CN103366945B - The manufacture method of multiphase inductor is installed in face - Google Patents

The manufacture method of multiphase inductor is installed in face Download PDF

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Publication number
CN103366945B
CN103366945B CN201310105411.2A CN201310105411A CN103366945B CN 103366945 B CN103366945 B CN 103366945B CN 201310105411 A CN201310105411 A CN 201310105411A CN 103366945 B CN103366945 B CN 103366945B
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China
Prior art keywords
coil
sheet material
encapsulant
face
core
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CN201310105411.2A
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CN103366945A (en
Inventor
斋藤公
斋藤公一
宗内敬太
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Murata Manufacturing Co Ltd
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Toko Inc
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Priority to CN201610671202.8A priority Critical patent/CN106158293B/en
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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/29Terminals; Tapping arrangements for signal inductances
    • H01F27/292Surface mounted devices
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/02Casings
    • H01F27/022Encapsulation
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/24Magnetic cores
    • H01F27/255Magnetic cores made from particles
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/2847Sheets; Strips
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/32Insulating of coils, windings, or parts thereof
    • H01F27/327Encapsulating or impregnating
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F17/00Fixed inductances of the signal type 
    • H01F17/04Fixed inductances of the signal type  with magnetic core
    • H01F2017/048Fixed inductances of the signal type  with magnetic core with encapsulating core, e.g. made of resin and magnetic powder
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00Details of transformers or inductances, in general
    • H01F27/28Coils; Windings; Conductive connections
    • H01F27/2847Sheets; Strips
    • H01F2027/2857Coil formed from wound foil conductor

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Coils Or Transformers For Communication (AREA)
  • Manufacturing Cores, Coils, And Magnets (AREA)

Abstract

It is an object of the invention to provide a kind of the manufacture method installing multiphase inductor.The face of the present invention is installed the manufacture method of multiphase inductor and is used mould to utilize the encapsulant being mainly made up of resin and magnetic powder to seal multiple coils.Encapsulant is pre-formed into the circumference at writing board shape there is the shape of cylindrical projection and form multiple sheet material.Coiled electrical conductor and form coil.Coil is positioned on sheet material, in the die cavity that the parts that multiple both ends making coil obtain along the outer lateral side extension of the cylindrical projection of sheet material are arranged in mould.State between outer lateral side and the internal face of die cavity of the cylindrical projection that use ester moulding method or powder pressing method are clipped in sheet material with the both ends of coil makes coil and encapsulant integration form core.The outer electrode that the part on the surface being exposed to core at least partially at the both ends being used for coil is connected is arranged on surface or the periphery of core.

Description

The manufacture method of multiphase inductor is installed in face
Technical field
The present invention relates to a kind of the manufacture method installing multiphase inductor.
Background technology
In recent years, produce along with miniaturization, the slimming of digital device etc. is highly dense The development of degree installationization, strengthens the miniaturization of electronic component, the requirement of slimming. Therefore, applicant proposed a kind of small-sized face and inducer and manufacture method thereof be installed, This small-sized face is installed inducer and is employed preformed sheet material material and with flat conductor Flat conductor is wound into swirl shape by the mode pulled out to periphery by two ends Coil.
Patent documentation 1: Japanese Unexamined Patent Publication 2010-245473
Formed can be installed in parallel on circuit boards multiple identical characteristics inducer this In the case of the circuit pattern of sample, compared with multiple single-pieces are installed, make multiple inducer The method being inside located in single encapsulation more can improve installation effectiveness.Therefore, one is sought Multiphase inductor is installed in the face making multiple inducer list encapsulation.
Summary of the invention
The problem that invention is to be solved
Therefore, it is an object of the invention to provide a kind of the system installing multiphase inductor Make method.
For solving the scheme of problem
In order to solve above-mentioned problem, the manufacturer of multiphase inductor is installed in the face of the present invention Method uses mould to utilize the encapsulant being mainly made up of resin and magnetic powder to seal many Individual coil, it has a following operation:
(1) encapsulant is pre-formed into the circumference at writing board shape, and to have column convex The shape in portion and form sheet material;
(2) coiled electrical conductor and form coil;
(3) coil is positioned on sheet material, makes the both ends of coil along sheet by multiple The parts that the outer lateral side of the cylindrical projection of material extends and obtains are arranged in mould A die cavity in;
(4) ester moulding method or powder pressing method is used to press from both sides with the both ends of coil State between outer lateral side and the internal face of die cavity of the cylindrical projection of sheet material makes line Circle is integrated with encapsulant and forms core;
(5) table being exposed to core at least partially at both ends that will be used for coil The outer electrode that the part in face is connected is arranged on surface or the periphery of core.
The effect of invention
The face of the present invention is installed the manufacture method of multiphase inductor and is capable of at circuit board On high-density installation.
In the manufacture method of multiphase inductor is installed in the face of the present invention, it is possible to easily Use sheet material that each coil and end thereof are positioned.Therefore, it is possible to prevent coil And the position skew of end.And, by using multiple coils and corresponding thereto Sheet material, it is possible to tackle the design such as the coiling direction of coil, number, configuration neatly Change.
As encapsulant, main use metal magnetic and resin, utilizing with by it Pcrmeability is set as that the encapsulant that the mode of 10~30 is modulated has made sheet material In the case of, it is possible to make the face peace that the coefficient of coup between coil is set as less than 0.1 Dress multiphase inductor.
Accompanying drawing explanation
Fig. 1 is the axonometric chart of the coil used in embodiments of the invention.
Fig. 2 is to represent the coil used in embodiments of the invention and sheet material and tabular The axonometric chart of the configuration of sheet material.
Fig. 3 is that the coil of the 1st embodiment representing the present invention and sheet material are in mould The top view of configuration.
Fig. 4 is the system that multiphase inductor is installed in the face with the 1st embodiment representing the present invention The sectional view that the A-B-C-D compound section of the Fig. 3 making a part for operation is corresponding.
Fig. 5 is the system that multiphase inductor is installed in the face with the 1st embodiment representing the present invention The sectional view that the A-B-C-D compound section of the Fig. 3 making a part for operation is corresponding.
Fig. 6 is the system that multiphase inductor is installed in the face with the 1st embodiment representing the present invention The sectional view that the A-B-C-D compound section of the Fig. 3 making a part for operation is corresponding.
Fig. 7 is the axonometric chart of the structure of the core of the 1st embodiment representing the present invention.
Fig. 8 is the axonometric chart of the face installation multiphase inductor of the 1st embodiment of the present invention.
Fig. 9 is that the face with other electrode structure in the 1st embodiment of the present invention is installed The axonometric chart of multiphase inductor.
Figure 10 is that the coil of the 2nd embodiment representing the present invention and sheet material are at mould The top view of interior configuration.
Figure 11 is the axonometric chart of the structure of the core of the 2nd embodiment representing the present invention.
Figure 12 is the axonometric chart of the face installation multiphase inductor of the 2nd embodiment of the present invention.
Figure 13 is that multiphase inductor is installed in the face of other the embodiment representing the present invention The axonometric chart of structure.
Figure 14 is that multiphase inductor is installed in the face of other the embodiment representing the present invention The axonometric chart of structure.
Detailed description of the invention
The manufacturer of multiphase inductor is installed in face hereinafter, with reference to the accompanying drawings of the present invention Method.
1st embodiment
Illustrate that with reference to Fig. 1~Fig. 9 many phase inductances are installed in the face of the 1st embodiment of the present invention The manufacture method of device.First, the coil used in embodiments of the invention is described. Fig. 1 represents the axonometric chart of coil used in embodiments of the invention.Such as Fig. 1 institute Show, flat conductor is wound into two-layer in the way of its both ends 1b becomes most peripheral Outer wound form volume (Japanese: outer I) and form winder 1a thus obtain coil 1. End 1b be formed as can by clip winder 1a relative in the way of be drawn out.
Then, the encapsulant used in embodiments of the invention is described.In this reality Execute in example, as encapsulant, employ and ferrous metal magnetic powder and epoxy resin are mixed Merge the encapsulant being a granulated into powder and obtain.In the present embodiment, have adjusted The loading of ferrous metal magnetic powder, so that the pcrmeability of encapsulant reaches 25.Use This encapsulant makes sheet material.Fig. 2 represents the coil of the 1st embodiment and sheet material and plate The configuration relation of shape sheet material.Sheet material 2 and tabular sheet material 3 utilize extrusion forming to make.? In the present embodiment, in order to improve the intensity of sheet material 2, carry out heat treatment further thus incite somebody to action Semi-hardened state made by encapsulant.As in figure 2 it is shown, sheet material 2 is to surround the side of coil 1 Formula is formed as the shape at the periphery of planar portions with two cylindrical projection 2a.Coil 1 Both ends 1b by along the outer lateral side of cylindrical projection 2a extension in the way of configure.
Then, being arranged in into sheet material by coil of manufacture method of the 1st embodiment is described Operation in mould.Fig. 3 and Fig. 4 represents the coil in mould and sheet material Configuration.It addition, Fig. 4 is the section view corresponding with the A-B-C-D compound section of Fig. 3 Figure.As shown in Figure 3 and Figure 4, in the 1st embodiment, use and there is lower mold 6 and by dividing The mould of the mould 4 that pattern 4a and typing mould 4b is constituted.By assembling die 4 He Lower mold 6 forms die cavity 5.Two sheet materials 2 being configured with coil 1 are loaded in die cavity 5. By configuring coil 1 and sheet material 2 in this wise, coil 1 can be by the planar portions of sheet material 2 The suitable height that is arranged in mould of thickness on.And, the end of coil 1 1b become be clipped between cylindrical projection 2a of sheet material 2 and the internal face of typing mould 4a or State between cylindrical projection 2a and the internal face of typing mould 4b of sheet material 2, so that line The both ends 1b of circle 1 can be secured in place.
Then, the operation forming core of the manufacture method of the 1st embodiment is described.Fig. 5 With expression in Fig. 6 for the core forming process of the manufacture method of the 1st embodiment is described Sectional view.It addition, the cross section of Fig. 5 with Fig. 6 is relative with the A-B-C-D compound section of Fig. 3 Should.As it is shown in figure 5, configure two tabular sheet materials 3 on coil 1 and sheet material 2, at plate Multipart punch 7 on shape sheet material 3, and it is preheated to mould.In the present embodiment, will become Mould is preheated to more than the softening temperature of encapsulant, makes sheet material 2 and tabular sheet material 3 Become soft state.
As shown in Figure 6, drift 7 is used to carry out pressurizeing so that two sheet materials 2 and two plates Shape sheet material 3 integration, makes sealing material curing.Now, sheet material 2 and tabular sheet material 3 For soft state, it is possible to easily integration thus two coils are sealed.Additionally, The both ends 1b of coil 1 with will not occur position skew and its be buried at least partially State in encapsulant is sealed.Then, from mould, taking-up makes sealing material The core 8 that material hardens and obtains.As it is shown in fig. 7, become the plane of the end 1b of coil 1 It is exposed to the state on the relative surface of core 8.
Then, this core 8 is carried out blasting treatment and remove the both ends 1b of flash removed and exposure Protecting film, the corner of core 8 utilizes infusion process cover conductive paste be allowed to hard Change.Thus, conductive paste turns on internal coil 1.Finally, electroplating processes is carried out And on the surface of conductive paste, form outer electrode 9, thus obtain the face shown in Fig. 8 Multiphase inductor is installed.As long as it addition, the electrode formed by electroplating processes from Ni, Sn, Cu, Au, Pd etc. suitably select one or more formed.Additionally, also Print process transfer coating conductive paste can be used, so that outer electrode 9 is formed as figure Alphabetical L-shaped shown in 9.
The face that is fabricated in the 1st embodiment tried to achieve install multiphase inductor coil it Between magnetic coupling coefficient be 0.03, the coupling between coil is not recognized.
Additionally, configure two coils 1 in point-symmetric mode in the 1st embodiment.Logical Crossing and configure in this wise, making face install multiphase inductor becomes the directivity not having left and right Structure.
2nd embodiment
Illustrate that the 2nd reality of multiphase inductor is installed in the face of the present invention with reference to Figure 10~Figure 12 Execute example.In the 2nd embodiment, use and the 1st mutually isostructural coil of embodiment, close Closure material, sheet material and identical mould have wrapped three coils in making Multiphase inductor is installed in face.It addition, omit the explanation with the 1st embodiment repeating part.
Figure 10 represents the configuration of the coil in mould and sheet material.Implement the 2nd In example, use identical with the 1st embodiment have lower mold, drift, by typing mould 11 Mould with the mould that typing mould 12 is constituted.Shape is carried out by assembling die and lower mold Become die cavity 13.As shown in Figure 10, the point different from the 1st embodiment is, the 2nd implements Example is provided with on typing mould 11 two protuberance 11a respectively, is provided with two at typing mould 12 Protuberance 12a.Three sheet materials 2 being configured with coil 1 are loaded in die cavity 13.Now, with Protuberance 11a, the 12a of mould mode between adjacent sheet material 2 configures sheet material 2 and Coil.Do so can play the location utilizing protuberance 11a, 12a to improve multiple sheet materials 2 The effect of precision.It addition, in the present embodiment, three coils are with in the same direction Mode in parallel configures and forms.
Then, the encapsulant after weighing is filled further in die cavity 13, is closing Use drift to carry out powder pressing after mould, and be allowed to hardening thus obtain Figure 11 Shown core 14.As shown in figure 11, by protuberance 11a, 12a, core 14 sudden and violent Dew has the side of overhang 1b to become the state being each formed with two recess 14a.
Then, this core 14 is carried out blasting treatment and goes to flash removed and the two ends exposed The protecting film of portion 1b, in order to make core 14 turn on internal coil 1, uses transfer print Brush method coats conductive paste on core 14 and is allowed to harden.Then, carry out at plating Reason forms outer electrode 15 thus obtains the face shown in Figure 12 and install multiphase inductor.As Shown in Figure 12, it is possible to form the external electrical easily split by the recess 14a of core 14 Pole 15.Thus, internal coil becomes and has the outer electrode the most corresponding with it Structure.In the present embodiment, protuberance is set in mould thus has made core The recess in portion, it is also possible to formed by carrying out the excision such processing of core.
The face made in the 2nd embodiment tried to achieve is installed between the coil of multiphase inductor Magnetic coupling coefficient be 0.03, the coupling between coil is not recognized.It addition, Inducer is installed, it is also possible to be in the face having made interior three coils of bag in the present embodiment Coil more than interior bag two or four, as long as being suitably increased or decreased the quantity of recess ?.
Other embodiments
With reference to Figure 13 and Figure 14, other embodiments are described.Figure 13 and Figure 14 represents have one The solid of multiphase inductor is installed in the face of the structure of individual input electrode and multiple output electrode Figure.Install heterogeneous to realize having the face of an input electrode and multiple output electrode Inducer, as shown in figure 13, the only side in the side of core 22 arranges any amount Recess 22a, thus be made and there is an input electrode 23 and multiple output electrode 24 Structure.Or, as shown in figure 14, the end making coil 31 is the most sudden and the most violent It is exposed on core 32, with the side with two ends conductings of the coil 31 being adjacent to exposure Formula forms electrode thus forms input electrode 33, with the end of 31 with other coil The mode of conducting forms output electrode 34 respectively.
In the above-described embodiments, as encapsulant, employ the ferrum as magnetic powder Metalloid magnetic powder, epoxy resin as resin mix, and so that its pcrmeability becomes The encapsulant that the mode of 25 is modulated and obtained.But, it is not limited to this, such as Ferrite class magnetic powder etc. can also be used as magnetic powder or carry out formation insulation protection The magnetic powder of the surface modification such as film, surface oxidation.Further, it is also possible to add glass dust etc. Inorganic matter.And, as resin, it is also possible to use polyimide resin, phenolic aldehyde tree The thermohardening type resins such as fat or the thermoplastic resin such as polyvinyl resin, polyamide.
In the above-described embodiments, as coil, the swirl shape being wound into two-layer is employed Coil, but be not limited to this, be wound into by flat for example, it is also possible to use Coil obtained by vertical winding, usual winding (normal winding), or not Be limited to be wound into ellipse can also be wound into circle, rectangle, trapezoidal, semicircle with And by the coil obtained by the shape of above-mentioned combination of shapes.
In the above-described embodiments, as the painting method of conductive paste, can be from transfer Method, infusion process, perfusion package method etc. suitably select optimal method.
In the above-described embodiments, as the side of protecting film of the end surface peeling off coil Method employs blasting treatment, but is not limited to this, it is also possible to use other machinery The methods such as stripping.In addition it is also possible to forming the guarantor of stripped end in advance before core Cuticula.
1st embodiment employs tabular sheet material, but is not limited to tabular, it is also possible to It is pre-formed into the shapes such as T-shaped, E type.In addition it is also possible to be not unhardened state but Semi-hardened state.And, as long as this manufacturing process can be press molding method or Be the method the most suitably selected with the purposes such as shearing on sheet-like formed thing i.e. Can.
Description of reference numerals
1 coil (1a: winder;1b: end);2 sheet materials;3 plate-like tile Material;4 moulds (4a, 4b: typing mould);5 die cavitys;6 lower molds;7 punchings Head;8 cores;9 outer electrodes;11,12 typing moulds (11a, 12a: Protuberance);13 die cavitys;14 cores;14a recess;15 outer electrodes;21、 31 coils;22,32 core;22a recess;23,33 input electrode; 24,34 output electrode.

Claims (3)

1. a manufacture method for multiphase inductor is installed in face, and many phase inductances are installed in this face Device uses mould to utilize the encapsulant being mainly made up of resin and magnetic powder to seal many Individual coil, wherein,
This face is installed the manufacture method of multiphase inductor and is included following operation:
Hollow coil wire wound in the way of periphery by its two-end part and formed Being placed in the circumference being pre-formed into by this encapsulant at writing board shape, to have column convex The shape in portion and on the sheet material that formed, make the pull-out end of this hollow coil along this sheet The outer lateral side of the cylindrical projection of material extends;
Multiple sheet materials being placed with this hollow coil are arranged in inwall and are provided with the one-tenth of protuberance In a die cavity in mould, the protuberance of this inwall is positioned at and multiple is placed with this hollow The sheet material of coil each other, and, the pull-out end of each hollow coil is to be clipped in Mode between outer lateral side and the internal face of this die cavity of the cylindrical projection of this sheet material is joined Put;
Use ester moulding method or powder pressing method with the pull-out end of this hollow coil Portion is clipped between outer lateral side and the internal face of this die cavity of the cylindrical projection of this sheet material State make multiple hollow coil and the integration of this encapsulant and by multiple hollow coils Putting, the side being formed at least more than one is provided with the core of recess;And
This core it is exposed at least partially by be used for both ends with this hollow coil The outer electrode that is connected of the part on surface be arranged on surface or the periphery of this core.
The most according to claim 1 the manufacture method installing multiphase inductor, Wherein,
In above-mentioned encapsulant,
Above-mentioned magnetic powder is made up of metal magnetic, with the pcrmeability of encapsulant become 10~ The mode of 30 is modulated with above-mentioned encapsulant.
The most according to claim 1 and 2 the manufacturer installing multiphase inductor Method, wherein,
In the operation forming said external electrode,
This outer electrode uses conductive cream.
CN201310105411.2A 2012-03-30 2013-03-28 The manufacture method of multiphase inductor is installed in face Active CN103366945B (en)

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JP2012079239A JP5689091B2 (en) 2012-03-30 2012-03-30 Manufacturing method of surface mount multiphase inductor
JP2012-079239 2012-03-30

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CN106158293B (en) 2018-03-06

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