embodiment 1 in addition, on a plurality of part main bodys 2, form and film, investigation matrix visual defects incidence.The incidence that the part main body 2 of matrix visual defects is arranged is 0.0%.Heat-treat with the embodiment 1 the same part main body that formation is filmed then.
Also have, the particle diameter of aluminium oxide is 0.4 trifling, and fusing point is about 2020 ℃.Again, with in the slurries, the ratio of alumina powder is 5 weight % on the top layer, and with respect to alumina powder, the content of adhesive resin is 5 weight %.
Again to part main body 2 measure after the heat treatments by the thickness deviation of overlay film, with respect to 10 microns of average film thickness, the standard deviation of expression thickness deviation is 0.93, confirms that the thickness deviation is little.
Again to part main body 2 measure after the heat treatments by the adhering to of foreign matters such as dust on the overlay film, the ratio that is observed the part that foreign matter adheres to is 0.1%, it is few to confirm that foreign matter adheres to.
Also use sweep electron microscope (SEM) to observe by near the top layer of overlay film, as shown in Figure 4, confirming has alumina particle to exist with point-like in face side, constitutes the top layer.
Claims (10)
1. electronic component, have the part main body and be formed on the described part body surfaces by overlay film, it is characterized in that,
Described by overlay film have at least be present in described by the top layer of the face side of overlay film be present in the la m of this inboard, top layer,
The softening point of skin glass composition that is contained in described top layer is than the softening point height of the la m glass ingredient that is contained in described la m.
2. electronic component according to claim 1 is characterized in that, at the softening point height than described la m glass ingredient, and the temperature lower than the softening point of described skin glass composition forms described by overlay film.
3. electronic component according to claim 1 and 2 is characterized in that, the content of the ornamental equivalent in the described skin glass composition is littler than the content of the ornamental equivalent in the described la m glass ingredient.
4. electronic component according to claim 1 and 2 is characterized in that, the softening point of described skin glass composition is higher 50～100 ℃ than the softening point of described la m glass ingredient.
5. electronic component according to claim 1 and 2 is characterized in that, the thickness on described top layer described by 1/8～1/2 scope of the gross thickness of overlay film in.
6. electronic component, have the part main body and be formed on the described part body surfaces by overlay film, it is characterized in that,
Described by overlay film have at least be present in described by the top layer of the face side of overlay film be present in the la m of this inboard, top layer,
The fusing point of crystalline material that is contained in described top layer is than the softening point height of the la m glass ingredient that is contained in described la m.
7. electronic component according to claim 6 is characterized in that, at the softening point height than described la m glass ingredient, and forms described by overlay film than the low-melting temperature of described crystalline material.
8. according to claim 6 or 7 described electronic components, it is characterized in that described crystalline material is select in pottery, metal and this group material of alloy at least a.
9. according to claim 6 or 7 described electronic components, it is characterized in that the fusing point of described crystalline material is higher more than 30 ℃ than the softening point of described la m glass ingredient.
10. according to claim 6 or 7 described electronic components, it is characterized in that, the particle diameter of described crystalline material described by 1/8～1/2 scope of the gross thickness of overlay film in.
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| CN105023743A (en) * | 2015-07-29 | 2015-11-04 | 深圳顺络电子股份有限公司 | Manufacturing method of composite-structure iron powder core green body and manufacturing method of composite-structure iron powder core |
| CN114845860A (en) * | 2019-11-29 | 2022-08-02 | 大日本印刷株式会社 | Laminate, method for producing laminate, film for lamination, and image display device |
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| JP2014216495A (en) * | 2013-04-25 | 2014-11-17 | Tdk株式会社 | Soft magnetic material composition, magnetic core, coil type electronic component, and process of manufacturing compact |
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| CN114845860B (en) * | 2019-11-29 | 2024-04-23 | 大日本印刷株式会社 | Laminate, method for producing laminate, film for lamination, and image display device |
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| CN101944429B (en) | 2014-06-04 |
| JP4888530B2 (en) | 2012-02-29 |
| JP2011014845A (en) | 2011-01-20 |
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