CN1265404C - Coil packaged magnetic dust core capable of obtaining excellent inductive property and mfg. method thereof - Google Patents
Coil packaged magnetic dust core capable of obtaining excellent inductive property and mfg. method thereof Download PDFInfo
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- CN1265404C CN1265404C CNB031019676A CN03101967A CN1265404C CN 1265404 C CN1265404 C CN 1265404C CN B031019676 A CNB031019676 A CN B031019676A CN 03101967 A CN03101967 A CN 03101967A CN 1265404 C CN1265404 C CN 1265404C
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Abstract
A coil packaged magnetic dust core capable of obtaining excellent inductive property and manufacture method thereof, a coil packaged magnetic dust core is consisted in a coil 1 twisting by a flat conductor and a dust body composed by ferromagnetism metallics having insulating material coating. The coil 1 contains a twist wiring part 3 and terminals 4a, 4b outbounded from the twist wiring part 3, the twist wiring part 3 is twisted by a flat conductor having opposite up and down surface in a predetermined distance. The outlet terminal 4a and 4b separatedly on either surface of up and down surface is on the same surface. Two terminals (outlet terminal 4a, 4b) of the coil 1 are in one surface, so the coil packaged magnetic dust core capable of obtaining excellent inductive property and realizes miniaturization.
Description
Technical field
The present invention is relevant for the manufacture method of the integrated inductor of magnetic core, the coil packaged type compressed-core that is used for other electronic units and coil packaged type compressed-core.
Background technology
In recent years, along with the miniaturization development of electric electronic Instrument, people are grown to even greater heights to the demand of the compressed-core of miniaturization (low clearance), the corresponding big electric current of energy.
Usually adopt the material as compressed-core such as ferrite powder or ferromagnetism metal dust, but because the ferromagnetism metal dust is compared with ferrite powder, saturation flux density is big, still can keep dc superposition characteristic under high-intensity magnetic field.Therefore, when making the compressed-core of corresponding big electric current, select the material of ferromagnetism metal dust mostly for use as compressed-core.
In addition, be to promote the further miniaturization (low clearance) of magnetic core, the motion that coil and magnetic powder work are integral has been arranged.Inductor with this structure in these claims is called coil packaged type compressed-core.
Present someone has proposed the manufacture method of surperficial real dress type inductor, and this sensing apparatus has coil packaged type compressed-core structure.For example, the spy opens flat 5-291046 communique and proposes, and insulated conductor is linked to each other with outer electrode, with Magnaglo this is encased and moulding.In this case because the wiring part in magnetic, is very easy to produce bad during shaping operation.In these claims, so-called wiring is meant, the part that is electrically connected between electronic unit partly calls portion of terminal to outer electrode and wiring.
Te Kaiping 11-273980 communique proposes, adopt binder with flat powder with the coil compression molding.In implementing example, make composite material with state than the silicone resin that is 20 the Fe-Al-Si alloy powder and the usefulness that insulate earlier, again with the coil compression molding.Wiring about coil and portion of terminal does not partly have to record and narrate, but relatively more difficult with electrode in the surface of magnetic core connection magnetic part, and bad connection takes place easily.
In addition, in No. 2958807 communique of patent, announced the method that adopts ferrite to make inductor as magnetic material.Here also be, because the part of the terminal that links to each other with coil is easy to generate bad in magnetic core inside in the coupling part when one-body molded.The manufacture method of inductor is in No. 3108931 communique of patent, and coil and portion of terminal clip compression forming up and down by the press-powder body, and this is easy to generate bad in the coupling part too.
Invent problem to be solved
As preceding described, the structure of coil packaged type compressed-core is miniaturization and can obtains big inductance.Yet it is, also more and more higher to the quality requirements of coil packaged type compressed-core along with developing rapidly of electric instrument miniaturization.To prevent exactly particularly coil and portion of terminal bad connection, prevent between coil and portion of terminal and magnetic powder defective insulation, want further miniaturization, obtain bigger inductance.
Above-mentioned spy opens flat 5-291046 communique, the spy opens coil packaged type compressed-core or the inductor described in flat 11-273980 communique, No. 2958807 communique of patent, No. 3108931 communique of patent, and the leeway of improvement is all arranged aspect quality.Promptly, Te Kaiping 5-291046 communique, spy open coil packaged type compressed-core or the inductor described in flat 11-273980 communique, No. 2958807 communique of patent, No. 3108931 communique of patent, owing to all adopted the way in coil and the portion of terminal inclosure magnetic powder, bad connection, coil and the portion of terminal of coil and portion of terminal and the defective insulation between the magnetic powder taken place easily.When bad connection or defective insulation took place, because coil and portion of terminal connect in magnetic powder inside, poor prognostic cause was difficult to determine, will ascertains the reason simultaneously also very time-consuming.
In addition, at the inductor described in No. 3108931 communique of patent, owing to adopted coil prior and that portion of terminal connects to make compressed-core, the coupling part of coil and terminal very easily produces bad connection after the moulding.When producing bad connection, determine that reason is very difficult and time-consuming in the coupling part.
Summary of the invention
Therefore, in view of above-mentioned some, the present invention aim to provide the defective insulation of the bad connection that can reduce coil and portion of terminal or coil and portion of terminal and magnetic powder generation, and can realize coil packaged type compressed-core of further miniaturization, the bigger inductance of acquisition and preparation method thereof.
The method of dealing with problems
The present inventor thinks, flat conductor is entwined by adopting, two end faces coil at grade, when can realize the further miniaturization of coil packaged type compressed-core, also can obtain bigger inductance.The feature that is coil packaged type compressed-core provided by the present invention is: the winding section of coil is to be entwined by the strap that has relative upper and lower surface according to the rules at interval, and draw end 1,2 from the different parts of conductor winding section, coil insulate simultaneously.The press-powder body that potted coil is used is made up of the ferromagnetism metallic of insulation.In the wherein one side of the upper and lower surface of end 1 and the upper and lower surface of end 2 wherein one side will be at grade.
In coil packaged type compressed-core involved in the present invention, conductor can be the line style with rectangular cross section.In addition above-mentioned end 1,2 partly or entirely preferably carried out punch process.And similar parallel the drawing of above-mentioned end 1,2 best conductors with the winding section.Also have in coil packaged type compressed-core involved in the present invention, at least one end of end 1,2 with want and the winding section between the bending of formation certain angle.I.e. bending by certain angle can place two ends of coil on the same plane.In addition, the ferromagnetism metallic of formation press-powder body preferably Fe-Ni is an alloy, because Fe-Ni is the good processability of alloy.If adopt Fe-Ni be alloy as press-powder body ferromagnetism metallic, under lower pressure, just can make the press-powder body.
Moreover in coil packaged type compressed-core provided by the present invention constituted, the press-powder body was made of the ferromagnetism metallic that the insulating compound coating is arranged, and the coil that encapsulates in the press-powder body is an insulated coil.The winding section of coil is entwined by the strap of insulation, draws pair of terminal from the winding section conductor again.From fixed datum level nearly equal to the distance of pair of terminal.Here fixed datum level can be the middle level of orlop, the superiors or the winding section of winding section.Also have in coil packaged type compressed-core involved in the present invention, desirable structure is the outside that partly or entirely preferably is exposed at the press-powder body of pair of terminal.Can connect in the external realization of press-powder like this, reduce the generation of bad connection and defective insulation.In addition, in coil packaged type compressed-core involved in the present invention, pair of terminal is preferably drawn from the different directions of conductor winding section, and the part of pair of terminal can also be done widely than other positions of coil.
In addition, the manufacture method feature of coil packaged type compressed-core provided by the present invention is: operation (a) is that primary raw material powder soft magnetic metal powder and the insulating compound with the press-powder body is filled in the mold slots.Operation (b) is that the coil that the insulation strap is wound in is put in the mold slots of filling material powder.Operation (c) continues to fill material powder until covering coil in mold slots.Operation (d) is that material powder is compressed sealing.Here the Fe-Ni series alloy powder is effective press-powder body soft magnetic metal powder.Because the good processability of Fe-Ni series alloy powder compresses sealing easily, it is injury-free and obtain coil packaged type compressed-core to guarantee to be embedded in coil in the material powder.In coil packaged type compressed-core involved in the present invention, the winding section that coil is entwined at interval according to the rules by the strap with relative upper and lower surface and constitute from the terminal 1,2 that the different parts of conductor winding section is drawn, and any one side of drawing in the upper and lower surface at 1 place, end is in the same plane with any one side of drawing in the 2 place's upper and lower surfaces of end.After finishing above-mentioned operation (d), overhang 1,2 is carried out bending operation (e) along the press-powder body.Bending operation (e) is in that coil packaged type compressed-core is adorned the terminal time spent in fact as the surface, and is effective especially.Also have, in operation (b), it would be desirable all or part of mold slots outside that places end winding 1,2.Because the function of end winding 1,2 is to use as portion of terminal, the words that are placed on external connection of press-powder can reduce bad connection.
In addition, coil feature provided by the present invention is, the winding section is to be entwined by the strap with relative upper and lower surface, and end 1,2 is drawn by the diverse location of conductor winding section, and any one side of any one side of end 1 place's upper and lower surface and end 2 place's upper and lower surfaces at grade.It would be desirable that in this coil end 1,2 is that benchmark is drawn from symmetric position with the winding section.Because when operating coil, need not distinguish direction like this.
In addition, the making feature of coil is among the present invention, obtains to have the winding around of pair of terminal by operation (f), pressurizes to the coil terminals portion that obtains by operation (f), under pressurized state or add pressure and carry out school shape treatment process (g) at once.In operation (g), portion of terminal can be processed into rectangular shape and wideer than other parts of coil.Coil manufacture method involved in the present invention can reduce coil and make required operation because punch process and the processing of school shape are almost carried out simultaneously.In addition, in school shape treatment process (g) or before and after it, can also carry out the Bending Processing operation of one or two terminal, make to decide the distance of datum level to two terminal nearly equal.
Description of drawings
Fig. 1 is the profile of the coil packaged type compressed-core in the present embodiment.
Fig. 2 is the front view of used coil in the present embodiment.
Fig. 3 is the end view of used coil in the present embodiment.
Fig. 4 be strap before coiling cross sectional shape and reel after cross sectional shape.
Fig. 5 is the coil production process flow chart in the present embodiment.
Fig. 6 is the winding process key diagram.
Fig. 7 is the forming process key diagram.
Fig. 8 is punch process specification figure.
Fig. 9 is a bending operation key diagram.
Figure 10 is the coil packaged type compressed-core production process flow chart in the present embodiment.
Figure 11 is Figure 10 S206 step forming process key diagram.
Figure 12 draws the not forming process key diagram during at grade coil of end for adopting.
The drawing reference numeral explanation
1-coil 2-conductor 3- winding section 4a, 4b-draw end (portion of terminal 100) 4c-sweep 10-press-powder body 20-mixed-powder
Embodiment
Below, based on embodiment shown in the drawings, carry out detailed description of the present invention.
Fig. 1 is the profile of coil packaged type compressed-core in the present embodiment.Fig. 2 is the front view of used coil 1 in the present embodiment, and Fig. 3 is the end view of coil 1.Except end 4a, the 4b of coil 1, the press-powder body covers around it.In addition, the back has detailed description, because draw end 4a, the 4b of coil 1 use as portion of terminal 100, coil 1 is exactly so-called terminal integral structure in the present embodiment.
At first, press-powder body 10 is described.
Press-powder body 10 is to add insulating material in the magnetropism metal dust to mix, add under certain conditions and be pressed into.Preferably will add the ferromagnetism metal dust drying of insulating material in addition, and then in the Magnaglo of drying, added mix lubricant.
The ferromagnetism metal dust that is used for press-powder body 10 can be that the metal dust of single metal dust, two or more heterogeneities mixes or alloy powder.Metal dust can be made up of the optional intermediate metallic element of soft magnetism, also can be by the alloy composition of transition metal and other metallic elements.Object lesson as soft magnetic metal, with in Fe, Co, three kinds of compositions of Ni more than one is the alloy of main component, only as, permalloy (Fe-Ni alloy, Fe-Ni-Mo alloy), ferromagnetism sendust (Fe-Si-Al alloy), Fe-Si alloy, Fe-Co alloy, Fe-P alloy etc.Wherein owing to permalloy magnetic susceptibility height and good processability, so very desirable.
When the ferromagnetism metal dust of employing Fe-Ni alloy (permalloy) used as the press-powder body, the composition ratio was: Fe:15~60wt%, Ni:40~85wt%.When adopting the ferromagnetism metal dust of Fe-Ni-Mo alloy (permalloy) to use as the press-powder body in addition, the composition ratio is: Fe:15~30wt%, Ni:70~85wt%, Mo:1~5wt%.
Shape to the ferromagnetism metal powder particles that is used as press-powder body 10 has no particular limits, but for guaranteeing the big inductance under the high-intensity magnetic field, preferably powder is made glomeration or ellipticity.
The ferromagnetism metal dust can be made by vapour spray-on process, water spray method, rotary disk method.
In addition, by adding insulating material, the ferromagnetism metal dust has just had insulating coating.Insulating material will suitably be selected according to needed magnetic core characteristic.All wait as various organic polymer resins, silicone resin, phenolic resin, epoxy resin, waterglass to be used as insulating material, and these resins can also and the inorganic matter matched combined use.
Needed magnetic core characteristic difference, the addition of insulating material are also different, and the interpolation scope is 1~10wt%.The addition one of insulating material surpasses 10wt%, and magnetic susceptibility will reduce, lose increasing.On the other hand, when the addition of insulating material is discontented with 1wt%, may produce defective insulation.The desirable addition of insulating material is 1.5~5wt%.
The addition of lubricant can be controlled at 0.1~1.0wt%, and desirable addition scope is 0.2~0.8wt%, preferably 0.3~0.8wt%.During the addition of lubricant is not enough 0.1wt%, the off-type difficulty after the shaping is easy to generate the shaping crackle.On the other hand, when the addition of lubricant surpasses 1.0wt%, can cause density reduction, magnetic susceptibility to reduce.
Lubricant can suitably be selected from aluminum stearate, barium stearate, dolomol, calcium stearate, zinc stearate, strontium stearate.Consider from the angle that resilience is little, select aluminum stearate more satisfactory.
In addition, can in the ferromagnetism metal dust, add a certain amount of bridging agent.By adding bridging agent, the magnetic characteristic of the press-powder body 10 that can not weaken also can be gained in strength.With respect to insulating material such as silicone resins, the desirable addition of bridging agent is 10~40wt%.Organic titanate can be used as bridging agent.
Then, with Fig. 2, Fig. 3, the structure of coil 1 is described.
As shown in Figures 2 and 3, coil is that conductor 2 is begun from the edge to form around 2.5 circles.Draw end 4a, the 4b of conductor 2 oppositely draw from the body part of coil.That is, coil 1 is do not have the breakpoint interface integrally formed.
The cross section that constitutes the conductor 2 of coil 1 is pancake.Here, pancake cross section can be a rectangle, trapezoidal, oval, wherein as the conductor 2 of square-section, can adopt the copper cash with rectangular cross section of insulation.When employing had the conductor 2 of rectangular cross-sectional face structure, sectional dimension can be vertical 0.1~1.0mm * horizontal 0.5~5.0mm.
The insulating coating of conductor 2 adopts enamel usually, about the about 3 μ m of coating layer thickness.
When adopting strap 2 to be wound in coil 1, as shown in Figure 3, can realize tight contact between each circle of coil 1, compare, can improve the electric capacity of unit volume with adopting the circular cross-section conductor.Also have, under the identical situation of the number of turn, compare with the coil that adopts the circular cross-section conductor, the square-section can increase substantially the electric wire utilization rate.Therefore, the most suitable coil packaged type compressed-core that is used as corresponding big electric current of the coil that adopts strap to be entwined.
Following shown in Figure 4 is that strap 2 twines preceding cross sectional shape, reaches the cross sectional shape after strap 2 twines.
When adopting the linear strap 2 of the straight angle, shown in Fig. 4 (a), conductor 2 is a homogeneous at the thickness that twines the starting section.Begin around conductor 2 from this state, shown in Fig. 4 (b), the excircle thickness of coil 1 (outside of coiling) is compared with the inner periphery thickness (inboard of coiling) of coil 1 and is wanted attenuation.Here as the above, coil 1 will form after the conductor 2 winding number circles.In the coiling process of conductor 2, though can contact between each circle line, because the perimeter thicknesses that the coiling athletic meeting of conductor 2 makes coil 1 is than interior all thin thickness, shown in Fig. 4 (b).Will prevent insulating coating from peeling off, damaging like this and make air core coil by conductor 2 coileds.
If the coil 1 of the conductor 2 that insulating barrier is peeled off or damages is encapsulated in the press-powder body 10, the inductance of coil packaged type compressed-core can significantly reduce.
In addition, shown in Fig. 4 (c), when making coils with strap 2, the excircle thickness of coil 1 can become than inner periphery thin thickness, pressurization processing in this state in the outer circumferential sides of coil 1, is difficult for producing the insulating coating damage.If shown in Fig. 4 (d), pressurization processing under the internal and external circumference thickness of coil state about the same, the outer circumferential sides insulating barrier of coil is very easy to produce flaw.
Also have, consider the cross sectional shape that conductor 2 is twined the formed coil 1 in back, the conductor of selecting the trapezoid cross section for use 2 that can be suitable.
The manufacture method of coil related in the present embodiment 1 then, is described with Fig. 5~8.
Fig. 5 is the production process flow chart of coil 1 related in the present embodiment.As shown in Figure 5, during related in the present embodiment coil is made, winding process (step S101), forming process (step S102), punch process operation (conquassation processing) (step S103), school shape treatment process (step S104), the Bending Processing operation (step S105) of conductor 2 arranged.
The winding process of conductor 2
At first in S101 step, shown in Fig. 6 (a) and (b), obtain the winding section 3 of the coil 1 that is entwined by strap 2 and 3 end 4a, the 4b that draw from the winding section.The number of turn of conductor 2 is suitably set according to needed inductance, generally is 1~6 circle, also can be set as 2~4 circles as required.Shown in Fig. 6 (b) be the end view of the coil 1 that conductor 2 is formed from limit portion here behind 2.5 circles.Shown in Fig. 6 (b), in the S101 winding process in step, allow closely to contact respectively forming between the circle line of coil 1, can reduce the flow chart number, improve the electric wire utilization rate.
Forming process
In step, carry out the shaping processing of coil 1 at ensuing S102.Fig. 7 is end 4a, 4b oppositely draw shaping from the winding section 3 of coil the plane graph of drawing of conductor 2.Here, end 4a draw direction and end 4b to draw direction different.If end 4a, 4b draw to equidirectional respectively, to be not easy to carry out punch process (after the content of punch process detailed description being arranged) to drawing end 4a, 4b, simultaneously when making coil packaged type compressed-core, the centre etc. of press-powder body will be difficult to coil 1 is placed on.Also have, as shown in Figure 7, draw end 4a, 4b and will on symmetric position, form processing respectively.Like this, when a coil packaged type compressed-core that adopts coil 1 being used as surperficial real dress portion product, just can realize the extraction location symmetry of portion of terminal 100, because draw end 4a, 4b as portion of terminal 100 uses.Also have, when operating coil 1, when for example being placed in the mould that moulding uses, need not distinguish the direction of coil 1 to coil 1.
Punch process (conquassation processing) operation
Finish the shaping processing of coil 1 in the S102 step after, enter the S103 step.To carry out punch process (conquassation processing) at S103 to drawing end 4a, 4b in step.This operation is in order to realize that drawing end 4a, 4b carries out as the function of portion of terminal 100.Through the processing of this operation, the part of drawing end 4a, 4b is wideer and thin than the part of conductor 2.
In the S102 punch process in step, the thickness of conductor 2 will be worked into 0.1~0.3mm..Punch process, as the above, purpose is that a plane of the ratio conductor 2 that do on the plane of drawing end 4a, 4b is wide and thin, simultaneously by punch process, can also increase the intensity of using as portion of terminal 100 of drawing end 4a, 4b.
Here, Fig. 8 has shown drawing the state after end 4a, 4b carry out punch process.Fig. 8 (a) is the front view of coil 1, and Fig. 8 (b) is the end view of coil 1.Shown in Fig. 8 (a), to after drawing end 4a, 4b and carrying out punch process, this part equal proportion of conductor 2 stretches out and is bowl-shape.
To adopt the coil packaged type compressed-core of coil 1 to install in the circuit board, in order to cooperate with the par pattern, the shape of drawing end 4a, 4b preferably makes rectangle.But will draw end 4a, 4b make rectangle be not will draw the necessary condition used as portion of terminal 100 of end 4a, 4b, as long as, just can omit school described later shape and handle so the size of drawing end 4a, 4b after the punch process can be put in the pattern of par.
School shape treatment process
After finishing the punch process of drawing end 4a, 4b in the S103 step, enter the S104 step.In step, draw end 4a, the 4b that finishes punch process carried out school shape processing at S104.In school shape is handled, can adopt and carry out towards wearing mould.Par pattern that coil packaged type compressed-core is installed is rectangle normally, cooperates therewith, preferably will draw end 4a, 4b and make rectangle.The coil packaged type compressed-core that is for example adopted in notebook computer will be processed into rectangle drawing end 4a, 4b, and size will be in 20 * 30mm~50 * 60mm scope.As mentioned above, although rectangle is not to draw the necessary condition that end 4a, 4b use as portion of terminal 100, but because now, raising along with surface real dress density, continuous narrow and smallization of par pattern, requirement to the shape of portion of terminal 100 and dimensional accuracy is also more and more higher, preferably draw end 4a, the 4b that finishes after the punch process is carried out school shape and handles.State shown in Figure 2 is exactly the front view that has carried out the coil 1 of school shape processing.
The Bending Processing operation
After finishing school shape and handle in S104 step, just enter the S105 step.In step, draw end 4a, the 4b that finishes after school shape is handled carried out Bending Processing at S105.This Bending Processing operation is the part of feature of the present invention.The purpose of this operation is that draw end 4a, the 4b that use as portion of terminal 100 are placed on the same plane.
Below, the content of the explanation bending operation that utilization Fig. 9 is more detailed.Also have, Fig. 9 (a)~Fig. 9 (c) is respectively the end view of coil 1.
Shown in Fig. 9 (a) being, is datum level with the middle level of winding section 3, places state on the same plane with drawing end 4a, 4b.Shown in Fig. 9 (a), when being datum level, will draw end 4a, the 4b identical angle of bending respectively with the middle level of winding section 3, drawing between end 4a and the winding section 3 and drawing formation sweep 4c between end 4b and the winding section 3.Middle level with winding section 3 is datum level, in the time of will drawing end 4a, 4b and place on the same plane, will draws the length of end 4a, 4b and do nearly equally in above-mentioned school shape treatment process (step S104) like this.Just shown in Fig. 8 (a), 8 (b), La is that center line from the winding section 3 of coil 1 is to the length of side of drawing end 4a, Lb is that center line from the winding section 3 of coil 1 is to the length of side of drawing end 4b, if La equates with Lb, drawing 3 of end 4a and winding sections and drawing end 4b and 3 of winding sections when forming bending part 4c respectively, the length of drawing end 4a just equates with the length of drawing end 4b.
State is shown in Fig. 9 (b), is datum level, draws end 4a, 4b state at grade with the superiors of winding section 3.That is, any one side of drawing end 4a upper and lower surface and any one side of drawing end 4b upper and lower surface are at grade.Shown in Fig. 9 (b), when being datum level, only will draw an end 4b bending certain angle of end with the superiors of winding section 3, form sweep 4c between end 4b and the winding section 3 drawing.In addition, be datum level will draw end 4a, 4b and place on the same plane time with the orlop of winding section 3, shown in Fig. 9 (c), like that, only will draw an end 4a bending certain angle of end, formation sweep 4c gets final product between end 4a and the winding section 3 drawing.
Shown in Fig. 9 (b),, in above-mentioned school shape treatment process (S104 step), should make the length of drawing end 4b longer than the length of drawing end 4a when the superiors with winding section 3 are datum level will draw end 4a, 4b and place on the same plane time.That is to say, in above-mentioned S101 step~the S104 step operation, make length of side Lb greater than length of side La.Lb be center line from the winding section 3 of coil 1 to the length of side of drawing end 4b, La is that center line from the winding section 3 of coil 1 is to the length of side of drawing end 4a.When the orlop with winding section 3 is that datum level will draw when end 4a, 4b place on the same plane also is the same reason.
Also have, will draw end 4a, when the 4b Bending Processing becomes sweep 4c, can bending through the part of punch process, can bending do not pass through the part of punch process yet.As mentioned above, be 0.1~1.0mm owing to draw end 4a, 4b thickness before punch process, and become 0.1~0.3mm that therefore drawing end 4a, 4b is easy to carry out Bending Processing through thickness after the punch process.
More than utilization Fig. 9 is illustrated characteristic operation Bending Processing operation of the present invention (step S105), and this operation is to place necessary operation on the same plane with drawing end 4a, 4b.Promptly shown in Fig. 6 (b), Fig. 8 (b),, so just can not make and draw end 4a and draw end 4b at grade if all do not form dogleg section 4c between end 4b and the winding section 3 drawing between end 4a and the winding section 3 and drawing.
Also have, in above-mentioned example, Bending Processing operation (S105 step) is carried out afterwards in punch process operation (S103 step) and school shape treatment process (S104 step).Also can after finishing, Bending Processing operation (S105 step) carry out punch process operation (S103 step) and school shape treatment process (S104 step).Can also between punch process operation (S103 step) and school shape treatment process (step S104), carry out Bending Processing operation (S105 step).
Shown in Fig. 9 (a)~9 (c), the coil that is adopted places on the same plane if will draw end 4a, 4b, when can obtain good inductance performance, can also reduce the discrete of inductance value, detailed description is arranged after concrete.Be not limited only to the datum level shown in the solid line among Fig. 9 (a)~Fig. 9 (c) in addition, can also adopt the such datum level shown in the dotted line among Fig. 9 (c) certainly.At this moment, can realize that Ha equates with H b by forming dogleg section 4c.Ha be from fixed datum level to the distance of drawing end 4a (the arbitrary face the upper and lower surface), Hb be from fixed datum level to the distance of drawing end 4b (the arbitrary face the upper and lower surface).
More than, the operation by S101 step~the S105 step is illustrated the manufacture method of coil 1, and punch process operation (step S103) can almost be carried out simultaneously with school shape treatment process (step S104).Here said " simultaneously similar " comprises two kinds of situations: when drawing end 4a, 4b as portion of terminal 100 uses, to drawing end 4a, 4b pressurization, a kind of is to carry out school shape to handle under pressurized state, and another kind is to carry out school shape processing immediately after adding pressure.In order almost to carry out punch process operation (step S103) and school shape treatment process (step S104) simultaneously, for example be set as around the punch press that punch process can be used to dash and wear the pattern structure of signing an undertaking, to drawing end 4a, 4b pressurization, allow immediately under pressurized state or after adding pressure fall, be cut into required shape drawing end 4a, 4b towards wearing the pattern tool.
Have, punch process operation (step S103), school shape treatment process (step S104) and Bending Processing operation (step S105) can almost be carried out simultaneously again.That is, from the state of coil shown in Figure 71 through obtaining coil shown in Figure 31 once going on foot.At this moment, as long as on one side to drawing end 4a, 4b pressurization, the part of an Edge Bend exit 4a of portion, 4b is processed into a sweep 4c at least and gets final product drawing between end 4a and the winding section 3 or draw between end 4b and the winding section 3.And after sweep 4c forms, fall immediately to dash and wear the pattern tool and will draw end 4a, 4b and be cut into needed shape.Also have, it is not situation about being shaped in advance that the present invention is not only applicable to the mo(u)ld bottom half core, is applicable to down the situation that core is shaped in advance yet.
As mentioned above, the structure of coil 1 is used as portion of terminal 100 with draw end 4a, the 4b of conductor 2, therefore there is no need to set up independently portion of terminal.That is, the coil packaged type compressed-core in the present embodiment does not have the wiring part between coil and the portion of terminal.And owing to there is not the wiring part, coil that is produced before can not taking place and the defective insulation between the bad connection between portion of terminal or coil and portion of terminal and magnetic powder.Related coil 1 is the air core coil that is entwined by strap 2 in the present embodiment in addition, therefore can obtain big inductance with the less number of turn, can also further advance the miniaturization of magnetic core.In addition, if carry out stamping procedure and school shape treatment process simultaneously, owing to can reduce the production process number of coil 1, so improved operating efficiency.And, carry out at the same time under the situation of stamping procedure and school shape treatment process, because moving of coil 1 can not taken place, compared with prior art just improved the positioning accuracy when school shape is handled, so also just improved the machining accuracy of drawing end 4a, 4b as portion of terminal 100 usefulness.Be exactly in addition, coil 1 draw end 4a, 4b owing to place on the same plane, inductance discrete little, performance is high.
Then, the manufacture method about coil packaged type compressed-core related in the present embodiment is illustrated with Figure 10 and Figure 11.
Shown in Figure 10 is the production process flow chart of coil packaged type compressed-core of the present invention.Here suppose that in addition the coil 1 that is entwined with strap 2 has performed in advance.
At first, select ferromagnetism metal dust and insulating material, carry out weighing (the 201st step) more respectively according to needed magnetic characteristic.Also have when needing to add bridging agent, be in advance to its weighing in the 201st step.
After the weighing, mix ferromagnetism metal dust and insulating material (the 202nd step).If add bridging agent in addition, in the 202nd step, mix strong metal powder, insulating material and bridging agent.Mix with kneading machine, under room temperature state, mix 20~60 minutes.The gained mixture will be 100~300 ℃ of dry 20~60 minutes down (the 203rd steps).Then pulverize dried mixture, obtain the ferromagnetism powder (the 204th step) that compressed-core is used.
Then in the 205th step, lubricant is added in the ferromagnetism powder that compressed-core uses.After adding lubricant, preferably can mix 10~40 minutes.
After having added lubricant, enter forming process (the 206th step).Below, with Figure 11 the 206th forming process that goes on foot is described.
Figure 11 is the compressed-core die forming schematic diagram that has added lubricant, mixed with the ferromagnetism metal dust.In addition, as shown in figure 11, mo(u)ld top half 5A will be located at respectively on the relative position with following pressing part 7 with mo(u)ld bottom half 5B, last pressing part 6.
At first, be that mixed-powder 20 is filled in the die cavity of mo(u)ld bottom half 5B shown in Figure 11 (A), wherein mixed-powder 20 is mixed-powders of using ferromagnetism powder and lubricant through the compressed-core of insulation processing.Then, like that, put down down pressing part 7 shown in figure (B), coil 1 is inserted in the mo(u)ld bottom half 5B, wherein coil 1 has formed and has drawn end 4a, 4b, and draws end 4a, 4b and use as portion of terminal 100.Can also before being inserted mo(u)ld bottom half 5B, coil 1 mixed-powder 20 of filling in the mo(u)ld bottom half 5B die cavity can be shaped in advance in addition.
Shown in Figure 11 (B), like that coil 1 is inserted in the mo(u)ld bottom half 5B, coil 1 can run-off the straight and level be positioned at mo(u)ld bottom half 5B.This is because as shown in Figure 9, coil 1 draw end 4a, 4b at grade, will draw end 4a, 4b and insert in the mould by mould guide rail 5C, the location easily.
In Figure 11 (B), such shown in Figure 11 (C) for another example behind coil 1 insertion mo(u)ld bottom half 5B, mo(u)ld top half 5A is buckled in mo(u)ld bottom half 5B goes up, mixed-powder 20 is filled in the mo(u)ld top half 5A.Then, shown in this figure (D), descend like that simultaneously and go up pressing part 6, lifting pressing part 7 down, by pressurization, just can obtain the formed body (coil packaged type compressed-core) that constitutes by coil 1 and press-powder body 10 then.Also have the condition of pressurization to be controlled between 100~600Mpa.In addition in order to allow coil 1, determine the loading of mixed-powder 20 among the loading of mixed-powder 20 among the mo(u)ld bottom half 5B and the mo(u)ld top half 5A just in time in the central authorities of press-powder body 10.
Here, Figure 12 be draw end 4a, 4b not at grade coil 200 place the schematic diagram of mould.Just as shown in Figure 12, draw end 4a, 4b not at grade the time, even will draw end 4a or 4b inserts mould by mould guide rail 5C, coil 200 also can be positioned at mo(u)ld bottom half 5B at a slant.Be not filled into mixed-powder 20 owing to may have part like this, it is just very difficult therefore will to obtain high inductance.In addition, wanting that at last coil 200 is placed on the central authorities of press-powder body also can be very difficult, and because in order not damage coil 200, also to control well mo(u)ld top half 5A and mo(u)ld bottom half 5B, go up pressing part 6 and following pressing part 7, increase operating efficiency difficulty.
After finishing Figure 10 and the 206th step forming process shown in Figure 11, just enter thermmohardening treatment process (S207 step) so.
In the thermmohardening treatment process, the formed body that obtains is heated to 150~300 ℃ and kept 15~45 minutes in forming process (S206 step).Can make the hardening of resin in the formed body like this.
Through entering antirust treatment process (S208 step) after the thermmohardening processing.Antirust processing can be adopted and carry out spray coating on the formed body of epoxy resin isocline circle 1 and press-powder body 10 and carry out.The about 15 μ m of the thickness of spray coating, finish antirust processing after, under 120~200 ℃, carry out 15~45 minutes heat treatment.
As mentioned above, in the related in the present embodiment coil packaged type compressed-core, can use the part of coil 1 as portion of terminal 100., as the original material such as enamel that just adopted of conductor 2 as dielectric film.And, in the 207th step thermmohardening treatment process, just below this layer dielectric film, formed the oxide-film of copper again according to present inventor's etc. observation.And in antirust treatment process (S208 step), formation one deck spray coating film on dielectric film again.Sandblast operation (S209 step) is to remove these films that form in portion of terminal 100 places.
As the method for removing, the chemicals etch is arranged at the surperficial formed trilamellar membrane of coil 1., must need different medicines, therefore will remove trilamellar membrane and will repeatedly handle owing to remove different films.When adopting the chemicals etch, chemicals need be heated, during heating, alkaline particulate or acid particulate might be attached on the coated film and dielectric film of portion of terminal 100.Such one sticks together, the time grown after will produce on coated film and the dielectric film through the time corrosion, cause the reduction of rustless property, the short circuit between coil turn easily.For fear of these danger, can adopt the machinery of dependence instrument to remove method, but, can not use to produce the instrument of damage to the copper of conductor 2 because the thickness of the portion of terminal 100 of related coil packaged type compressed-core is less than 5mm (about 0.1~0.3mm), very thin in the present embodiment.So, adopt blasting treatment to remove 3 tunics in the present embodiment.
When portion of terminal 100 is used as surperficial real equipment used portion of terminal, the scolding tin (S210 step) of will burn-oning at portion of terminal 100 places.Afterwards, portion of terminal 100 bending as required that will broaden through punch process has like this and is convenient to coil packaged type compressed-core is installed on the wiring board.
Coil packaged type compressed-core by in the present embodiment can obtain following effect.
(1) because the coil 1 that adopts is a conductor 2 by flat is entwined, can obtain big inductance with few number of turn.And can obtain small-sized (low clearance) coil packaged type compressed-core about long 5~15mm * wide 5~15mm * high 2~5mm.
(2) because portion of terminal 100 is draw end 4a, 4b by coil 1 constitutes, do not need the wiring between coil 1 and portion of terminal, so can eliminate bad connection, the defective insulation that causes by wiring.
(3) place on the same plane owing to drawing end 4a, 4b, when coil 1 is placed mould, can easily realize correct positioning.Can fill mixed-powder uniformly thus, obtain discrete little inductance value.
(4) owing to adopt draw end 4a, the 4b of coil 1 to use, just need not prepare portion of terminal in addition as portion of terminal.So just reduced required parts kind.
(5) owing to need not twine frame coil 1 is encapsulated in the press-powder body 10, very close to each other between coil 1 and magnetic core, can obtain the electronic units such as big inductance inductor of miniaturization (low clearance).
(6) owing to adopted press-powder body 10, the DC stacked performance of corresponding big electric current is good, and magnetic characteristic is stable.
Embodiment
With embodiment coil packaged type compressed-core of the present invention is described in detail.
For the inductance value of the packaged type compressed-core of confirming to adopt coil 1 and coil 200 and test, test as embodiment with this and be illustrated.Coil 1 is to place coil on the same plane by Bending Processing drawing end 4a, 4b.Coil 200 is to draw not at grade coil of end 4a, 4b.Also have coil 1 and coil 200 all behind 2.5 circles, to form by conductor 2.
Sample by 20 coil packaged types of following program making compressed-core.
Raw material has:
Magnaglo: spray-on process is made permalloy powder (45%Ni-Fe) (mean particle diameter 25 μ m)
Insulating material: silicone resin (SR2414LV)
Bridging agent: organic titanate (the TBT B-4 of day Cao Co., Ltd. manufacturing)
Lubricant: aluminum stearate (SA-1000 that the Sakai chemistry is made)
Then,, add the insulating material of 2.4wt% (weight %) and the bridging agent of 0.8wt% (weight %), in kneading machine, pressurize under the room temperature, keep mixing in 30 minutes with respect to Magnaglo.Then, in air 150 ℃ dry 30 minutes down.In dried Magnaglo, add the lubricant of 0.4wt%, mixed 15 minutes with vee-blender.
Next, form processing, make the sample of 20 coil packaged type compressed-cores according to the program of Figure 11 (A)~(D).In the sample of 20 coil packaged type compressed-cores, 10 shown in Figure 11 (B), inserted and drawn end 4a, 4b coil 1 at grade, remaining 10 are inserted in the program shown in Figure 11 (B) and draw not at grade coil 200 of end 4a, 4b.Also have, 140Mpa all pressurizes in Figure 11 (D).The magnetic core size is long 12.5mm * wide 12.5mm * high 3.3mm.
In 20 samples, No.1~No.10 adopts to draw the not sample made of at grade coil 200 of end 4a, 4b, and No.11~No.20 adopts to draw the sample that end 4a, 4b coil 1 is at grade made.Table 1 table 2 is represented the inductance value of No.1~No.10 sample and the inductance value of No.11~No.20 sample respectively.[0A] in table 1 table 2, [10A], [20A] expression in addition, the DC stacked current value of AC signal during inductance measuring (0.05V, 100kHz).
Table 1
Sample number into spectrum | Inductance value (μ H) | ||
| 10A | 20A | |
1 | 0.589 | 0.550 | 0.519 |
2 | 0.595 | 0.568 | 0.549 |
3 | 0.646 | 0.616 | 0.590 |
4 | 0.591 | 0.568 | 0.564 |
5 | 0.647 | 0.604 | 0.562 |
6 | 0.726 | 0.687 | 0.653 |
7 | 0.652 | 0.620 | 0.601 |
8 | 0.688 | 0.656 | 0.625 |
9 | 0.653 | 0.623 | 0.602 |
10 | 0.709 | 0.655 | 0.599 |
Mean value | 0.650 | 0.615 | 0.586 |
MAX | 0.726 | 0.687 | 0.653 |
MIN | 0.589 | 0.55 | 0.519 |
MAX-MIN | 0.137 | 0.137 | 0.134 |
Table 2
Sample number into spectrum | Inductance value (μ H) | ||
0A | 10A | 20A | |
11 | 0.776 | 0.715 | 0.648 |
12 | 0.791 | 0.729 | 0.657 |
13 | 0.782 | 0.724 | 0.651 |
14 | 0.789 | 0.726 | 0.653 |
15 | 0.779 | 0.718 | 0.652 |
16 | 0.786 | 0.727 | 0.649 |
17 | 0.777 | 0.715 | 0.649 |
18 | 0.786 | 0.725 | 0.653 |
19 | 0.789 | 0.727 | 0.655 |
20 | 0.781 | 0.724 | 0.650 |
Mean value | 0.784 | 0.723 | 0.652 |
MAX | 0.791 | 0.729 | 0.657 |
MIN | 0.776 | 0.715 | 0.648 |
MAX-MIN | 0.015 | 0.014 | 0.009 |
From can seeing shown in the table 1, sample No.1~No.10 inductance value discrete big is to draw not at grade coil 200 of end 4a, 4b and it adopts.Specifically take a single example, as under the interchange condition (DC stacked electric current is 0), the inductance value of No.6 sample is 0.726 μ H, and No.1 sample inductance value is 0.589 μ H, and the difference between them is 0.137 μ H.
Another side, shown in Figure 2 is the inductance value of sample No.11~No.20, sample No.11~No.20 has all adopted and will draw end 4a, 4b through Bending Processing and place coil 1 on the same plane, can find the discrete little of inductance value.All obtaining the inductance value more than the 0.7 μ H under the interchange condition.In addition, the inductance mean value of No.11 under the interchange condition~No.20 sample has reached 0.784 μ H, and the average inductance value of No.1~No.10 sample is 0.650 μ H, and the difference of both mean values reaches more than the 0.1 μ H.
In addition, from table 1 and table 2 as can be seen, when the direct current of stack 10A, 20A, also equally present same trend when exchanging.Promptly, adopted the No.1~No.10 sample of the coil 200 that does not pass through Bending Processing, dispersing of inductance value is big, will draw No.11~No.20 sample that end 4a, 4b place the coil 1 on the same plane and adopt through Bending Processing, inductance value is discrete little, and DC stacked performance is good.
Can draw to draw a conclusion from above result, adopt the coil packaged type compressed-core of drawing end 4a, 4b coil 1 at grade, can not only obtain good inductance value, good DC stacked performance, can also reduce the discrete of inductance value.Infer that this is because by draw end 4a, the 4b that use as portion of terminal 100 are placed on the same plane, when making coil packaged type compressed-core, when can realize placing easily coil 1, also can realize correct positioning (please refer to Figure 11 (B)).Draw end 4a, 4b not during at grade coil 200 and adopt, add man-hour in shaping, coil 200 can produce, cause the inhomogeneous of the interior mixed-powder of mould 20 fillings, some places just might not be filled into mixed-powder 20, size after being shaped like this disperses or density is discrete can become big, just might strengthen inductance value and disperse, reduces inductance value.
More than be the explanation of embodiments of the invention and relevant embodiment, the present invention is not limited only to above-mentioned explanation, various possible approximate change, distortion in the scope of project that has also comprised in claims to be put down in writing.This point should be the truism in the industry.
The effect of invention
As mentioned above, by the present invention, when can realize the further miniaturization of coil packaged magnetic dust core, can also obtain high-precision larger inductance.
Claims (18)
1. coil packaged type compressed-core with coil, potted coil with the press-powder body,
Wherein: coil is the winding section that is entwined at interval in accordance with regulations by the strap with relative upper and lower surface, and the first terminal portion, second portion of terminal of being drawn by aforementioned conductor winding section diverse location are formed, the while coil is covered by insulating material, the press-powder body is made of the ferromagnetism metallic that insulation coating is arranged, it is characterized in that the wherein one side of the wherein one side of the upper and lower surface of described the first terminal portion and the upper and lower surface of second portion of terminal at grade.
2. coil packaged type compressed-core according to claim 1 is characterized in that described conductor is made of the line with rectangular cross section.
3. coil packaged type compressed-core as claimed in claim 1 or 2 is characterized in that, described the first terminal portion, second portion of terminal are thinner than the conductor that constitutes described winding section.
4. coil packaged type compressed-core according to claim 1 is characterized in that, the coiled conductor almost parallel of described the first terminal portion, second portion of terminal and winding section is drawn.
5. as coil packaged type compressed-core as described in 1 in the claim, it is characterized in that having a bend between at least one of described the first terminal portion, second portion of terminal and the winding section.
6. as coil packaged type compressed-core as described in 1 in the claim, it is characterized in that the ferromagnetism metallic that constitutes the press-powder body is that Fe-Ni is an alloy.
7. coil packaged type compressed-core is made up of press-powder body, the insulated coil that is encapsulated in the press-powder body, and the ferromagnetism metallic of forming the press-powder body has insulating coating,
It is characterized in that, described coil is by the winding section that is entwined of flat conductor of insulation and draw the described conductor that constitutes described winding section and the pair of terminal portion that forms formed, the orlop of described winding section, in the superiors and the intermediate layer any one be as datum level, from described datum level to described pair of terminal portion apart from approximate equality.
8. coil packaged type compressed-core described in claim 7 is characterized in that, part or all of described pair of terminal portion is to be exposed at external of press-powder.
9. as claim 7 or 8 described coil packaged type compressed-cores, it is characterized in that described pair of terminal portion draws to different directions from the winding section.
10. coil packaged type compressed-core as claimed in claim 7 is characterized in that, described pair of terminal portion is wideer than other parts of described coil.
11. a coil is encapsulated in the manufacture method of the coil packaged type compressed-core in the press-powder body, it is characterized in that comprising following operation:
Operation a: the material powder that soft magnetic metal powder and insulating compound with formation press-powder body are principal component is rendered in the die cavity of mould;
Operation b: in the mold cavity that drops into press-powder body powder, place the coil that is tied with the flat insulating conductor;
Operation c: in described mold cavity, continue to throw in press-powder body powder, cover above-mentioned coil;
Operation d: envelope is pressed the described press-powder body of densification material powder.
12. the manufacture method as coil packaged type compressed-core as described in the claim 11 is characterized in that described soft magnetic metal powder is the Fe-Ni series alloy powder.
13. manufacture method as coil packaged type compressed-core as described in claim 11 or 12, it is characterized in that, described coil is the winding section that is entwined at interval in accordance with regulations by the strap with relative top and bottom, reaching the first terminal portion, second portion of terminal of being drawn by aforementioned conductor winding section diverse location forms, and the wherein one side of the wherein one side of the upper and lower surface of described the first terminal portion and the upper and lower surface of second portion of terminal at grade
After finishing operation d, again the first terminal portion of described coil, second portion of terminal are carried out the Bending Processing of operation e along the press-powder body.
14. the manufacture method as coil packaged type compressed-core as described in the claim 13 is characterized in that in the production process b of packaged type compressed-core, all or part of of the first terminal portion of coil, second portion of terminal is to place outside the die cavity of mould.
15. coil, it is characterized in that, the winding section that is entwined at interval in accordance with regulations by flat conductor with relative top and bottom, and the first terminal portion, second portion of terminal of being drawn by aforementioned conductor winding section diverse location form, and the upper and lower surface of the first terminal portion wherein arbitrarily the upper and lower surface of one side and second portion of terminal wherein arbitrarily simultaneously at grade.
16., it is characterized in that the first terminal portion of coil, second portion of terminal are that benchmark is drawn from the position of symmetry with described winding section as coil as described in the claim 15.
17. the manufacture method of a coil, described coil has pair of terminal portion, the sub-portion of this pair of end is wideer and be cuboid than other parts of coil, it is characterized in that, its making will be passed through operation f and operation g, operation f is coiling and reserves pair of terminal, operation g is a school shape treatment process, promptly the pair of terminal portion that obtains after by the f working procedure processing adds certain pressure, under pressurized state or the school shape processing of carrying out immediately after the pressurization so that described pair of terminal portion to make than the wide cuboid in other positions of coil.
18. manufacture method as coil as described in the claim 17, it is characterized in that, on the make, the Bending Processing of described one or two terminal is carried out simultaneously in the front and back of operation g or with operation g, so that make the orlop of described winding section, in the superiors and the intermediate layer any one be as datum level, and the distance from described datum level to described pair of terminal portion reaches impartial.
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JP4546712B2 (en) * | 2003-10-02 | 2010-09-15 | 株式会社細川洋行 | Bag making apparatus and bag making method |
CN100373506C (en) * | 2004-03-23 | 2008-03-05 | 乾坤科技股份有限公司 | Choking-winding and producing method thereof |
CN100437847C (en) * | 2004-07-16 | 2008-11-26 | 台达电子工业股份有限公司 | Method for manufacturing buried loop type inductor |
CN101797812A (en) * | 2009-02-09 | 2010-08-11 | 美磊电子科技(昆山)有限公司 | Powder processing die with leading-out structure |
JP5167382B2 (en) | 2010-04-27 | 2013-03-21 | スミダコーポレーション株式会社 | Coil parts |
JP5605058B2 (en) * | 2010-07-29 | 2014-10-15 | 東洋製罐株式会社 | Film-like member bending apparatus and bending method |
CN102723190A (en) * | 2012-06-26 | 2012-10-10 | 信源电子制品(昆山)有限公司 | Method for manufacturing inductance coil |
JP6237268B2 (en) * | 2014-01-28 | 2017-11-29 | Tdk株式会社 | Reactor |
KR101792317B1 (en) * | 2014-12-12 | 2017-11-01 | 삼성전기주식회사 | Chip electronic component and manufacturing method thereof |
JP2020077794A (en) * | 2018-11-08 | 2020-05-21 | 株式会社村田製作所 | Surface mount inductor |
CN111682307A (en) * | 2019-03-11 | 2020-09-18 | 夏普株式会社 | Antenna device and display device having the same |
CN111755233A (en) * | 2020-06-24 | 2020-10-09 | 华萃微感电子(江苏)有限公司 | Sectional forming micro-inductor manufacturing process |
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2002
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