JP2006228825A - Inductor and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing an inductor which can secure the insulating property on the side face of a core. <P>SOLUTION: The inductor is such that a coil 3 is embedded in a square pole-shaped core consisting of a press-formed body of a ferromagnetic metal powder wherein the surface of ferromagnetic metal particles is coated with a thermosetting insulating material. The inductor is formed by using a molding die 11 which consists of a square pole-shaped upper punch 12, an upper die 14 consisting of a pair of upper die members 14a and 14b which form a square frame and can be separated from each other in a diagonal direction, a square pole-shaped lower punch 13, and a lower die 15 consisting of a pair of lower die members 15a and 15b which form a square frame and can be separated from each other in a diagonal direction. In manufacturing the inductor, the inside of the lower die 15 is filled with the ferromagnetic metal powder, and then the coil 3 is placed across the lower die members 15a and 15b. Then, the upper die 14 is placed on the lower die 15 with ends b1 and b2 of the coil 3 held between the upper and lower dies, and then the inside of the upper die 14 is filled with the ferromagnetic metal powder so as to embed the coil 3 therein. After the core is compression-molded by applying molding pressure to the ferromagnetic metal powder by the upper and lower punches 12 and 13, the upper die members 14a and 14b are separated in a diagonal direction and so are the lower die members 15a and 15b to take out the core from a gap between the upper and lower punches 12 and 13. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to an inductor used as a choke coil or other coil components.

  Conventionally, a core that has been press-molded by compressing and molding the ferromagnetic metal powder by press molding in a state where the coil is embedded in the ferromagnetic metal powder made of ferromagnetic metal particles coated with an insulating material. There is known an inductor in which a coil is integrally embedded therein (see, for example, Patent Document 1).

  The inductor of Patent Document 1 is manufactured by the following procedure. First, by executing the first compression molding process, the ferromagnetic metal powder is filled into a cylindrical lower mold frame in which the lower punch is inserted, and then the lower core is formed by compression molding. Next, after performing a coil placement step of placing a coil on the lower core in the lower mold, a cylindrical upper mold is placed on the lower mold, and the coil is placed in the upper mold. A coil embedding step is performed in which the ferromagnetic metal powder is refilled so as to be buried. Thereafter, a second compression molding step is performed in which the upper core is molded by applying pressure in the direction in which the lower core and the coil are laminated by the upper punch and the lower punch inserted into the upper mold. Thereby, a coil enclosure powder core is shape | molded. Next, while raising an upper mold and an upper punch, a lower mold is lowered and a coil enclosure dust core is extracted from a lower mold. Finally, heat treatment to improve the mechanical strength of the core by thermosetting the insulating layer made of resin insulation coated with ferromagnetic metal powder is performed on the coil-enclosed dust core removed from the mold. Applied.

Also, take out the dust core from the mold by embedding the coil in the core consisting of the pressure-molded body of ferromagnetic metal powder coated with the surface of the ferromagnetic metal particles with thermosetting organic insulating binder. After that, it is known that the organic insulating binder is heated and cured to increase the bond strength of the ferromagnetic metal powder (see, for example, Patent Document 2).
JP-A-2001-267160 (Claim 1, paragraphs 0002, 0016 to 0017, 0021 to 0022, 0035 to 0045, 0049, FIGS. 1A to 1D, FIGS. 5A to 5I) Japanese Patent Publication No. 54-28577 [Claims, page 2, left column, line 2 to page right column, line 6]

  Patent Document 2 does not mention how to take out the molded core from the mold, but in Patent Document 1, the upper punch and the cylindrical upper mold are raised and the lower mold is lowered. Taking out the core. That is, the core is removed by relatively moving the cylindrical mold and the core along the thickness direction of the core.

  For this reason, when the molded core is taken out, the side surface of the core is not prevented from rubbing against the inner surface of the cylindrical molding die, and accordingly the ferromagnetic metal particles are coated on the side surface of the core. Insulation material is destroyed. Therefore, the insulating property of the molded core is lowered.

  Furthermore, in the technique of Patent Document 1, the upper surface of the cylindrical lower mold and the lower surface of the cylindrical upper mold are flush with each other. The height position varies depending on the number of turns of the coil. For this reason, when molding pressure is applied by the upper and lower punches, there is a high possibility that the coil portion excluding both terminal portions sandwiched between the upper and lower molds will be displaced in the vertical direction. When such a coil shift occurs, the variation in the magnetic characteristics of the product increases, cracks occur, and the inductance decreases.

  Moreover, in the technique of patent document 1, 2, the hardening process with respect to the shape | molded core is implemented in the state which took out the core from the shaping die. Thereby, since the molding density of a core falls according to the thermosetting insulating material which doubles as a binder expand | swells with a hardening process, the inductance of a product falls.

  A first object of the present invention is to provide a method for manufacturing an inductor capable of ensuring insulation on a core side surface.

  A second object of the present invention is to provide an inductor manufacturing method capable of ensuring insulation on the side surface of the core and improving the inductance.

  A third object of the present invention is to provide an inductor capable of ensuring insulation on the side of the core while suppressing variations in magnetic characteristics and improving the inductance, and a method for manufacturing the same.

  In order to achieve the first object, an inductor manufacturing method according to a first aspect of the present invention is a method of manufacturing a magnetic metal powder by pressing a surface of a ferromagnetic metal particle coated with a curable insulating material. An inductor manufacturing method in which a coil is embedded in a quadrangular columnar core, comprising a quadrangular columnar upper punch, a pair of upper mold members that are combined in a rectangular frame shape and contacted and separated diagonally. An upper die into which a punch is inserted, a rectangular pillar-like lower punch, and a lower die which is combined into a square frame shape and has a pair of lower die members that are diagonally contacted and separated and into which the lower punch is inserted A primary filling step in which the ferromagnetic metal powder is filled in the lower die in which the lower punch is inserted, and a coil set in which the coil is placed across both lower die members of the lower die And on the lower mold A mold clamping process in which molds are overlapped and a terminal portion of the coil is sandwiched between the upper mold and the lower mold, and a secondary filling process in which the ferromagnetic metal powder is filled in the upper mold so that the coil is buried A pressure forming step of compressing the core by applying a molding pressure to the ferromagnetic metal powder with the upper punch and the lower punch, and the pair of upper mold members and the pair of lower mold members in a diagonal direction, respectively. And a mold opening step of taking out the core from between the upper punch and the lower punch.

  In the mold opening process, the pair of upper mold members forming the upper mold of the rectangular frame is opened in the diagonal direction, and the pair of lower mold members forming the lower mold of the square frame is opened in the diagonal direction. Since the compression-molded core is taken out, the side surface of the core does not rub against the upper mold and the lower inner surface. Thereby, destruction of the insulating material coated with the ferromagnetic metal particles on the side surface of the core can be prevented.

  In order to achieve the second object, the inductor manufacturing method according to the second aspect of the present invention is the pressure molding of a ferromagnetic metal powder in which the surface of the ferromagnetic metal particle is coated with a curable insulating material. A method of manufacturing an inductor in which a coil is embedded in a rectangular columnar core made of a body, having a square columnar upper punch, a pair of upper mold members that are combined in a rectangular frame shape and contacted and separated diagonally An upper die into which the upper punch is inserted, a rectangular pillar-like lower punch, and a lower die into which the lower punch is inserted with a pair of lower die members that are combined in a square frame shape and are contacted and separated diagonally A primary filling step of filling the ferromagnetic metal powder into the lower mold in which the lower punch is inserted, and placing the coil over both lower mold members of the lower mold Coil setting process and on the lower mold A mold clamping step in which the upper mold is overlapped and the terminal portion of the coil is sandwiched between the upper mold and the lower mold, and the secondary mold is filled with the ferromagnetic metal powder in the upper mold so that the coil is buried A filling step, a pressure forming step of compressing the core by applying a molding pressure to the ferromagnetic metal powder by the upper punch and the lower punch, and pressing the compression molded core by the upper punch and the lower punch A curing process for curing the insulating material in a held state, a mold opening for opening the pair of upper mold members and the pair of lower mold members in a diagonal direction, and taking out the core from between the upper punch and the lower punch And a process.

  In the mold opening process, the pair of upper mold members forming the upper mold of the rectangular frame is opened in the diagonal direction, and the pair of lower mold members forming the lower mold of the square frame is opened in the diagonal direction. Since the compression-molded core is taken out, the side surface of the core does not rub against the upper mold and the lower inner surface. Thereby, destruction of the insulating material coated with the ferromagnetic metal particles on the side surface of the core can be prevented. Further, since the present invention performs the curing process in a state where the compression-molded core is pressed and held between the upper and lower punches, the expansion of the insulating material is suppressed, and the density of the core decreases with the curing process. Can be suppressed.

  In addition, the hardening process process which pressurizes and cures a core can be implemented with respect to the core taken out from the shaping | molding die, and can anticipate the expected effect by it. However, using a molding die that compresses the core and pressurizing and curing the upper mold member and the lower mold member eliminates the need for setting the core and is effective in terms of manufacturability. Means.

As a preferred form of the method of the present invention, the inductor manufacturing method according to claim 3 performs the curing process step while applying the pressure of 500 kg / cm ² or more from the start of curing of the insulating material to the completion of curing. I am doing so.

In the present invention, since the compression-molded core is pressurized and cured by applying a pressure of 500 kg / cm ² or more with the upper and lower punches, the core density is suppressed from decreasing with the curing process, and the product Inductance can be improved.

  In order to achieve the third object, according to a fourth aspect of the present invention, there is provided an inductor manufacturing method in which a depth corresponding to the thickness of the end portion of the coil is formed on the upper surface of each of the pair of lower mold members. The lower mold member is formed higher than the other lower mold member, and the upper surface of the higher lower mold member and the lower mold member having the lower height have the above-mentioned fitting groove. The height dimension difference from the bottom surface of the fitting groove is the same as the height dimension of the coil, and one of the pair of upper mold members that is superimposed on the lower mold member having the lower height. The upper mold member is formed higher than the other upper mold member superimposed on the lower mold member having the higher height, and the mold clamping step is performed by sandwiching the coil between the upper mold and the lower mold. Like to do.

  In this invention, it can suppress that a coil shifts | deviates to the horizontal direction orthogonal to a pressurization direction by a press molding process because the terminal part of a coil fits into a fitting groove, and is positioned. In addition, considering the height of the coil, both ends of the coil are shifted in the height direction and sandwiched between the upper mold and the lower mold, so that the coil is prevented from shifting in the pressing direction in the pressure molding process. it can.

  In order to achieve the third object, an inductor according to the invention of claim 5 is manufactured by the manufacturing method of claim 4, and the surface of the ferromagnetic metal particles is coated with a curable insulating material. An inductor formed by embedding a coil in a quadrangular columnar core made of a pressed compact of ferromagnetic metal powder, and a parting line mark attached to two adjacent side surfaces of the core; The parting line marks attached to the other two side surfaces are provided shifted in the height direction of the core.

  Since the inductor of the present invention is manufactured by the method of the invention of claim 4, it is possible to ensure insulation on the side surface of the core while suppressing variations in magnetic characteristics and improve inductance.

  According to the first aspect of the present invention, since the core of the formed inductance can be removed from the molding die without the side surface being rubbed against the inner surface of the molding die, the method for manufacturing an inductor capable of ensuring insulation on the side surface of the core Can provide.

  According to the second and third aspects of the invention, the molded core of the inductance can be removed from the molding die without the side surface being rubbed against the inner surface of the molding die, and the expansion of the insulating material in the curing process is suppressed. Therefore, it is possible to provide an inductor manufacturing method capable of ensuring insulation on the side surface of the core and improving the inductance.

  According to the invention of claim 4, the molded inductance core can be removed from the molding die without the side surface being rubbed against the inner surface of the molding die, and the expansion of the insulating material in the curing process is suppressed. In addition, since variations in the position of the coil in the core can be suppressed, it is possible to provide an inductor manufacturing method capable of ensuring insulation on the side of the core while suppressing variations in magnetic characteristics and improving inductance.

  According to the invention of claim 5, since it is manufactured by the method of the invention of claim 4, it is possible to provide an inductor capable of ensuring insulation on the side surface of the core and improving inductance while suppressing variations in magnetic characteristics.

  An embodiment of the present invention will be described with reference to FIGS.

  The inductor according to this embodiment is used as the choke coil 1 through which a large current flows, and can be suitably used by being mounted on an electronic device such as a computer game machine such as a TV game machine or a personal computer. As shown in FIG. 1 (C), the choke coil 1 includes a quadrangular columnar core 2 integrally formed in a hexahedron shape in which each surface is continuous at a right angle to each other, and both end portions of the core 2 are excluded. A coil 3 shown in FIG. 1A is provided.

  For the coil 3, a conductive metal wire, for example, a copper wire, preferably a rectangular copper wire having a rectangular cross section, can be suitably used. Although not shown, the coil 3 is coated with an insulating layer on the outer periphery. The number of turns of the coil 3 is, for example, 2 to 5 turns. One end b1 of the coil 3 projects outward from one end (lower end in the figure) in the height (thickness) direction of the coil 3, and the other end b2 is the other end in the height (thickness) direction of the coil 3 (shown in the figure). In FIG. These terminal portions b1 and b2 extend and project in the diameter direction of the coil portion. In FIG. 1A, symbol W indicates the coil length dimension between the tips of the terminal portions b1 and b2, and symbol H is the coil height. The dimensions, specifically, the height dimension between the lower surface of the lower terminal portion b1 of the coil 3 and the upper surface of the upper terminal portion b2 of the coil 3 are shown in the drawing. The coil length dimension is, for example, 30 mm, and the coil height dimension H is, for example, 2.0 mm.

  As shown in FIG. 1 (B), both terminal portions b1 and b2 of the coil 3 protrude outward from the intermediate portion in the height direction of two side surfaces of the core 2 parallel to each other. Both the terminal portions b 1 and b 2 are bent along the side surface of the core 2 and are bent along the back surface of the core 2. As shown in FIG. 1C, both terminal portions of the coil 3 along the back surface of the core 2 are used as terminals 3a. The insulating layer of these terminals 3a is removed. The terminal 3a is reflow soldered to a printed wiring of a printed wiring board of an electronic device (not shown). Therefore, the choke coil 1 can be mounted on a printed board as a surface mount component.

  As shown in FIGS. 1B and 1C, a parting line mark is provided on the side surface of the core 2 of the choke coil 1. That is, the first parting line marks 4a that are continuous with each other at the same height position on the adjacent side surfaces of the core 2 are formed, and the second part lines that are also continuous with each other at the same height position on the other side surfaces adjacent to the core 2 are formed. A parting line trace 4b is formed. These parting line marks 4 a and 4 b are provided with their positions shifted in the height direction of the core 2. The parting line marks 4a and 4b are formed on the core 2 on the basis of the manufacturing method described below. The choke coil 1 manufactured by the method of the present invention has external features, that is, other inductors. The identification function is given.

  Next, a molding die (molding die) of a press machine which is a pressure molding apparatus used for manufacturing the core 2 of the choke coil 1 will be described with reference to FIG. The molding die 11 includes an upper punch 12, a lower punch 13, an upper die 14, and a lower die 15. The upper punch 12 and the lower punch 13 are formed in a rectangular column shape having the same size, and can move independently in the vertical direction. These upper punch 12 and lower punch 13 are provided in the same direction on a line obtained by extending the center axis of each other.

  The upper mold 14 has a pair of upper mold members 14a and 14b and is moved in the vertical direction by an upper mold vertical mechanism (not shown). Each of the upper mold members 14a and 14b is formed in a shape bent at a right angle, and these end portions are joined together to form the upper mold 14 continuously in a square frame shape. The upper punch 12 is inserted into and removed from the upper die 14 by an upper punch driving mechanism (not shown).

  The upper mold members 14a and 14b are contacted and separated in the diagonal direction of the upper mold 14 by an upper mold opening / closing mechanism (not shown). In FIG. 2, arrows A and B indicate the contact and separation directions. When the upper mold members 14a and 14b are moved in the approaching direction A and are disposed at the closed position, the upper mold members 14a and 14b are joined together so that the upper mold 14 is closed. On the other hand, when the upper mold members 14a and 14b are moved in the separation direction B and arranged at the open position, the upper mold members 14a and 14b are separated from each other in the horizontal direction and the upper mold 14 is opened.

  The upper mold member 14a is higher than the upper mold member 14b. Accordingly, when the upper mold members 14a and 14b are moved to the closed position by the upper mold opening / closing mechanism and the upper mold 14 is assembled as shown in FIG. 2, the upper mold members 14a and 14b are interposed between the lower mold members 14a and 14b. A step G1 corresponding to the height difference between 14a and 14b is formed.

  The lower mold 15 includes a pair of lower mold members 15a and 15b, and is moved in the vertical direction by a lower mold vertical mechanism (not shown). The upper mold members 15a and 15b are both formed in a shape bent at a right angle, and these end portions are joined together to form the lower mold 15 continuously in a square frame shape. The lower punch 13 is inserted into and removed from the lower mold 15 from below by a lower punch driving mechanism (not shown).

  The upper mold members 15a and 15b are contacted and separated in the diagonal direction of the lower mold 15 by a lower mold opening / closing mechanism (not shown). In FIG. 2, arrows A and B indicate the contact and separation directions. When the lower mold members 15a and 15b are moved in the approaching direction A and disposed at the closed position, the ends of the lower mold members 15a and 15b are brought together to close the lower mold 15. On the other hand, when the lower mold members 15a and 15b are moved in the separation direction B and arranged at the open position, the lower mold members 15a and 15b are separated from each other in the horizontal direction and the lower mold 15 is opened.

  The lower mold member 15a is lower in height than the other lower mold member 15b. Thus, when the lower mold members 15a and 15b are moved to the closed position by the lower mold opening / closing mechanism and the lower mold 15 is assembled as shown in FIG. 2, the lower mold members 15a and 15b are placed between the lower mold members 15a and 15b. A step G2 corresponding to the difference in height between the members 15a and 15b is formed. The step G2 is the same as the height dimension difference between the upper mold members 14a and 14b.

  The lower mold member 15a having a lower height than the lower mold member 15b and the upper mold member 14a having a higher height than the upper mold member 14b face each other in the vertical direction. Similarly, the upper mold member 14b whose height is lower than that of the upper mold member 14a and the lower mold member 15b whose height is higher than that of the lower mold member 15a face each other in the vertical direction. For this reason, when the upper mold 14 and the upper mold 15 are overlapped, the lower surface of the lower mold 14 and the upper surface of the lower mold 15 are joined to each other.

  Fitting grooves 16 and 17 are individually formed on the upper surface of the lower mold 15, specifically, the upper surfaces of the lower mold members 15 a and 15 b having different heights. The depth of the fitting grooves 16 and 17 is substantially equal to the thickness of each of the terminal portions b1 and b2 of the coil 3, and the width is substantially equal to the width of each of the terminal portions b1 and b2 of the coil 3. The vertical dimension G3 (see FIG. 3) from the bottom surface of the fitting groove 16 provided in the lower mold member 15a having the lower height to the upper surface of the lower mold member 15b having the higher height is determined by the coil 3 equal to the height dimension H of 3. Further, the maximum separation dimension X between the pair of fitting grooves 16 and 17 provided in the lower mold 15 shown in FIG. 3 is equal to the coil length dimension W.

  The choke coil 1 is a green compact (pressure-molded body) that is pressure-molded using the molding die 11. The coil 3 is positioned and arranged in the molding die 11 before the core 2 is molded, and is embedded in the core 2 integrally with the pressure molding of the core 2. Therefore, this choke coil 1 can be referred to as an integrally molded coil component.

  The core 2 is made of a ferromagnetic metal powder. However, the core 2 may be made of a main component and a small amount of a coupling agent mixed therein. The ferromagnetic metal powder is a group of ferromagnetic metal particles coated with an insulating layer that functions as a binder. As the ferromagnetic metal particles, iron-based metal particles having features such as low powder hardness, high saturation magnetic flux density, and low loss characteristics can be used. Examples of this type of material include Fe powder, permalloy powder, carbonyl iron powder, Sendust powder and the like, and at least one of them can be selected.

  For the insulating layer coated on the surface of the ferromagnetic metal particles, a curable insulating material, preferably a thermosetting organic material that also functions as a binder can be used. Examples of the organic material include thermosetting resins such as epoxy resins, urethane resins, and polyimide resins, and at least one of them can be selected.

  Next, a method for manufacturing the choke coil 1 will be described. This manufacturing method includes a primary filling process, a coil setting process, a mold clamping process, a secondary filling process, a pressure forming process, a curing process, and a mold opening process, and the choke is sequentially performed through these processes. The coil 1 is manufactured.

  In the primary filling step, the pair of lower mold members 15a and 15b are arranged in a closed position to form a rectangular frame-shaped lower mold 15 and the lower punch 13 is inserted so as to form the bottom of the lower mold 15; A predetermined amount of ferromagnetic metal powder is filled in the lower mold 15.

  In the next coil setting step, one end b1 of the coil 3 is fitted into the fitting groove 16 of the lower mold member 15a having a lower height, and the other end b2 of the coil 3 is higher in height. It is made to fit in the fitting groove 17 of the lower mold member 15b. As a result, the coil 3 is placed over the lower mold members 15a and 15ba of the lower mold 15 filled with the ferromagnetic metal powder. In this mounted state, the coil 3 is positioned with respect to the lower mold 15 in the direction orthogonal to the direction in which the terminal portions b1 and b2 extend by engaging with the fitting grooves 16 and 17. In this case, the terminal portions b1 and b2 are prevented from protruding from the fitting grooves 16 and 17, respectively. Accordingly, since the maximum separation dimension X between the fitting grooves 16 and 17 and the coil length dimension W are equal, the coil 3 is also positioned with respect to the lower mold 15 in the direction in which the terminal portions b1 and b2 extend. . That is, in this coil setting process, the coil 3 is positioned in the XY direction.

  In the next mold clamping step, the upper mold 14 is held in a square frame shape, and the upper mold 14 is lowered and overlapped with the lower mold 15. As a result, the lower surface of the upper die 14 having a step and a rectangular frame shape is joined to the upper surface of the lower die 15 having a step and a rectangular frame shape, and the upper die 14 and the lower die are joined. 15, the terminal portions b <b> 1 and b <b> 2 of the coil 3 are sandwiched between the upper and lower mold apparatuses.

  In the next secondary filling step, the upper mold 14 is filled with a ferromagnetic metal powder. Thereby, the ferromagnetic metal powder is filled over the lower mold 15 and the upper mold 14, and the coil 3 is buried therein.

In the next pressure forming step, first, the upper punch 12 is lowered and inserted into the upper die 14, and then the upper punch 12 and the lower punch 13 are moved so as to be relatively close to each other. In this case, it is preferable to move at least one of the upper and lower punches, preferably both. Thereby, a molding pressure is applied to the ferromagnetic metal powder in the upper and lower mold apparatus by the upper punch 12 and the lower punch 13, and the core 2 is compression molded. In this case, the molding pressure is desirably ² to 5 ton / cm ² .

  In the next curing treatment step, the compression-molded core 2 is heated while being pressed and held by the upper punch 12 and the lower punch 13 to thermally cure the insulating material coated with the ferromagnetic metal particles forming the core. In this case, the optimum thermosetting temperature can be set in the range of 100 ° C. to 300 ° C., although it varies depending on the type of insulating material. The pressure applied to the core 2 is maintained from the start of curing to the end of curing, and this applied pressure is applied in a magnitude that prevents the core from expanding due to an insulating material whose temperature rises during the curing process, for example, in a pressure molding process. It can be set equal to or lower than the molding pressure. The time required for this curing process is 10 to 30 minutes.

  The mold opening process is a process of taking out the core 2 enclosing the coil 3 from the molding die 11. In this step, the pair of upper mold members 14a and 14b of the upper mold 14 and the pair of lower mold members 15a and 15b of the lower mold 15 are opened diagonally, and the upper punch 12 and the lower punch 13 are separated from each other. To move the upper and lower punches away from the core 2 and take out the core 2. In this case, when the lower die 15 is opened, the lower die 15 is slightly lowered or the lower punch 13 is slightly raised to correspond to the thickness of the terminal portions b1 and b2 of the coil 3, and the fitting groove This is performed after removing the terminal portions b1 and b2 from 16 and 17.

  On the side surface of the core 2 thus manufactured, parting line marks 4a and 4b corresponding to the joints of the upper die 14 and the lower die 15 are shown in FIGS. 1B and 1C in the thickness direction of the core 2. It is formed to be shifted. Then, as shown in FIG. 1 (B), the end portions b1 and b2 of the coil 3 protruding from the side surface of the core 2 are bent as shown in FIG. 1 (C) to form the choke coil 1 as the final product. Is done.

  The core 2 of the choke coil 1 manufactured by the above procedure can be removed from the molding die without rubbing the side surface of the core against the inner surface of the molding die 11 by the mold opening process described above. In addition, since the movement for removing the terminal portions b1 and b2 from the fitting grooves 16 and 17 is very slight, the friction of the core 2 against the inner surface of the lower mold 15 can be ignored in practice. Furthermore, the expansion of the insulating material of the core 2 is suppressed by the curing process step under pressure holding. In addition, by positioning the coil 3 with respect to the molding die 11 in the coil setting step, variations in the position of the coil 3 in the core 2 due to molding pressure can be suppressed. In particular, since the fitting grooves 16 and 17 of the lower mold 15 are displaced in the vertical direction (thickness direction of the coil 3) in accordance with the difference in height between both end portions b1 and b2 of the coil 3, the coil 3 is the core 2 The occurrence of cracks in the core 2 can be suppressed without shifting in the vertical (thickness) direction.

  Therefore, according to the manufacturing method described above, it is possible to manufacture the choke coil 1 that can suppress variations in magnetic characteristics, ensure insulation on the side surface of the core, and improve inductance. This was confirmed by the following examples.

(Example)
Five samples A were manufactured by the described manufacturing procedure using a ferromagnetic metal powder obtained by mixing 3% by weight of an insulating material made of epoxy resin with carbonyl iron powder and the molding die 11, and inductance and The insulation resistance between the terminal and the core was measured. In this case, the used coil 3 has the dimensions described above, the molding pressure in the pressure molding process is 3 ton / cm ² , the pressing force by the upper and lower punches in the curing process is 500 kg / cm ² , and heating at that time The temperature was 150 ° C.

In addition, using the same magnetic metal powder as sample A and the molding die 11, five samples B were manufactured under the conditions where the curing process was omitted, and the inductance and the insulation resistance between the terminal and the core were measured for each sample B. It was measured. In this case, the molding pressure in the pressure molding step is 3 ton / cm ² which is the same as that of the sample A.

  Furthermore, using the metal mold | die which concerns on the conventional manufacturing method, and using the same magnetic metal powder as the sample A, five samples C were manufactured and the inductance and the insulation resistance between a terminal and a core were measured about each. Therefore, these samples C were extruded from the mold while rubbing the side surfaces against the inner surface of the mold.

Table 1 shows the measurement results for the above samples A to C.

  According to Table 1, compared with the insulation resistance of the sample C of the conventional product, the insulation resistance of 10 times or more is recognized for the samples A and B obtained by the mold opening process and taking out the core 2 from the molding die 11. Insulation performance was greatly improved. Moreover, it was recognized that the sample B can obtain a higher inductance than the inductance of the sample C of the conventional product, and further, it was recognized that the sample A can obtain a higher inductance than the sample B.

  The present invention can also be applied to an inductor such as a choke coil having a structure in which the coil and the terminal are separated and connected by welding or the like, and the coil is not a flat copper wire but has a circular cross-sectional conductivity. In the case of a metal wire, it can also be applied to an inductor such as a choke coil having a structure in which this is not a single layer winding but a multiple layer winding.

(A) is a perspective view which shows the coil used for the choke coil which concerns on one Embodiment of this invention. FIG. 2B is a perspective view showing a core in which the coil of FIG. FIG. 2C is a perspective view showing a state where the core of FIG. 1B is completed as a choke coil. The perspective view which decomposes | disassembles and shows the metal mold | die used for manufacture of the choke coil of FIG. 1 (B) with a coil. The perspective view which shows the state by which the coil was set to the lower mold | type of the shaping die of FIG.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... Choke coil (inductor), 2 ... Core, 3 ... Coil, b1, b2 ... End part of coil, 4a, 3b ... Parting line trace, 11 ... Molding die, 12 ... Upper punch, 14 ... Upper die, 14a, 14b ... upper die member, 15 ... lower die, 15a, 15b ... lower die member, 16, 17 ... fitting groove

Claims (5)

A method of manufacturing an inductor in which a coil is embedded in a quadrangular columnar core made of a pressure-formed body of ferromagnetic metal powder coated with a surface of ferromagnetic metal particles with a curable insulating material,
Square columnar upper punch, upper die having a pair of upper die members that are combined in a square frame shape and are contacted and separated in a diagonal direction and into which the upper punch is inserted, a square columnar lower punch, and a square frame shape And using a molding die having a lower mold into which the lower punch is inserted, having a pair of lower mold members that are combined and separated in a diagonal direction,
A primary filling step of filling the ferromagnetic metal powder into the lower mold in which the lower punch is inserted;
A coil setting step of placing the coil over both lower mold members of the lower mold;
A mold clamping step of overlapping the upper mold on the lower mold and sandwiching a terminal portion of the coil between the upper mold and the lower mold;
A secondary filling step of filling the ferromagnetic metal powder in the upper mold so that the coil is embedded;
A pressure molding step of compressing and molding the core by applying a molding pressure to the ferromagnetic metal powder with the upper punch and the lower punch;
A mold opening step of opening the pair of upper mold members and the pair of lower mold members in a diagonal direction and taking out the core from between the upper punch and the lower punch,
An inductor manufacturing method comprising: A method of manufacturing an inductor in which a coil is embedded in a quadrangular columnar core made of a pressure-formed body of ferromagnetic metal powder coated with a surface of ferromagnetic metal particles with a curable insulating material,
Square columnar upper punch, upper die having a pair of upper die members that are combined in a square frame shape and are contacted and separated in a diagonal direction and into which the upper punch is inserted, a square columnar lower punch, and a square frame shape And using a molding die having a lower mold into which the lower punch is inserted, having a pair of lower mold members that are combined and separated in a diagonal direction,
A primary filling step of filling the ferromagnetic metal powder into the lower mold in which the lower punch is inserted;
A coil setting step of placing the coil over both lower mold members of the lower mold;
A mold clamping step of overlapping the upper mold on the lower mold and sandwiching a terminal portion of the coil between the upper mold and the lower mold;
A secondary filling step of filling the ferromagnetic metal powder in the upper mold so that the coil is embedded;
A pressure molding step of compressing and molding the core by applying a molding pressure to the ferromagnetic metal powder with the upper punch and the lower punch;
A curing treatment step for curing the insulating material in a state where the compression-molded core is pressed and held by the upper punch and the lower punch;
A mold opening step of opening the pair of upper mold members and the pair of lower mold members in a diagonal direction and taking out the core from between the upper punch and the lower punch,
An inductor manufacturing method comprising: The method for manufacturing an inductor according to claim 2, wherein the curing process is performed while applying a pressure of 500 kg / cm ² or more from the start of curing of the insulating material to the completion of curing.   Each of the pair of lower mold members has a fitting groove having a depth corresponding to the thickness of the terminal portion of the coil on the upper surface thereof, and one lower mold member is formed higher than the other lower mold member. The height difference between the upper surface of the lower lower mold member and the bottom surface of the fitting groove of the lower lower mold member is the same as the height dimension of the coils, and the pair One upper mold member that is superimposed on the lower mold member having the lower height among the upper mold members of the upper mold member is more than the other upper mold member that is superimposed on the lower mold member having the higher height. The inductor manufacturing method according to any one of claims 1 to 3, wherein the mold clamping step is performed with the coil interposed between the upper mold and the lower mold.   An inductor manufactured by the manufacturing method according to claim 4 and having a coil embedded in a quadrangular columnar core made of a pressure-molded body of ferromagnetic metal powder coated with a curable insulating material on the surface of the ferromagnetic metal particles. The parting line marks attached to the two adjacent side surfaces of the core and the parting line marks attached to the other two side surfaces adjacent to the core are arranged in the height direction of the core. Inductor provided by shifting.

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