EP3134907A1

EP3134907A1 - Method for producing an induction component, and induction component

Info

Publication number: EP3134907A1
Application number: EP15717127.3A
Authority: EP
Inventors: Markus Stark; Klaus Richter; Dorian DEGEN
Original assignee: Wuerth Elektronik Eisos GmbH and Co KG
Current assignee: Wuerth Elektronik Eisos GmbH and Co KG
Priority date: 2014-04-23
Filing date: 2015-04-09
Publication date: 2017-03-01
Anticipated expiration: 2035-04-09
Also published as: TW201606820A; RU2660915C2; AU2015251054B2; KR20160145776A; WO2015162016A1; RU2016144981A3; KR101873673B1; TWI594278B; RU2016144981A; EP3134907B1; IL248167A; JP2017514308A; CA2946346A1; CA2946346C; AU2015251054A1; US20170053741A1; SG11201608783TA; DE102014207636A1; CN106415746B; CN106415746A

Abstract

The invention relates to a method for producing induction components, each containing a coil, in order to wind the coils on a wire winding plate containing a plurality of wire winding pins arranged in rows and columns, using a continuous wire for a number of coils. The template provided with the coils is then pressed in a moulding press together with ferromagnetic powder substrate, which surrounds the coils. After removing the template, the inner regions of the coils are again provided with powder substrate in a moulding press, and pressed. Finally, the connections are contacted, and the blocks are broken up into individual induction components, each containing a coil.

Description

Method for producing an induction component and induction component

The invention relates to a method for producing an induction component and to an induction component produced by this method.

A method of manufacturing an inductor has already been known (KR 10-1044607). In this case, a coil core, a coil sheath and a lid made of a metallic-magnetic powder and pressed with the previously wound coil in a mold. The winding ends are in the region of the front side of the inductor produced in this way.

In another known method (KR 10-1044608), a plurality of terminal terminals in a first form and a plurality of individual coils are inserted into a second mold. The two forms are stacked and the coil terminals are soldered to the connection terminals.

In another known method (KR 10-201 1 -0100096), the coil core, the coil jacket and the coil cover are pressed together with the coil in a mold. The lying in the end face of the resulting inductor winding ends are contacted by sputtering.

The invention is based on the object to provide a method for the manufacture of induction components, which can be carried out easily and with the aid of a variety of induction components can be produced simultaneously.

To solve this problem, the invention proposes a method with the features mentioned in claim 1. Further developments of the invention are the subject of dependent claims.

Thus, according to the method, a multiplicity of coils are arranged next to one another and embedded in a block of pressed ferromagnetic substrate common to all coils. The interior of the coils arranged in the block is filled with the powdered, for example, ferromagnetic substrate, and the substrate powder is then pressed. This creates a block with a variety of coils. The wires leading to the coil turns of each coil are exposed and provided with terminal contacts. Only then is a division of the block in the individual induction components, which then normally contain only a single coil. In some cases, induction components can also be made by dividing the block containing more than one coil. The individual coils of the plurality of coils can be identical to one another. But it is also possible that the coils deviate from each other, both in number of turns and in shape.

According to the invention, it can be provided that, in a development of the invention, the block is formed only after the coils have been arranged, for example by the substrate powder being applied around the coils and then being pressed.

However, it is also possible and within the scope of the invention that the block is first produced by pressing the substrate powder for each coil of a cavity which corresponds in shape and size to a respective coil, and then the coils are inserted into the cavity become.

In a further development of the invention it can be provided that for the preparation of the coils, a teaching is provided which has a plurality of juxtaposed and mutually parallel pin. A winding wire can then make the coils by wrapping the individual pins using a suitable device. It can be provided that a continuous wire for a plurality of coils, possibly also for all coils, is used.

After winding the pins on the gage, this gage may also serve to locate the coils during manufacture of the ferromagnetic material block. For this purpose, it can be provided that the gauge is placed in a molding press with the coils wound on its spigot. Subsequently, the substrate powder is poured into the molding press until the pins are completely covered with powder. Then, a compression of the substrate powder, so that is produced as a result of the provided with the embedded coil block.

In a further development of the invention can be provided that the teaching is removed with the pin from the block, so that now the block remains with the coils whose interior is hollow. The block can now be turned over, so that the leading into the interior of the coil opening is directed upward. In this orientation, the block is placed in a molding press and replenished substrate powder, which now fills the interior of the coil. By subsequent compression of the bobbin is formed and connected to the block. Alternatively, a prefabricated spool core can be used.

Prior to attaching the terminal contacts may be provided in a further development of the invention, the top of the block, so the side on which the wires between the coils dur- fen, to provide with cuts between the coils. In making these cuts, continuous wires can be separated so that at the same time the coil ends of the coils are defined. The attachment of the terminal contacts, for example by sputtering, then takes place in the incisions, so that the walls of the incisions are provided with metallization.

In a development of the invention, provision may be made for the incisions between the coil regions to be made at the location of the subsequent division of the block in order to form the individual induction components.

It has been found to be particularly useful to arrange the coils in the block in a matrix-like arrangement in rows and columns. The arrangement of the cuts is then only between the rows of coils, in the direction transverse to the course of the wires.

A masking before the application of the connection contacts can then be done in rows.

Further features, details and advantages of the invention will become apparent from the claims and the abstract, the wording of which is incorporated by reference into the content of the description, the following description of preferred embodiments of the invention and with reference to the drawing. Individual features of the different embodiments can be combined with each other in any way, without exceeding the scope of the invention. Hereby show:

Figure 1 is a plan view of a jig for winding a plurality of coils; Figure 2 is a side view of the teaching of Figure 1;

Figure 3 shows schematically the top view of the teaching of Figure 1 after the winding of the individual pins;

FIG. 4 shows the lateral view of the gauge corresponding to FIG. 2 after the manufacture of the invention

Do the washing up;

Figure 5 shows schematically the arrangement of the wound gauge in a molding press;

Figure 6 shows schematically the block produced in the molding press after removal of the teaching; Figure 7 shows the arrangement of the inverted block in a molding press; FIG. 8 shows the block with coils removed from the molding press of FIG. 7; FIG. 9 shows the block after the production of incisions; FIG. 10 shows the block after the application of the connection contacts;

Figure 1 1 in an enlarged scale a side view of a manufactured induction component.

12 is a perspective view in simplified form of a block with in the example eight cavities of different shape;

Figure 13 is a perspective view of a coil;

Figure 14 is the view of the spool of Figure 13 from the side;

Figure 15 is a section through the block with inserted coils;

FIG. 16 shows the process of isostatic pressing;

FIG. 17 shows the method step of exposing the coil ends of the coils;

Figure 18 shows the result of exposing the coil ends;

Fig. 19 shows the induction components produced by the dicing of the block;

Figure 20 is a perspective view of an induction component according to the invention;

FIG. 21 shows the partially opened induction component of FIG. 20.

The proposed method of the invention for the simultaneous production of induction components is explained below with reference to a possible embodiment.

First, a gauge 1 is used, which can be used several times. This teaching 1 is shown in FIG. 1 and FIG. It contains a wire winding plate 2, which is formed at right angles in the example shown. On top of the wire winding plate 2 are three rows of Pins 3 arranged, which are aligned in four columns. In the example shown, all circular cylindrical pins 3 have the same diameter and, as is apparent from Figure 2, the same length. All pins 3 on the top of the wire winding plate 2 are perpendicular to the wire winding plate and are thereby aligned parallel to each other. The distance between the individual pins 3 in the direction of the rows is identical, as well as in the direction of the columns. The pins 3 pass with a radius in the plate 2, which ensures that the coil, see Fig. 14, on the side on the winding start and winding end, a conical depression has. As a result, winding end and winding start are guided out of the coil in a radius to the outside. This prevents damage to the insulation of the winding wire and also kinking and damaging of the winding wire when embedding in the substrate and when pressing the substrate.

With a wire winding machine, a wire 4 is now wound around the pins, which is continuous in the example shown in Figure 3 for each of a number of pins 3. This results in a coil 5 for each pin 3. For example, the number of windings in each coil 5 may be identical.

Instead of the arrangement shown in Figure 3, in which a separate wire 4 is used for each row of pin 3, an arrangement is also possible in which a continuous wire 4 is used for all pins 3.

FIG. 4 schematically shows the wound teaching of FIG. 3 from the side, that is to say from the same direction as the view of FIG. 2.

The overhanging the side edges of the wire winding plate 2 part of the wire 4 is cut off, and the teaching 1 is now placed in a schematically illustrated molding press 6, see Fig. 5. The teaching 1 is oriented so that the wire winding plate 2 is below and the pins 3 protrude with the coils 5 in the interior of the molding press 6. Subsequently, a first substrate powder 7 is introduced into the interior of the molding press 6 until the pins 3 are completely hidden in the substrate powder 7. The substrate powder 7 is now pressed to form a solid block, which is not shown in detail. In this pressing operation of the first substrate powder 7, for example, a pressure of 250 kg / cm ² can be applied.

Subsequently, the so far compressed block 8 is removed with the doctrine 1 from the molding press 6 and turned over. Thereafter, the teaching 1 is taken out of the block, in the now the coils 5 are embedded, see Fig. 6. At the point where previously the pins 3 were, there is now a protruding into the block 8 cavity. 9

The block 8 is then inserted again in accordance with FIG. 7 in the reverse orientation in a molding press 10 and in the openings a second substrate powder 1 1 is filled until the interiors of the coils 5 are completely filled with substrate powder 1. The second substrate powder 11 may differ from the first substrate powder 7. The cavity 9 can also be filled with a pre-pressed coil core, wherein intermediate spaces are additionally filled with substrate powder. Subsequently, a compression takes place again until the coil cores formed in this way are connected to the block 8. In this second pressing operation, for example, a pressure of 200 kg / cm ² can be applied.

The result is a block 8 with embedded coils 5, each having a coil core, as well as with continuous wires 4 between all the coils 5 of a row. The result is shown in the schematic side view or in section in FIG.

This block 8 can, if necessary, be provided with a further layer of substrate powder to achieve required dimensions of the block 8 or of the induction components produced therefrom in the mold 10, which is then pressed. The substrate powder may be the same as or different from the first or second substrate powder 7, 11. The use of different substrate powders in the individual pressing operations with different magnetic properties makes it possible to set a desired inductance of the manufactured induction components. In this third pressing process, for example, a pressure of 220 kg / cm ² can be applied. The pressing operations for producing or pressing the block 8 are carried out, for example, at a pressure between 200 kg / cm ² and 300 kg / cm ² .

Subsequently, the block 8 can be pressed isostatically, wherein the pressure is much higher than in the previous pressing operations, for example with at least ten times the pressure, in particular 4500 kg / cm ² . In isostatic pressing, a temperature and pressure profile is advantageously followed over time.

As a next step, all coils of a column are provided with a mask 12. Then, cuts 5 are made in the block 8 between the columns of the coils 5, which are less deep than the coils 5, see FIG. 9. The cuts 13 thus run transversely to the course of the wires 4, see FIG. Now contacting takes place by known methods, for example by sputtering. In this case, the metal is applied both to the surface of the block 8 and to the side walls of the incisions 13. The result is shown in Figure 10, where the contacts 14 rest on both the wiring 4 and in the recesses 13.

Subsequently, the block 8 is cut, by cuts, which are guided both between the rows and between the columns of the coils 5. Die beiden Teile sind in der Mitte der Block 8 angeordnet. The cuts run in the middle of the cuts 13th

This results in a large number of induction components 15, see FIG. 11, which have the respective terminal contact 14 both on their underside 16 and on the two adjacent sides 17. When soldered to a circuit board 18, the solder 19 also adheres to the sides 17 of the induction component 15. The presence of the solder 19 can therefore be recognized optically from a direction perpendicular to the circuit board. This can be an automatic error detection perform.

The method proposed by the invention will now be explained with reference to a further embodiment. FIG. 12 shows a perspective view of a block 101, which was produced at the beginning of the process as a pressed substrate in a high-pressure process from a particularly ferromagnetic powder mixture. The block 101 has the shape of a flat rectangular plate with a flat top 102 and a likewise flat bottom 103 which is parallel to the top 102. Starting from the upper side 102, eight cavities 104 are formed in the block in the illustrated example, which cavities are designed as blind holes, that is, each having a bottom 105. In the example illustrated, these are two rectangular cavities 104, two square cavities 104, two circular cavities 104 and two elliptical cavities 104. This is intended to show that the block 101 can be designed for induction components of various shapes and sizes.

FIG. 13 now shows the perspective view of a coil 108, which has the coil ends 106, 107 at its one axial end, shown at the top in FIG. Both winding ends 106, 107 are bent so that they extend transversely to the axis of the coil 108 and protrude beyond the outer contour of the coil 108 to the outside. In addition, the two winding ends 106, 107 extend along a diameter of the coil shape. As can be seen, the winding ends 106, 107 are led out of the winding in a radius.

FIG. 14 shows the coil 108 of FIG. 13 from the side. Again, it can be seen that the winding ends 106, 107 of the winding forming the coil on the outer contour of the coil project and lie in a common plane. The winding end 106 forms the winding start.

The block 1 of Figure 12 is, as already mentioned, intended for receiving a plurality of coils. In the further method, all coils 108 are now inserted into the associated cavities 104. In the case of a coil 108, as shown in FIGS. 13 and 14, the cavities 104 are adapted to the coil 108 in such a way that the coil ends 106, 107 do not fit into the cavity but come to rest on the upper side 102 of the block 101. The winding ends 106, 107 are then just on the top 102.

FIG. 15 now shows the arrangement of a block 101 in a molding press 109. First, the coils 108 are inserted into the respective cavity 104, the winding ends 106,

107 on the top 102 of the block 101 to the plant. When inserting the coils

In the respective cavity, care is taken to ensure that the winding ends assume a specific orientation with respect to the cavities. Subsequently, the free space within each cavity is filled with a powdery substrate, in particular a ferromagnetic powder, or with a pre-pressed core and additional powder, which is filled to the extent that a layer 1 10 from this powder throughout the top 102 of the block 101 covers , In this layer 1 10 are the winding ends 106, 107. The block 101 is located in the molding press on a backing plate 1 1 1. The upper part 1 12 of the molding press 109 is pressurized in the direction of arrows 1 13, wherein the course of the pressure a time / Pressure profile corresponds. This profile is selected so that the absorbed energy can not damage the wire insulation or pre-compressed structure. In addition, a temperature can be applied in accordance with a predetermined time / temperature profile. After the time corresponding to the profile, the pre-compression of the block 101 with the coils 108 is completed. During prepressing, for example, a first pressure in the range between 200 kg / cm ² and 300 kg / cm ^{2 is} applied.

The block 101 is now removed from the molding press 109 and placed in a pressure vessel 1 14, which is shown schematically in Figure 16. In the pressure vessel 1 14 is a support plate 1 15 with a block 101 facing top 1 16, the surface quality does not exceed a roughness of 0.1 μηη, and therefore may also be referred to as a polished plate. This upper side 16 contains for each cavity a marking 17 forming a mark in the form of a small cone. Each of these cones 1 17 is associated with the orientation of the coil ends 106, 107 of the respective coil 108, in particular the beginning of the coil. In other words, the winding start 106 of each coil 108 is in each case opposite a cone 1 17. On the support plate 1 15 of the block 101 is placed aligned. On the top of 102 of the block 101 applied layer 1 10 now a silicone layer 1 18 is placed. Conveniently, the unit of block 101, pad plate 1 15 and silicone layer 1 18 is then packed liquid-tight and optionally evacuated. Subsequently, the pressure vessel 1 14 is completely filled with liquid, for example with water, and placed under pressure on all sides, as indicated by the arrows 1 19. The silicone layer 1 18 is to prevent damage to the winding ends 106, 107 contained in the layer 1 10 during pressurization. By the application of pressure, the cones 17 create a complementary depression 21 in the bottom 103 of the block 101.

During the pressurization is also a temperature application. The pressurization is advantageously carried out according to a predetermined time / pressure profile. The temperature application can also follow a predetermined time / temperature profile. In isostatic pressing, a much higher pressure is applied than during forcing / pressing. For example, isostatic pressing at a maximum pressure of 4500 kg / cm ² in a temperature range of 20 ° C to 100 ° C, preferably at 80 ° C. In isostatic pressing, a given temperature profile and pressure curve over time are followed, a so-called temperature-pressure-time profile.

After completion of the isostatic pressing of the thus prepared, provided with the layer 1 10 block from the pressure vessel 1 14 is removed. The result is now shown on the left in FIG. In the bottom 103 of the block 101, each of which a mark representing by the cone 1 17 generated recesses 121 are formed, which lie opposite the respective winding start 106 of the coil 108.

Next, the top of the layer 110, which can still be seen in FIG. 17 at the left end, is removed with the aid of a grinding or milling device 122 so far that the winding ends 106, 107 of each coil 108 are freed of their insulation and, in particular, approximately to Half of its cross section are exposed. This is shown in the right part of FIG. 17.

As a result, there is now a block 101 in which the coil ends 106, 107 of all coils 108 are exposed. These winding ends 106, 107 can now be provided with connection contacts by a known method.

Subsequently, the induction components desired as end products are produced by dividing the block 101, see FIG. 19. FIG. 19 shows, starting from FIG. 18, how individual inductors 124 are produced by sawing from the contiguous block 101. The following figure 20 shows an inductor 124 in a perspective view. The former lower side 103 of the block 101 now forms the upper side of the inductor 124. In this upper side a hole 121 is seen, which was generated by the cone 17 of the base plate 15. On the bottom of the inductor 124 forming the former upper side of the block 101, two terminal contact elements 126, 127 are attached, each with a winding end 106 and

107 are electrically and mechanically connected. This connection of the contact elements 126, 127 with the winding ends 106, 107 is indicated in Figure 21, in which the coils

108 actually tightly surrounding ferromagnetic material is not shown. The top of the inductor 124 has a very low surface roughness since it has been pressed by means of the polished platen 15 and can therefore be gripped reliably with the smallest suction pads in a pick-and-place process. Typically, the inductor 24 has an edge length between about 1 mm and 5 mm. The hole 121, which is formed as a conical blind hole, indicates the orientation of the winding start 106, so that the induction component 124 can be automatically placed with the desired orientation of the winding start 106.

Claims

claims

1 . Method for producing induction components (15) with the following method steps:

it is wound a plurality of juxtaposed coils (5) with parallel coil axes;

the coils (5) are embedded in a block (8) of compressed substrate spaced apart;

the interior of the coils (5) in the block (8) is filled with the substrate present in powder material;

the substrate powder is pressed;

the two ends of the coil winding of all coils (5) are exposed;

the exposed ends of the coil windings are provided with terminal contacts (14);

the block (8) is then divided to form the individual at least one coil (5) containing induction components (15).

2. The method of claim 1, wherein the block (8) is formed by pressing the substrate powder around the arranged coils (5) around.

3. The method of claim 1, wherein the block (8) each having a shape and size of at least one coil (5) of the plurality of coils (5) produced corresponding cavity and the coils (5) are inserted into the respective cavity.

4. The method according to any one of the preceding claims, wherein for the preparation of the coils (5) a gauge (1) having a plurality of juxtaposed and parallel pins (3) is used, around which a wire (4) is wound.

5. The method of claim 4, wherein the doctrine with the on its pin (3) wound coils (5) inserted into a molding press (6), then the substrate powder applied to the gauge (1) and pressed in the molding press (6) becomes.

6. The method of claim 5, wherein the gauge (1) after pressing the Sub- stratpulvers taken from the block produced by the compression of the substrate powder (8), the block (8) is inserted into a molding press (10), and then substrate in the molding press (10) for filling the interior of the coil (5) filled and pressed becomes.

7. The method according to claim 6, characterized in that the interior of the coils is at least partially filled with a prefabricated core.

8. The method according to any one of the preceding claims, wherein prior to attaching the terminal contacts (14) the top of the block (8) between the individual coils containing the coil (5) is cut to a portion of the height of the block and the terminal contacts ( 14) are also applied to the walls of the incisions (13).

A method according to claim 8, wherein the cuts (13) are made at the location of the subsequent division of the block (8) to form the individual induction members (15).

10. The method according to any one of the preceding claims, wherein the coils (5) in the block (8) are arranged in a matrix-like arrangement in rows and columns.

1 1. Method according to one of the preceding claims, in which after exposing the ends of the coil winding of all coils (5), a strip-shaped masking (12) takes place.

12. The method according to any one of the preceding claims, characterized in that the block (8) isostatically, in particular in a liquid-filled pressure vessel, is pressed.

13. The method according to any one of the preceding claims, characterized in that the exposure of the ends of the coil directions by means of a mechanical ablation process takes place.

14. Induction component, producible by a method according to one of the preceding claims.