JP2007081306A - Sealed coil-type magnetic component and method of manufacturing same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a sealed coil-type magnetic component that prevents the occurrence of cracks in a magnetic body portion and can reduce a degradation of DC superposition characteristics, and to provide a method of manufacturing the sealed coil-type magnetic component. <P>SOLUTION: In the sealed coil-type magnetic component 10, having an air-core coil and a magnetic body portion made of the mixture of magnetic powder including the coil and resin, the magnetic body portion 7 comprises a region including the coil and a region without including the coil. When the average density of the region including the coil of the magnetic body section and that of a region without including the coil of the magnetic body section are expressed as D1 and D2, respectively, the sealed coil-type magnetic component 10 is composed so that a relationship of D1<D2 is satisfied. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a coil-enclosed magnetic component composed of an air-core coil and a magnetic body part that encloses the coil, and more particularly, a large-current compatible coil-enclosed magnetic component mounted on a power supply system circuit and its It relates to a manufacturing method.

  In recent years, it has been required to mount a large number of high-performance magnetic components along with the improvement in performance of electronic devices, and further downsizing of magnetic components has been particularly required as electronic devices have been downsized. Further, magnetic parts in a circuit such as a DC / DC converter are required to handle a large current, and safety of magnetic parts, that is, high reliability is also required.

  2. Description of the Related Art Conventionally, as a coil-enclosed magnetic component that can achieve the above-described requirements, a chip-type inductor that is pressure-molded with a mixture of metal magnetic powder and resin so as to enclose a coil wound with an air core and a molding method thereof are known. (See Patent Document 1). According to this, after a metal magnetic powder of about 70% of the total amount is filled in the lower mold in advance, the work consisting of the coil and the lead frame is installed so as to be sandwiched between the upper mold and the middle mold, The chip type inductor is obtained by filling the remaining powder from above and performing pressure molding.

  In addition, the coil-encapsulated type has a configuration in which the powder density of the magnetic body portion of the coil-enclosed magnetic component is substantially uniform as a whole, which improves the electrical characteristics of the magnetic component and eliminates internal stress. A magnetic component and a manufacturing method thereof are known (see Patent Document 2). According to this, when manufacturing the coil-embedded dust core, the cylindrical divided body (tubular member) of the mold used in the consolidation step is moved, so that the coil and the lead frame in the magnetic body portion are moved. The coil-embedded powder magnetic core is molded while appropriately moving and adjusting so as to eliminate the density difference of the magnetic powder between the corresponding portion and the other portions.

  Furthermore, in order to achieve a reduction in the height of the coil-enclosed magnetic component, the density of the magnetic powder in the magnetic body portion of the upper surface portion and the lower surface portion of the coil component exterior portion is made larger than the density of the magnetic powder in the intermediate portion. 2. Description of the Related Art A coil-enclosed magnetic component molded into a mold is known (see Patent Document 3). According to this, the magnetic permeability of the portion of the magnetic body portion that tends to be thin can be improved, and characteristics equivalent to those of the intermediate portion of the magnetic body portion can be ensured.

JP 2003-290992 A JP 2003-282346 A Japanese Patent No. 3654251

  However, in the coil-encapsulated magnetic component described in Patent Document 1, when the component is pressure-molded, when the substance is compressed into the region where the coil is included in the magnetic body portion by the elasticity of the coil A springback phenomenon occurs in which the material is returned to its original state, and there is a problem that cracks and cracks occur in the magnetic body portion.

  Further, in the coil-encapsulated magnetic component described in Patent Document 2, the cross-sectional area of the portion through which the magnetic flux generated in the magnetic core is transmitted is small in the region where the coil is contained. Magnetic saturation is likely to occur. Therefore, the problem that the direct current superimposition characteristic of a coil enclosure powder magnetic core falls arises.

  In addition, the coil-enclosed magnetic component described in Patent Document 3 requires a molding process for creating green compacts that are temporarily molded separately from the upper and lower sides, and the upper and lower surfaces of the outer surface of the coil-enclosed magnetic component. It is necessary to increase the density of the magnetic powder throughout. For this reason, in the coil-enclosed magnetic part, the area where the density of the magnetic material should be increased is large. Therefore, when the manufacturing technology of the coil-enclosed magnetic part that requires general high-pressure molding is used, the pressurizing apparatus is increased in size and size. There arises a problem such as an increase in cost due to an increase in pressure treatment time.

  Furthermore, in the coil-enclosed magnetic component described in the above-mentioned patent document, no particular consideration is given to the outer region of the region in which the coil is encapsulated, that is, the vicinity of the side periphery, and the desired electrical characteristics. In order to obtain a sufficient amount of cross-sectional area in the vicinity of the side periphery where the magnetic flux passes, it is necessary to secure a sufficient cross-sectional area by design. In mounting, the mounting substrate becomes large, and the problem arises that the electronic device on which the coil magnetic component is mounted becomes large. Further, when the air-core coil has a strong spring property, there is a possibility that a crack may occur in the side peripheral portion of the coil-enclosed magnetic component.

  In view of the above-described problems, an object of the present invention is to provide a coil-enclosed magnetic component that is small in size and excellent in mountability, and a method for manufacturing the same.

  In order to solve the above-described problems and achieve the object of the present invention, a coil-encapsulated magnetic component according to the present invention comprises an air-core coil, a magnetic body part comprising a mixture of magnetic powder and resin containing the coil. The magnetic body portion includes a region in which the coil is included and a region in which the coil is not included, and the coil of the magnetic body portion includes the coil. When the average density of the green compact located in the region is D1, and the average density of the green compact located in the region where the coil of the magnetic part is not included is D2, the relationship is D1 <D2. It has a certain configuration.

  Preferably, it is appropriate that the magnetic part has a step at a boundary between a region in which the coil is included and a region in which the coil is not included.

  A method for manufacturing a coil-enclosed magnetic component according to the present invention is a method for manufacturing a coil-enclosed magnetic component including an air-core coil, and a magnetic body portion made of a mixture of magnetic powder and resin containing the coil. A step (a) of filling the magnetic powder so as to cover the coil, and a step (b) of consolidating the magnetic powder covering the coil in the axial direction of the coil. a) The magnetic material powder is filled so that the amount of the magnetic powder filled in the region where the coil is not included is larger than the amount of the magnetic powder filled in the region where the coil is included. An average density of the green compact that is filled with body powder and is located in a region where the coil of the magnetic part is included is D1, and a green compact that is located in a region where the coil of the magnetic part is not included When the average density of D2 is D2 D1 <and is to a relationship of D2.

  In the coil-enclosed magnetic component according to the present invention, the amount of the mixed magnetic powder filled in the region where the coil is not included is larger than the amount of the mixed magnetic powder filled in the region where the coil is included. That is, the average density of the compressed mixed magnetic powder (green compact) in the region where the coil is not included is calculated as the average density of the compressed mixed magnetic powder (green compact) in the region where the coil of the magnetic body is included. The thickness of the magnetic body in the direction perpendicular to the winding axis direction of the coil is reduced.

  In the method for manufacturing a coil-enclosed magnetic component according to the present invention, the amount of the mixed magnetic powder filled in the region where the coil is not included is the same as the amount of the mixed magnetic powder filled in the region where the coil is not included. In other words, the average density of the compressed mixed magnetic powder (green compact) in the area where the coil of the magnetic part is not included is compressed magnetic mixed in the area where the coil is included. The mixed magnetic powder is filled so as to be higher than the average density of the powder (green compact), and the thickness of the magnetic body portion in the direction perpendicular to the coil winding axis is reduced.

  According to the coil-enclosed magnetic component according to the present invention, by increasing the average density of the compressed mixed magnetic powder (green compact) in the region where the coil is not included, that is, in the vicinity of the side periphery of the magnetic body portion. Since the side periphery can be made small and thin, the floor area of the coil-enclosed magnetic part can be reduced.

  In addition, according to the coil-enclosed magnetic component according to the present invention, since the step is provided between the region in which the coil is included and the region in which the coil is not included, the region in which the coil is included, and the coil It is possible to increase the difference in the average density of the green compact with respect to the region in which no is included. Further, by providing such a step, it is possible to simplify the molding conditions of the coil-enclosed magnetic component for obtaining a desired difference in average density.

  According to the method of manufacturing a coil-encapsulated magnetic component according to the present invention, the mixed magnetic powder is filled so that the average density of the green compact is increased in the region where the coil is not included, that is, in the vicinity of the side periphery of the magnetic body portion. By doing so, it is possible to manufacture a small coil-enclosed magnetic component with a small and thin side periphery.

  BEST MODE FOR CARRYING OUT THE INVENTION The best mode for carrying out a coil-encapsulated magnetic component and a method of manufacturing the component according to the present invention will be described below with reference to the drawings. However, the present invention is not limited to the following mode. .

  FIG. 1A is a perspective view of a coil-enclosed magnetic component according to an embodiment of the present invention. FIG. 1B is a perspective view showing the inside of the coil-enclosed magnetic component according to the embodiment of the present invention.

  As shown in FIG. 1A, the coil-enclosed magnetic component 10 of the present embodiment includes a three-dimensional magnetic body portion 7 having an upper surface and a lower surface whose upper and lower surfaces are substantially square, and a side surface portion of the magnetic body portion 7. It consists of a pair of terminal electrodes 4 and 5 exposed from. As shown in FIG. 1B, the coil 1 connected to the terminal electrodes 4 and 5 is included in the magnetic body portion 7 of the coil-embedded magnetic component 10. The coil 1 has an air core having a hollow portion composed of a winding portion 3 around which a flat conductor 2 is wound and laminated, and end portions 3 a and 3 b provided at the end of the winding portion 3. It is a coil. Terminal electrodes 4 and 5 are connected to the coil ends 3a and 3b, respectively.

  FIG. 2A is a cross-sectional view of the coil-enclosed magnetic component taken along the line AA shown in FIG. FIG. 2B is a cross-sectional view of the coil-enclosed magnetic component taken along the line BB shown in FIG.

  Here, as shown in FIG. 2A, the region in which the coil 1 is included in the magnetic body portion 7, that is, the region R <b> 1 corresponding to the winding portion 3 of the coil 1 is the axial direction (thickness) of the coil 1. The direction corresponding to the upper surface and the lower surface of the winding part 3 in the magnetic body part 7 with respect to (direction). In addition, the region in which the coil 1 is not included in the magnetic body portion 7, that is, the region that does not correspond to the winding portion 3 of the coil 1 is the hollow of the coil 1 in the magnetic body portion 7 on the basis of the axial direction of the coil 1. A portion obtained by extending the portion to the upper surface and the lower surface is referred to as R2, and a portion obtained by extending the outer peripheral outer side portion (side peripheral portion) of the coil 1 in the magnetic body portion 7 to the upper surface and the lower surface is referred to as R3.

  Further, as shown in FIG. 2A, the coil-encapsulated magnetic component 10 of the present embodiment is magnetic on the mounting end side of the terminal electrodes 4 and 5 connected to the coil 1 with respect to the thickness direction. It extends from near the center of the body part 7. That is, the coil-encapsulated magnetic component 10 in the present embodiment includes the distance H1 from the terminal electrodes 4 and 5 protruding from the magnetic body portion 7 to the upper surface of the magnetic body portion 7 and the terminal electrode 4 protruding from the magnetic body portion 7. The distance H2 from 5 to the lower surface of the magnetic part 7 is equal. Further, the distance H3 from the upper surface of the winding part 3 of the coil 1 enclosed in the magnetic body part 7 to the upper surface of the magnetic body part 7 and from the lower surface of the winding part 3 of the coil 1 to the lower surface of the magnetic body part 7 The distance H4 is also equal. Furthermore, as will be described later, the coil-encapsulated magnetic component 10 according to the present embodiment has the coil 1 in which the average density of the compressed magnetic powder mixture (green compact) in the magnetic body portion 7 is defined as D. The average density D2 of the region R2 corresponding to the hollow portion and the region R3 corresponding to the side peripheral portion of the coil 1 is higher than the average density D1 of the region R1 corresponding to the winding portion 3 of the coil 1.

  First, the magnetic body portion 7 of the coil-enclosed magnetic component 10 will be described. The magnetic part 7 is produced by adding and mixing an insulating material to the magnetic metal powder, and then pressurizing under predetermined conditions. Further, after producing a magnetic metal powder to which an insulating material has been added, a lubricant may be further added and mixed. The lubricant may be appropriately selected from, for example, aluminum stearate, barium stearate, magnesium stearate, calcium stearate, zinc stearate and strontium stearate.

  Examples of the magnetic metal powder used for the magnetic body portion 7 include a single metal powder, two or more kinds of metal powders having different compositions, or a metal alloy powder. The metal powder can be composed of any transition metal element exhibiting soft magnetism, or an alloy composed of a transition metal element and another metal element. Specific examples of the soft magnetic metal include an alloy mainly composed of one or more of Fe, Co, and Ni. For example, permalloy (Fe—Ni alloy, Fe—Ni—Mo alloy), sendust (Fe—Si). -Al alloy), Fe-Si alloy, Fe-Co alloy, Fe-P alloy and the like are preferable.

  In the present embodiment, Si—Fe based powder is used as the magnetic powder. Further, the shape of the particles of the ferromagnetic powder used for the magnetic part 7 is not particularly limited, but it is preferable to use a spherical powder or an elliptical powder. The magnetic powder can be obtained by a gas atomizing method, a water atomizing method, a rotating disk method or the like.

  Also, the magnetic powder particles are insulated by mixing with the insulating material. The insulating material is appropriately selected according to the required characteristics of the magnetic core. For example, various organic polymer resins, silicone resins, phenol resins, epoxy resins, water glass, etc. may be used as the insulating material. In addition, these resins and inorganic substances may be used in combination. In the present embodiment, the magnetic powder is insulated and coated using an epoxy resin.

  Next, the structure of the coil 1 used in the present embodiment will be described with reference to FIG. As shown in FIG. 1B, the coil 1 is obtained by winding a strip-like conductor 2 having a flat cross section having an insulating film by edgewise winding with a number of turns specified by desired electrical characteristics. Here, examples of the flat cross section include a rectangular, trapezoidal, and elliptical cross section. As the conductor 2 having a rectangular cross section, there is a flat wire that is an insulation-coated copper wire. Further, the insulating coating of the conductor 2 can usually be enamel coating, but a self-bonding coating capable of maintaining the shape of the coil wound around the air core by coating coating may be adopted. In this case, there is an advantage that the shape of the coil is not easily collapsed even if high pressure molding is performed.

  When the coil 1 is formed by winding the flat conductor 2, the layers of the windings constituting the coil 1 can be brought into extremely close contact with each other. Therefore, the current capacity per volume can be improved as well as being advantageous for lowering the height than the case of using a conductor having a circular cross section. In addition, the wire occupation ratio can be greatly improved as compared with the case where the coil 1 is formed by winding a conductor having the same number of turns and a circular cross section. Therefore, the coil 1 produced by winding the flat conductor 2 is preferable in producing a coil encapsulated magnetic component for large current.

  Next, the structure of the terminal electrodes 4 and 5 used in the coil-encapsulated magnetic component 10 according to the present embodiment will be described with reference to FIG.

FIG. 4 is a perspective view of a terminal electrode used in the coil-encapsulated magnetic component of the present embodiment.
As shown in FIG. 4, a pair of bifurcated connection end portions 4a and 5a for connecting to the end portions 3a and 3b of the coil 1 are formed at one end portion of the terminal electrodes 4 and 5 by welding or the like. Yes. In addition, mounting end portions 4c and 5c for connection to a substrate or the like are formed on the other end portion of the terminal electrodes 4 and 5 by solder or the like. The terminal electrodes 4 and 5 are formed by punching a metal plate lead frame of 0 mm <thickness dimension ≦ 0.5 mm and bending it.

  Of the end portions 3a and 3b of the edgewise coil 1 described above, the terminal electrode 4 connected to the end portion 3a positioned below with respect to the thickness direction is provided between the connection end portion 4a and the mounting end portion 4c. A two-stage bent portion 4b is formed. The connecting end 4a is formed at a position lower than the connecting end 5a of the paired terminal electrode 5 by the bent portion 4b on the connecting end 4a side. That is, when the terminal electrodes 4 and 5 are included in the magnetic body portion 7, the connection end portion 4 a of the terminal electrode 4 and the connection end portion 5 a of the terminal electrode 5 are arranged to be different from each other. become. Then, the upper surface of one connection end 4a of the terminal electrode 4 and the lower surface of the end 3a of the coil 1 are connected by welding, a conductive adhesive, or the like. Further, the lower surface of one connection end 5a of the terminal electrode 5 and the upper surface of the end 3b of the coil 1 are connected by welding or a conductive adhesive.

  In the coil-encapsulated magnetic component 10 according to the present embodiment, a pair of terminal electrodes 4 and 5 formed so that the heights of the connecting end portions are different from each other when used in the magnetic body portion 7 are used. To do. Therefore, even when the edgewise winding coil 1 having different heights of the coil end portions 3a and 3b of the coil 1 is used, the connection between the coil 1 in the magnetic body portion 7 and the terminal electrode is reliably performed. be able to. In addition, by using the terminal electrodes 4 and 5 thus configured, in the molding process of the coil-enclosed magnetic component 10 described later, the terminal electrodes 4 and 4 are formed from the center of the magnetic body portion 7 with the thickness direction as a reference. 5 can be pulled out and held in the horizontal direction. For this reason, at the time of pressure molding of magnetic powder, it has excellent balance when consolidating from the top and bottom direction of the coil-enclosed magnetic core, and there are defects such as cracks even if the side periphery of the magnetic body is small and thin. It has the advantage that it does not occur easily.

  Further, as shown in FIG. 2A, the coil-enclosed magnetic component 10 according to the present embodiment has a height of a region R2 that does not correspond to the winding portion 3 of the coil 1 with respect to the winding axis direction of the coil 1. H6 is formed to be higher than the height H5 of the region R1 corresponding to the winding part 3 of the coil 1. That is, a step h is formed between the region R2 that does not correspond to the winding part 3 of the coil 1 and the region R1 that corresponds to the winding part 3 of the coil 1. The step h is formed on the side where the terminal ends 4 c and 5 c are bent and the mounting end portions 4 c and 5 c are arranged, that is, on the mounting surface side of the coil-encapsulated magnetic component 10.

  In the present embodiment, the axial height H6 of the region R2 that does not correspond to the winding portion 3 is about 0.1 mm higher than the height H5 of the region R2 that does not correspond to the winding portion 3 of the coil 1. It is formed as follows. That is, the height of the step h is set to be 0 mm <h ≦ 0.4 mm, and the terminal electrodes 4 and 5 are set to be 0.1 mm ≦ the height in the axial direction ≦ 0.5 mm. . In addition, the intensity | strength with respect to the bending process at the time of forming a mounting terminal part is securable by making the dimension of the height direction of the terminal electrodes 4 and 5 used into said dimension. In addition, by setting the cross-sectional area of the terminal electrodes 4 and 5 in the thickness direction to a predetermined size, it is possible to apply a voltage necessary for flowing a large current to the magnetic component.

  In addition, the cream is set by setting the height at which the lower surfaces of the terminal electrodes 4 and 5 are located lower than the height at which the lower surface of the region R2 not corresponding to the winding part 3 is positioned with respect to the axial direction. When the terminal electrodes 4 and 5 are mounted on the substrate by solder or the like, it is possible to prevent the cream solder or the like from being excessively attached to the region R2 that does not correspond to the winding part 3 by mistake. That is, the accuracy of attaching the coil-encapsulated magnetic component 10 to the substrate can be increased.

  Furthermore, by setting the height of the step h to a value smaller than the height dimension of the terminal electrodes 4 and 5, when the coil-enclosed magnetic component 10 is mounted on the substrate, the substrate and the coil magnetic component The gap formed between them can be reduced, and the mountability of the coil-enclosed magnetic component to the substrate can be improved.

  As described above, according to the coil-encapsulated magnetic component 10 of the present embodiment, the step h is provided between the region R1 in which the coil is included and the region R2 in which the coil is not included. The difference in the average density of the green compacts can be increased, and the work efficiency when mounting the magnetic component on the substrate can be improved.

  Further, as shown in FIG. 2B, a magnetic path l through which the magnetic flux Φ passes in the direction indicated by the arrow is formed inside the coil-encapsulated magnetic component 10 of the present embodiment.

  Here, let S1 be the cross-sectional area of the portion where the magnetic flux Φ penetrates in the region R3 corresponding to the side periphery of the magnetic body portion 7, and let S2 denote the cross-sectional area of the portion where the magnetic flux Φ penetrates in the region R2 corresponding to the hollow portion of the coil. Then, in a normal coil-enclosed magnetic component, since the relationship of S1 ≦ S2 is established, magnetic saturation first occurs in the S1 portion. For this reason, in the region R3 corresponding to the side peripheral portion, the cross-sectional area S1 needs to be secured to a certain size, so that a certain amount of thickness is provided in the direction perpendicular to the winding axis direction of the coil. The problem that parts become large will arise.

  However, in the coil-encapsulated magnetic component 10 according to the present embodiment, by increasing the filling amount of the mixed magnetic powder in the region R3 corresponding to the side periphery, the magnetic body portion of the portion where the cross-sectional area S1 through which the magnetic flux Φ passes is formed. The average density D is formed so as to be high. As a result, the maximum saturation magnetic flux density Bm of the magnetic material in the region R3 can be increased. Therefore, even if the thickness in the direction perpendicular to the winding axis direction of the coil is reduced, the direct current of the coil-encapsulated magnetic component is comparable to that of the conventional case. The superposition characteristics can be maintained, and the strength of the magnetic body portion in the region R3 is improved, so that the stress generated by the spring property of the air-core coil is affected, and cracks that can occur in the coil side periphery are generated. It becomes possible to suppress.

FIG. 3 is a cross-sectional view comparing the coil-encapsulated magnetic component of the present embodiment and a conventional coil-encapsulated magnetic component.
As shown in FIG. 3, the present embodiment is compared with the region R3 corresponding to the side periphery of the magnetic body portion 7 in the conventional coil-encapsulated magnetic component 100 with reference to the length in the direction perpendicular to the winding axis direction of the coil 1. The region R3 of the coil-encapsulated magnetic component 10 in the form is thinner by d. Thus, according to the coil-encapsulated magnetic component 10 of the present embodiment, the maximum saturation magnetic flux density Bm is increased by increasing the average density of the green compact in the region R3 near the side periphery of the magnetic body portion 7. Therefore, the side periphery can be made small and thin, and the coil-enclosed magnetic component 10 can be made small.

  FIG. 5 is a bottom view of the coil-enclosed magnetic component according to the present embodiment. FIGS. 6A to 6D are bottom views of coil-enclosed magnetic components according to other embodiments.

  As shown in FIG. 5, the magnetic body portion 7 on the mounting surface side of the coil-enclosed magnetic component is formed with a portion where the mounting end portions 4c and 5c of the terminal electrodes 4 and 5 are bent. A step h ′ is formed so as to be connected to the step h. That is, a concave portion is formed at the bottom of the magnetic body portion 7 along the mounting end portions 4c and 5c. By providing such a recess, the height of the coil-enclosed magnetic component 10 can be reduced without increasing the height dimension of the coil-enclosed magnetic component.

  Further, in the present embodiment, the step h provided in the magnetic part 7 is formed along the boundary between the region R1 in which the coil is included and the regions R2 and R3 in which the coil is not included. However, the shape of the level difference h is not limited to this. For example, as shown in FIGS. 6A to 6D, depending on the connection means between the coil and the terminal electrode, the state of stress generation, and the like. You may change suitably to the level | step difference h. In this case, the shape of the step h can be specified by changing the shapes of the lower punch and the movable punch in the mold used in the molding process described later.

  Next, an embodiment of a method for manufacturing a coil-enclosed magnetic component according to the present invention will be described with reference to FIGS. In addition, the manufacturing method of the coil enclosure type magnetic component which concerns on this invention is not restricted to the following embodiment.

  FIG. 8 is a flowchart showing the manufacturing process of the coil 1 contained in the magnetic body portion 7 of the coil-enclosed magnetic component 10 and the lead frame that becomes the terminal electrode. As shown in FIG. 8, in producing the coil and the terminal electrode, in the winding process (step S101), the coil end film peeling process (step S102), the lead frame creating process (step S103), the coil and the lead And a step of connecting to the frame (step S104).

  First, in step S101, the winding portion 3 of the coil 1 is formed by winding the flat conductor 2 as shown in FIG. The number of turns of the conductor 2 is appropriately set according to the required inductance value. Next, in step S102, the coating at the coil end obtained as described above is peeled off. Next, in step S103, a metal plate is punched out to produce a lead frame having a connection portion for connection with the coil. Furthermore, in step S104, the connection between the coil end portion from which the coating has been peeled off in step S103 and the lead frame connection portion is performed by means such as welding.

  FIG. 9 is a flowchart showing a manufacturing process of the coil-encapsulated magnetic component of the present embodiment. In addition, the coil 1 which wound the flat conductor 2 with which the terminal electrodes 4 and 5 were connected shall be produced previously. First, a magnetic metal powder and an insulating material are selected according to necessary magnetic characteristics, and these are weighed (step S201). After weighing, the magnetic metal powder is coated with an insulating material and granulated at the same time (step S202).

  After adding a lubricant as necessary, the process proceeds to the molding step (step S203). Hereinafter, the molding process in step S203 will be described with reference to FIGS. FIG. 10 is a flowchart showing each step of the molding process. Moreover, FIGS. 11-12 has shown the mode of the shaping | molding process using a metal mold | die.

  First, the metal mold | die used for the shaping | molding process in this Embodiment is demonstrated using Fig.11 (a). As shown in FIG. 11 (a), the mold is composed of an upper part mold 15 a and a lower part mold 15 b, an upper punch 16 and a lower punch 17. The upper die 15a and the lower die 15b, the upper punch 16 and the lower punch 17 are provided at positions facing each other, and the upper punch 15a and the upper punch that moves up and down in the upper die 15a are provided. 16 constitutes an upper die, and a lower die 15b and a lower punch 17 moving up and down in the lower die 15b constitute a lower die. The lower punch 17 is divided into a lower punch 17a and a lower punch (movable punch) 17b having a top portion substantially the same as the planar shape of the coil 1. The lower punch 17a and the movable punch 17b are arranged on the lower side. It moves up and down freely in the part mold 15b. Further, the lower punch 17a has a structure that moves in conjunction so as to consolidate the region R2 corresponding to the air core portion of the coil 1 and the region R3 corresponding to the side peripheral portion of the coil-embedded magnetic component 10. Accordingly, the average density D2 of the regions R2 and R3 other than the region where the connection end portions 4a and 5a of the terminal electrode 4 are embedded is substantially equal.

  Thus, the reason why the movable punch 17b is provided in the lower punch 17 is that the region R1 corresponding to the winding portion 3 of the coil 1 in the magnetic body portion 7 and the region R2 not corresponding to the winding portion 3 of the coil 1; This is to make the average density D different from R3. That is, this is a device for filling the regions R2 and R3 not corresponding to the winding portion 3 of the coil 1 with more mixed magnetic powder than the region R1 corresponding to the winding portion 3 of the coil 1.

  Before starting the molding process (step S203), the mold is in the state shown in FIG. As will be described below, the positions of the upper mold 15a, the upper punch 16, the lower punch 17a, and the movable punch 17b are changed from the state shown in FIG. 11A in each step of the molding process (step S203). However, the lower mold 15b does not move from the predetermined reference plane in any step.

  Hereinafter, using the upper surface of the lower mold 15b as a reference plane (hereinafter referred to as “reference plane”), the upper mold 15a, the lower mold 15b, the upper punch 16, and the lower punch in the molding step (step S203). The relative movement of 17a and movable punch 17b will be described. Here, in FIGS. 11 to 12, description will be made using a cross section taken along line BB in FIG. 1B. In the present invention, the density of the pressure-molded magnetic body part may vary depending on the physical properties of the powder material used, and therefore, it is treated as an average density.

  (Step S301 Primary Filling) From the reference plane, the lower punch 17a and the movable punch 17b are simultaneously lowered to predetermined positions to form a cavity in the lower mold 15b (FIG. 11 (a)). Here, as shown in the figure, since the moving distance of the lower punch 17a is larger than the moving distance of the movable punch 17b, the lower punch 17a and the movable punch 17b are different from each other with the lower punch 17a being downward. It becomes arrangement.

  When positioning of the lower punch 17a and the movable punch 17b is completed, a predetermined amount of mixed magnetic powder 20 (insulated magnetic powder, for example, Si-Fe alloy powder is coated with an epoxy resin and granulated at the same time, The one having good fluidity is preferable) is filled in the cavity of the lower mold 15b (FIG. 11 (b)). In addition, since the wear-off filling is performed, the primary filling amount and the volume of the cavity of the lower mold 15b substantially coincide with each other. Further, it is necessary to accurately control in advance the positions of the lower punch 17a and the movable punch 17b based on the thickness of the coil-enclosed magnetic component to be finally obtained and the number of turns of the coil 1.

  (Step S302 Insertion of Coil 1) Next, as shown in FIG. 11C, the lower punch 17a and the movable punch 17b are lowered downward from the reference plane by ½ of the coil height dimension. As a result, the upper surface of the filled mixed magnetic powder is also lowered downward from the reference surface by a half of the coil height dimension. Thereafter, the coil 1 to which a lead frame (not shown) serving as a terminal electrode is connected is inserted into the lower mold 15b. Note that the coil 1 is an air-core coil having a hollow portion prepared in advance by the above-described procedure. An engraving (groove) is formed on the upper surface of the lower mold 15b in accordance with the shape of a lead frame (not shown). In step S302, the coil 1 is placed in the lower mold 15b so that the lead frame is inserted into the engraving. Since the lead frame is connected to the coil 1 so as to be on the same plane, for example, if the lead frame is inserted by fitting into the engraving of the lower mold 15b, the coil 1 is not inclined and is not inside the lower mold 15b Since the lower punch 17a and the movable punch 17b are lowered downward from the reference plane by ½ of the coil height dimension, the lower bottom surface of the coil 1 is filled with magnetic powder. Are arranged so as to contact with each other without generating contact pressure with each other. That is, by the above-described control, the coil 1 can finally be positioned horizontally and centrally with respect to the horizontal direction as a reference.

  (Step S303 Fixing of coil 1 and cavity formation) After inserting the coil 1 into the lower mold 15b in step S303, as shown in FIG. 11 (d), the upper mold 15a is moved to the lower mold. Lower to 15b. Due to the lowering of the upper mold 15a, the lead frame connected to the coil 1 is sandwiched and fixed between the upper mold 15a and the lower mold 15b. Thereby, the vertical and horizontal movement of the coil 1 is controlled. Further, as shown in FIG. 11D, a new cavity is formed by the upper part mold 15a on the upper surface side of the coil 1 as the upper part mold 15a is lowered.

  (Step S304 Secondary Filling) As shown in FIG. 11E, a predetermined amount of the mixed magnetic powder 20 is filled into the cavity newly formed in step S303 so as to cover the upper surface of the coil 1. The filling amount of the mixed magnetic powder 20 to be secondarily filled is the distance H7 from the upper surface of the movable punch 17b of the mixed magnetic powder already filled in the cavity to the lower surface of the coil 1 and the second filling from the upper surface of the coil 1. Further, the distance H8 to the upper surface of the mixed magnetic powder 20 is controlled to be substantially equal. At this time, it is possible to easily achieve the above-mentioned filling by using the mixed magnetic powder 20 having good fluidity. By setting the secondary filling amount of the mixed powder in this manner, when the coil-encapsulated magnetic component is generated as described later, the coil 1 existing in the magnetic body portion 7 is magnetically formed with reference to the thickness direction. It can be accurately placed in the center of the body part 7.

  (Step S305 Upper Punch 16 Lowering) When the filling is finished in step S304, the upper punch 16 is lowered at substantially the same time as shown in FIG. In addition, the filling density of the mixed magnetic powder 20 filled in the cavity before the pressurization by the upper punch 16 is started is substantially equal in all parts.

  (Step S306 Primary Pressurization) In step S305, the upper punch 16 descends and pressure is applied to the portion R1 in the mixed magnetic powder 20, and at the same time, the movable punch 17b starts to rise to the mixed magnetic powder 20 in the region R1. Apply pressure. As a result, the region R1 corresponding to the winding part 3 of the mixed magnetic powder 20 sandwiched between the upper punch 16 and the movable punch 17b is equally pressurized from above and below, and the lower surface of the coil 1 and the upper surface of the movable punch 17b The coil 1 is consolidated in the axial direction (thickness direction) so that the distance is equal to the distance between the upper surface of the coil 1 and the upper surface of the mixed magnetic powder (FIG. 12B).

  (Step S307 Secondary Pressurization) In step S306, the lower punch 17a is raised and pressure is applied to the mixed magnetic powder 20 in the regions R2 and R3 (FIG. 12C). Further, the upper punch 16 continues to descend and the lower punch 17a continues to rise, and pressure is applied to the mixed magnetic powder 20 in the regions R2 and R3. Thereby, pressure is applied to the mixed magnetic powder 20 in the regions R2 and R3 not corresponding to the winding part 3 sandwiched between the upper punch 16 and the lower punch 17a from above and below, and the mixed magnetic powder 20 in the regions R2 and R3 is The pressure is increased in the winding axis direction of the coil 1.

  Further, when applying pressure to the mixed magnetic powder 20, by controlling the lower punch 17a and the movable punch 17b so that the position of the upper surface of the lower punch 17a is lower than the position of the upper surface of the movable punch 17b, On the bottom surface on the mounting surface side of the coil-enclosed magnetic component 10 to be molded, a step h is formed so that the region R1 corresponding to the winding portion 3 becomes a recess. That is, a step h is formed between the region R1 in which the coil is included and the regions R2 and R3 in which the coil is not included. Thus, the formation of the step h is effective as a means for realizing the simplicity of density adjustment when the average density of each of R1, R2, and R3 in the magnetic body portion is set to a desired value. Become.

  When the step h is formed on the bottom surface on the mounting surface side of the coil-enclosed magnetic component 10, the step R is formed so that the region R1 corresponding to the winding portion 3 is a convex portion as shown in FIG. h may be formed. That is, by making the compression amount of the regions R2 and R3 larger than that of the region R1, it is possible to increase the difference in the average density of the green compacts in each region, and the direction perpendicular to the winding axis direction of the coil 1 Further miniaturization can be realized with respect to the dimensions. In this case, the lower punch 17a and the movable punch 17b are controlled so that the position of the upper surface of the lower punch 17a is positioned higher than the position of the upper surface of the movable punch 17b. Even in such a case, the formation of the step h is a means for realizing the simplicity of density adjustment when the average density of each region of R1, R2, and R3 in the magnetic part is set to a desired value. It becomes effective.

  Here, in the present embodiment, the lower punch 17 b has substantially the same shape as the planar shape of the coil 1, and the regions R 2 and R 3 that do not correspond to the winding part 3 are larger than the region R 1 that corresponds to the winding part 3. The mixed magnetic powder 20 is filled. Thereby, finally, the average density D2 of the region not corresponding to the winding portion 3, specifically, the region R2 corresponding to the hollow portion of the coil 1 and the region R3 corresponding to the side peripheral portion is determined as the winding of the coil 1. The average density D1 of the region R1 corresponding to the portion 3 can be made higher.

  Moreover, in this Embodiment, as shown in FIG.12 (b), after once realizing the state of the average density D1 in area | region R1 corresponding to the winding part 3, as shown in FIG.12 (b), as shown in FIG.12 (c). Pressure is applied to the entire mixed magnetic powder 20 in the region R2 and the region R3 to realize a state in which the average density D2 in the regions R2 and R3 not corresponding to the winding part 3 is higher than the average density D1. Therefore, it is possible to reliably realize a state in which the average density D2 in the regions R2 and R3 not corresponding to the winding part 3 is higher than the average density D1 of the region R1 corresponding to the winding part 3.

  (Step S308 Extraction) After the pressure forming in step S307, as shown in FIG. 12D, the upper die 15a and the upper punch 16 are raised, and the lower die 15b, the lower punch 17a and the movable punch are raised. 17b is raised to the reference plane. And the molded object of a magnetic component is extracted from a metal mold | die, and this complete | finishes one cycle of a formation process. Further, at the time of extraction in step S308, the upper die 15a and the upper punch 16 are also raised to their original positions, and the lower punch 17a and the movable punch 17b are lowered to their original positions, It returns to the state shown in FIG. 11A (FIG. 12E).

  A small molded body can be obtained through the steps shown in steps S301 to S308. The operation of the mold has been described using the upper surface of the lower mold 15b as the reference surface. However, the reference surface is not limited to the above as long as the mold moves relatively similarly. Absent.

  Now, after the molding process in step S203 shown in FIG. 9, the process proceeds to a heat curing process (step S204). In the heat curing process, the molded body obtained in the molding process (step S203) is held at a predetermined temperature for a predetermined time. Thereby, the resin in the molded body is cured. After the heat curing process, the process proceeds to the rust prevention process (step S205). The rust prevention treatment is performed, for example, by impregnating the molded body with a rust prevention treatment liquid made of a specific raw material.

  Next, the lead frame is cut to proceed to a lead frame cutting step for forming the mounting ends 4c and 5c of the terminal electrodes 4 and 5 (step S206). Further, in the terminal electrode bending process in step S207, the mounting end parts 4c and 5c formed in the lead frame process in step S206 are bent along the magnetic body part 7. Finally, in the appearance / characteristic inspection step (step S208), the appearance and characteristics of the coil-enclosed magnetic component 10 formed in step S207 are checked to complete the coil-enclosed magnetic component.

  The coil-enclosed magnetic component according to the present invention is not limited to the above-described embodiments, and various modifications and changes can be made without departing from the configuration of the present invention in terms of other materials and configurations. Needless to say.

  According to the method for manufacturing the coil-encapsulated magnetic component 10 according to the present embodiment, the average density of the region not corresponding to the winding portion 3 of the coil 1, particularly the region R <b> 3 near the side periphery of the magnetic body portion 7 is high. By filling the mixed magnetic powder in such a manner, the maximum saturation magnetic flux density Bm can be increased by increasing the average density of the region R3 in the vicinity of the side periphery of the magnetic body portion 7. Since it can be made small and thin, the coil-enclosed magnetic component 10 can be made small.

  Further, according to the method for manufacturing the coil-enclosed magnetic component 10 according to the present embodiment, the mixed magnetic powder in the regions R2 and R3 that do not correspond to the winding part 3 of the coil 1 is reliably compressed. The strength of the side peripheral portion of the magnetic body portion 7 affected by the stress due to the spring property of the turning portion 3 can be ensured. Thereby, the coil enclosure type magnetic component 10 which can suppress the crack which generate | occur | produces in the area | region of the side peripheral part of the magnetic body part 7 can be manufactured. Moreover, the average density D of the magnetic substance powder of the side periphery which is going to make the cross-sectional area of the magnetic body part 7 small among the parts through which the magnetic path l formed in the magnetic body part 7 passes, By making the density higher than that locally, it is possible to obtain the coil-encapsulated magnetic component 10 that can improve the maximum saturation magnetic flux density Bm in the region R3 and prevent the deterioration of the DC superposition characteristics.

  Further, according to the method for manufacturing the coil-encapsulated magnetic component 10 according to the present embodiment, the lower punch 17b has substantially the same shape as the planar shape of the coil 1, and the regions R2 and R3 that do not correspond to the winding portion 3 are Since the mixed magnetic powder 20 more than the region R1 corresponding to the winding portion 3 is filled and then pressurized, the average density D in each region of the magnetic body portion 7 can be reliably varied.

  In addition, according to the method for manufacturing the coil-encapsulated magnetic component 10 according to the present embodiment, the amount of mixed magnetic powder filled in the region R1 corresponding to the winding portion 3 is accurately controlled. 1 can be accurately positioned in the center of the magnetic part 7. Thereby, it is possible to prevent the coil 1 from being biased with respect to the axial direction, and to suppress local magnetic saturation in the magnetic body portion 7. According to the coil-encapsulated magnetic component 10 molded by such a manufacturing method, a large inductance value can be obtained, and a desired inductance value can be obtained by greatly reducing variations in the inductance value.

  Furthermore, according to the method for manufacturing coil-encapsulated magnetic component 10 according to the present embodiment, step h is provided between region R1 corresponding to winding portion 3 and regions R2 and R3 not corresponding to the winding portion. Therefore, it is possible to obtain a coil-enclosed magnetic component having a large difference in average density between regions. Furthermore, it is possible to obtain a coil-enclosed magnetic component that is excellent in mountability to the substrate.

FIG. 1A is a perspective view of a coil-enclosed magnetic component according to an embodiment of the present invention. FIG. 1B is a perspective view showing the inside of the coil-enclosed magnetic component according to the embodiment of the present invention. FIG. 2A is a cross-sectional view of the coil-enclosed magnetic component taken along the line AA shown in FIG. FIG. 2B is a cross-sectional view of the coil-enclosed magnetic component taken along the line BB shown in FIG. FIG. 3 is a cross-sectional view comparing the coil-encapsulated magnetic component of the present embodiment and a conventional coil-encapsulated magnetic component. FIG. 4 is a perspective view of a terminal electrode used for the coil-encapsulated magnetic component according to the present embodiment. FIG. 5 is a bottom view of the coil-enclosed magnetic component according to the present embodiment. FIG. 6 is a bottom view of a coil-enclosed magnetic component according to another embodiment. FIG. 7 is a cross-sectional view of a coil-encapsulated magnetic component according to another embodiment. FIG. 8 is a flowchart showing manufacturing steps of the coil / terminal electrode in the present embodiment. FIG. 9 is a flowchart showing the manufacturing process of the coil-encapsulated magnetic component in the present embodiment. FIG. 10 is a flowchart showing each step of the molding process in step S203 of FIG. FIG. 11 is a diagram for explaining the molding process in step S203 of FIG. FIG. 12 is a diagram for explaining the molding process in step S203 of FIG.

Explanation of symbols

1 .. Coil 2 .. Conductor 3 .. Winding part 4, 5 .. Terminal electrode 4a, 5a .. Connection end part, 4b, 5b .. Bent part, 4c, 5c .. Mounting end .., 7 .. Magnetic body part, 10 .. Coil-enclosed magnetic part, 15 a .. Upper part mold, 15 b .. Lower part mold, 16 .. Upper punch, 17 .. Lower punch, 17 a. Movable punch, 20 ·· Mixed magnetic powder, R1 ·· region containing coil, R2, R3 ·· region not containing coil, h ·· step, H ·· height, S ·· cross-sectional area, D ... average density, Φ ... magnetic flux, l ... magnetic path

Claims (3)

A coil-enclosed magnetic component comprising an air-core coil and a magnetic part made of a mixture of magnetic powder and resin containing the coil,
The magnetic part has a region in which the coil is included and a region in which the coil is not included,
The average density of the green compact located in the region where the coil of the magnetic part is included is D1,
When the average density of the green compact located in the area where the coil of the magnetic part is not included is D2, D1 <D2
Coil-enclosed magnetic parts characterized by the following relationship. 2. The coil-encapsulated magnetic component according to claim 1, wherein the magnetic body portion has a step at a boundary portion between a region in which the coil is included and a region in which the coil is not included. A method of manufacturing a coil-enclosed magnetic component including an air-core coil, and a magnetic body portion made of a mixture of magnetic powder and resin containing the coil,
Filling the magnetic powder so as to cover the coil (a);
And (b) consolidating the magnetic powder covering the coil in the axial direction of the coil,
In the step (a), the amount of the magnetic powder filled in the region not including the coil is larger than the amount of the magnetic powder charged in the region including the coil. Filling the magnetic powder,
The average density of the green compact located in the region where the coil of the magnetic part is included is D1,
When the average density of the green compact located in the area where the coil of the magnetic part is not included is D2, D1 <D2.
A method for manufacturing a coil-enclosed magnetic component, characterized in that:

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