JP2010147272A - Method for manufacturing molded coil - Google Patents

Method for manufacturing molded coil Download PDF

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JP2010147272A
JP2010147272A JP2008323401A JP2008323401A JP2010147272A JP 2010147272 A JP2010147272 A JP 2010147272A JP 2008323401 A JP2008323401 A JP 2008323401A JP 2008323401 A JP2008323401 A JP 2008323401A JP 2010147272 A JP2010147272 A JP 2010147272A
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coil
cavity
air
core coil
positioning pin
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JP5329202B2 (en
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Yoshizumi Fukui
義純 福井
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Toko Inc
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Toko Inc
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a molded coil that is small, is excellent in mass productivity, and has a small number of molding defects. <P>SOLUTION: An air-core coil is sealed by a magnetic mold resin, where magnetic powder and resins are kneaded, by a plastic formation method. An air core coil that is not completely round is used. A forming mold is used, which includes a cavity formed by a plurality of molds and a positioning pin for being vertically moved in the cavity. The following motions are included, namely disposing the air-core coil at a prescribed position in the cavity by the positioning pin (a), filling a magnetic mold resin into the cavity (b), and moving the positioning pin to a prescribed position during the filling (c). <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

本発明は、モールドコイルの製造方法に関し、特に空芯コイルを磁性体モールド樹脂で封止する方法に関する。   The present invention relates to a method for manufacturing a molded coil, and more particularly to a method for sealing an air-core coil with a magnetic mold resin.

従来から、コイルを磁性体粉末と樹脂とを混練した磁性体モールド樹脂で封止してなるモールドコイルが広く利用されている。従来のモールドコイルの製造方法は、フェライトコアなどの巻芯に巻かれたコイルを金型のキャビティ内に配置し、その後キャビティ内に溶融状態の磁性体モールド樹脂を充填してコイルを封止する。特許文献１と特許文献２には巻芯を用いたモールドコイルの製造方法が開示されている。   Conventionally, a molded coil in which a coil is sealed with a magnetic mold resin obtained by kneading magnetic powder and resin has been widely used. In a conventional method of manufacturing a molded coil, a coil wound around a core such as a ferrite core is placed in a cavity of a mold, and then the molten magnetic mold resin is filled in the cavity to seal the coil. . Patent Document 1 and Patent Document 2 disclose a method of manufacturing a molded coil using a winding core.

例えば、巻芯を用いずに空芯コイルをそのまま磁性体モールド樹脂で封止しようとすると、磁性体モールド樹脂の充填圧力によって空芯コイルが変形したり、キャビティ内の片側に寄ったり、または傾いたりして所定の位置からずれてしまうこともあった。これらコイルの変形や位置ずれは、外観的不良を引き起こすだけではなく、インダクタンス値や直流重畳特性等の電気的特性にも影響を与えてしまう。そこで、従来ではコイルの変形や位置ずれを防止するために巻芯やフレーム等を用いることが一般的だった。
特開平４−３３８６１３号公報 特開２００６−３２８４７号公報 For example, if an air core coil is to be sealed with a magnetic mold resin as it is without using a winding core, the air core coil may be deformed by the filling pressure of the magnetic mold resin, or may be inclined to one side of the cavity or tilted. Sometimes deviated from a predetermined position. These deformation and misalignment of the coils not only cause appearance defects, but also affect electrical characteristics such as inductance values and DC superimposition characteristics. Therefore, conventionally, in order to prevent deformation and displacement of the coil, it has been common to use a winding core, a frame, or the like.
JP-A-4-338613 JP 2006-32847 A

近年における電子機器の小型化や高機能化の技術革新は著しく、それに伴い、モールドコイルのような電子部品もまた小型化や高性能化、更には低価格化などの要求が高まっている。しかし、従来のモールドコイルで用いられる巻芯やフレームなどはモールドコイルの小型化や低背化の妨げになり、さらにコストの上昇を招く原因となっていた。   In recent years, technological innovation for downsizing and high functionality of electronic devices has been remarkable, and accordingly, electronic components such as molded coils are also demanded for downsizing, high performance, and low price. However, the cores and frames used in the conventional mold coil hinder the miniaturization and low profile of the mold coil, and further increase the cost.

そこで出願人は、先に出願した特願２００８−９７８７４において、位置出しピンと支持ピンを有する成形金型を用いた巻芯やフレームが不要なモールドコイルの製造方法を提案した。しかし、この方法を用いるときに空芯コイルの内径の形状が真円に近い形状（以下、略真円状）であると、成形金型のキャビティ内に空芯コイルを配置するときやキャビティ内に磁性体モールド樹脂を充填するときに、図１７に示すように位置出しピン１０３ａを中心に空芯コイル１０１が回転移動してしまうこともあった。空芯コイルが回転移動した状態で封止してしまうと、コイルの端部が不適当な位置にずれてしまったり、コイルがゆがむこともあった。また、コイルの端部にスポット溶接などで外部電極を取り付けた状態で一体成形を行う場合に、外部電極が金属箔のような材料であると外部電極がゆがむこともあった。そして、コイルが回転移動したままで磁性体モールド樹脂を充填すると、外部電極とコイルの端部との接続部に応力がかかり、最悪の場合には断線などの成形不良を引き起こす可能性があった。   Therefore, the applicant has proposed a method for manufacturing a molded coil that does not require a winding core or a frame using a molding die having a positioning pin and a support pin in Japanese Patent Application No. 2008-97874 filed earlier. However, when this method is used, if the shape of the inner diameter of the air-core coil is a shape close to a perfect circle (hereinafter referred to as a substantially perfect circle), when the air-core coil is disposed in the cavity of the molding die, When the magnetic mold resin is filled in, the air-core coil 101 sometimes rotates around the positioning pin 103a as shown in FIG. If the air-core coil is sealed while being rotated, the end of the coil may be shifted to an inappropriate position or the coil may be distorted. In addition, when integral molding is performed with the external electrode attached to the end of the coil by spot welding or the like, the external electrode may be distorted if the external electrode is made of a material such as metal foil. If the magnetic mold resin is filled while the coil is rotating, stress is applied to the connection portion between the external electrode and the end portion of the coil, and in the worst case, there is a possibility of causing molding defects such as disconnection. .

本発明は、小型且つ量産性に優れ、成形不良の少ないモールドコイルの製造方法の提供を目的とする。   An object of the present invention is to provide a method for manufacturing a molded coil that is small in size, excellent in mass productivity, and has few molding defects.

上記の課題を解決するために、本発明のモールドコイルの製造方法は、プラスチック成形法を用いて、磁性体粉末をと樹脂とを混練させた磁性体モールド樹脂で空芯コイルを封止する。形状が略真円状ではない空芯コイルを用いる。複数の金型から形成されるキャビティと、キャビティ内を垂直方向に移動可能な位置出しピンとを有する成形金型を用い、以下の動作を含むことを特徴とする。
（ａ）位置出しピンによってキャビティ内の所定の位置へ空芯コイルを配置する。
（ｂ）キャビティ内に磁性体モールド樹脂をキャビティ内に充填する。
（ｃ）その充填中に位置出しピンを所定の位置まで移動させる。 In order to solve the above-described problems, the mold coil manufacturing method of the present invention uses a plastic molding method to seal an air-core coil with a magnetic mold resin obtained by kneading a magnetic powder and a resin. An air-core coil whose shape is not substantially circular is used. A molding die having a cavity formed from a plurality of molds and a positioning pin movable in the vertical direction in the cavity is used, and includes the following operations.
(A) An air core coil is arranged at a predetermined position in the cavity by a positioning pin.
(B) Fill the cavity with a magnetic mold resin.
(C) During the filling, the positioning pin is moved to a predetermined position.

本発明のモールドコイルの製造方法では、複数の金型から形成されるキャビティと、キャビティ内を垂直方向に移動可能な位置出しピンを有する成形金型と形状が略真円状でない空芯コイルとを用いる。そのため、空芯コイルはキャビティ内で位置出しピンによってキャビティ内の適正な位置に位置出しされる。さらに内径の形状が略真円状ではない空芯コイルを用いるため、キャビティ内で回転移動することがない。これにより成形精度の高いモールドコイルを成形することができる。   In the mold coil manufacturing method of the present invention, a cavity formed from a plurality of molds, a molding die having positioning pins that can move in the vertical direction in the cavity, and an air core coil that is not substantially circular in shape Is used. Therefore, the air-core coil is positioned at an appropriate position in the cavity by the positioning pin in the cavity. Further, since an air core coil whose inner diameter is not substantially circular is used, it does not rotate in the cavity. Thereby, a mold coil with high forming accuracy can be formed.

（第１の実施例）
図１〜図６を参照しながら、本発明のモールドコイルの製造方法の第１の実施例について説明する。図中の参照符号はそれぞれ、１は空芯コイル、２は上型、３は下型、４はキャビティ、５は磁性体モールド樹脂、６はパンチ、７は外部電極を示す。 (First embodiment)
A first embodiment of a method for manufacturing a molded coil according to the present invention will be described with reference to FIGS. In the drawings, reference numeral 1 denotes an air core coil, 2 denotes an upper die, 3 denotes a lower die, 4 denotes a cavity, 5 denotes a magnetic mold resin, 6 denotes a punch, and 7 denotes an external electrode.

まず、第１の実施例で用いる空芯コイル１について説明する。図１に第１の実施例で用いる空芯コイル１の斜視図を示す。空芯コイル１は、幅が０．２５ｍｍ、厚さが０．０６ｍｍの自己融着性の平角線を用い、断面が長円状の芯材を用いて外外巻きで１２ターン巻いたものを用いる。   First, the air-core coil 1 used in the first embodiment will be described. FIG. 1 shows a perspective view of an air-core coil 1 used in the first embodiment. The air-core coil 1 uses a self-bonding rectangular wire having a width of 0.25 mm and a thickness of 0.06 mm, and a core material having an elliptical cross section and wound by 12 turns with external and external windings. Use.

次に、本実施例で用いる成形金型について説明する。図２は本発明の実施例で用いる成形金型を示し、図２（ａ）は上面図、図２（ｂ）は図２（ａ）のＡ−Ａ断面図を示す。図２に示すように、本実施例で用いる成形金型は上型２と下型３を有し、上型２と下型３を組み合わせることによってキャビティ４が形成される。また、下型３は上型２と組み合わさることでキャビティ４の底部を形成する。さらに下型３は、キャビティ４の底部にキャビティ４の開口部方向に突出したキャビティ４の上下方向に昇降可能（垂直方向に移動可能）な位置出しピン３ａと支持ピン３ｂが設けられている。   Next, the molding die used in the present embodiment will be described. FIG. 2 shows a molding die used in the embodiment of the present invention, FIG. 2 (a) is a top view, and FIG. 2 (b) is a cross-sectional view taken along line AA of FIG. As shown in FIG. 2, the molding die used in this embodiment has an upper die 2 and a lower die 3, and the cavity 4 is formed by combining the upper die 2 and the lower die 3. The lower mold 3 is combined with the upper mold 2 to form the bottom of the cavity 4. Further, the lower die 3 is provided with a positioning pin 3a and a support pin 3b which can be moved up and down (movable in the vertical direction) in the vertical direction of the cavity 4 protruding toward the opening of the cavity 4 at the bottom of the cavity 4.

本実施例では、位置出しピン３ａは断面が長円状で、空芯コイル１を形成したときの芯材よりも径が２０μｍ小さい柱状の金属棒を用いた。支持ピン３ｂは直径０．４ｍｍの円柱状の金属棒を用いた。そして、位置出しピン３ａはキャビティ４の底部から突出する高さｈ１を初期状態として０．７５ｍｍに設定し、支持ピン３ｂはキャビティ４の底部から突出する高さｈ２を初期状態として０．３８ｍｍに設定した。   In this embodiment, the positioning pin 3a is a columnar metal bar having an oval cross section and a diameter 20 μm smaller than the core material when the air-core coil 1 is formed. A cylindrical metal rod having a diameter of 0.4 mm was used as the support pin 3b. The positioning pin 3a has a height h1 protruding from the bottom of the cavity 4 set to 0.75 mm as an initial state, and the support pin 3b has a height h2 protruding from the bottom of the cavity 4 to 0.38 mm as an initial state. Set.

次に、第１の実施例のモールドコイルの製造方法について説明する。図３は本発明の第１の実施例の空芯コイルの配置を示す上面図である。図４及び図５に第１の実施例のモールドコイルの製造工程の主要部分を示す。図６に本発明の第１の実施例のモールドコイルの斜視図を示す。なお、図４及び図５は、図２（ａ）のＡ−Ａ断面図における各段階での断面を示している。   Next, a method for manufacturing the molded coil of the first embodiment will be described. FIG. 3 is a top view showing the arrangement of the air-core coil according to the first embodiment of the present invention. 4 and 5 show the main part of the manufacturing process of the molded coil of the first embodiment. FIG. 6 shows a perspective view of the molded coil of the first embodiment of the present invention. 4 and 5 show cross sections at each stage in the AA cross sectional view of FIG.

図３及び図４（ａ）に示すように、空芯コイル１をキャビティ４内に配置し、成形金型（上型２、下型３）を１８０℃で予熱する。このとき、空芯コイル１は、位置出しピン３ａが空芯コイル１の内径部分に挿入され、さらに支持ピン３ｂ上に空芯コイル１の底面が載るように配置される。そうして空芯コイル１は、位置出しピン３ａによってキャビティ４内における水平方向が回転移動せずに固定され、支持ピン３ｂによって中空保持される。また、予熱温度は磁性体モールド樹脂が軟化できる温度以上（磁性体モールド樹脂中の樹脂の軟化温度以上の温度）に設定すればよく、本実施例では１８０℃に設定した。   As shown in FIGS. 3 and 4 (a), the air-core coil 1 is placed in the cavity 4, and the molding dies (upper mold 2 and lower mold 3) are preheated at 180 ° C. At this time, the air-core coil 1 is arranged such that the positioning pin 3a is inserted into the inner diameter portion of the air-core coil 1, and the bottom surface of the air-core coil 1 is placed on the support pin 3b. Thus, the air core coil 1 is fixed by the positioning pin 3a without rotating in the horizontal direction in the cavity 4, and is held hollow by the support pin 3b. Further, the preheating temperature may be set to a temperature at which the magnetic mold resin can be softened (a temperature equal to or higher than the softening temperature of the resin in the magnetic mold resin), and is set to 180 ° C. in this embodiment.

図４（ｂ）に示すように、上型２の開口部から空芯コイル１の上に所定量秤量した磁性体モールド樹脂５をキャビティ４内に投入し、成形金型の予熱で磁性体モールド樹脂５を溶融させる。本実施例では磁性体モールド樹脂５として、アモルファス合金粉末とノボラック型エポキシ樹脂とを混練分散し、その混練物を冷却後粉砕した粉末状のものを用いた。なお、磁性体モールド樹脂中のアモルファス合金粉末の充填率は６０Ｖｏｌ％になるように調製した。   As shown in FIG. 4B, a magnetic mold resin 5 weighed in a predetermined amount from the opening of the upper mold 2 onto the air core coil 1 is put into the cavity 4, and the magnetic mold is preheated by the molding die. Resin 5 is melted. In this embodiment, the magnetic mold resin 5 is a powdery material obtained by kneading and dispersing an amorphous alloy powder and a novolac-type epoxy resin, and cooling and kneading the kneaded product. In addition, it prepared so that the filling rate of the amorphous alloy powder in magnetic body resin might be set to 60 Vol%.

図４（ｃ）に示すように、上型２の開口部にパンチ６をセットする。次に、図５（ａ）に示すように、パンチ６を用いて３ｋｇｆで５秒間加圧する。次に、図５（ｂ）に示すように、位置出しピン３ａをキャビティ４の底部の位置まで下降させた後、パンチ６を用いて５ｋｇｆで２０秒間加圧する。このようにすると、位置出しピン３ａのあった部分に磁性体モールド樹脂５が充填される。次に、パンチ６からの加圧をやめてパンチ６をフリー状態とした上で、図５（ｃ）に示すように支持ピン３ｂをキャビティ４の底部の位置まで下降させる。続いて再びパンチ６を用いて１０ｋｇｆで２０秒間加圧する。このようにすると、支持ピン３ｂのあった部分に磁性体モールド樹脂５が充填される。その後、１８０℃で１０分間加熱放置して磁性体モールド樹脂５を硬化させる。   As shown in FIG. 4 (c), the punch 6 is set in the opening of the upper mold 2. Next, as shown in FIG. 5A, the punch 6 is pressurized with 3 kgf for 5 seconds. Next, as shown in FIG. 5B, the positioning pin 3 a is lowered to the position of the bottom of the cavity 4, and then pressurized with a punch 6 at 5 kgf for 20 seconds. If it does in this way, the magnetic body mold resin 5 will be filled in the part with the positioning pin 3a. Next, after the pressurization from the punch 6 is stopped and the punch 6 is brought into a free state, the support pin 3b is lowered to the position of the bottom of the cavity 4 as shown in FIG. Subsequently, the punch 6 is again pressed at 10 kgf for 20 seconds. If it does in this way, the magnetic body mold resin 5 will be filled in the part with the support pin 3b. Thereafter, the magnetic mold resin 5 is hardened by heating at 180 ° C. for 10 minutes.

磁性体モールド樹脂５を硬化させて得た成形体を成形金型から取り出して、サンドブラストでバリ取りを行うとともに空芯コイル１の端部を露出させる。成形体の外部電極を形成する部分以外をエポキシ樹脂で被覆する。露出させた空芯コイル１の端部と接続するようにめっきにより外部電極７を形成して、図６に示すようなモールドコイルを得る。   The molded body obtained by curing the magnetic mold resin 5 is taken out of the molding die, deburred by sandblasting, and the end of the air-core coil 1 is exposed. The molded body is covered with an epoxy resin except for the portion where the external electrode is formed. The external electrode 7 is formed by plating so as to connect to the exposed end portion of the air-core coil 1 to obtain a molded coil as shown in FIG.

（第２の実施例）
図７〜図９を参照しながら、本発明のモールドコイルの製造方法の第２の実施例について説明する。図７は本発明の第２の実施例で用いるコイル部材を示す図である。図８は本発明の第２実施例の空芯コイルの配置を示す図である。図９は本発明の第２の実施例のモールドコイルを示す図である。第２の実施例では外部電極に金属箔を用いて、空芯コイルと同時に一体成形する方法を示す。なお、第２の実施例では第１の実施例で用いた成形金型を用い、第１の実施例と共通する部分の説明は割愛する。 (Second embodiment)
A second embodiment of the method for producing a molded coil according to the present invention will be described with reference to FIGS. FIG. 7 is a view showing a coil member used in the second embodiment of the present invention. FIG. 8 is a view showing the arrangement of air-core coils according to the second embodiment of the present invention. FIG. 9 is a view showing a molded coil according to a second embodiment of the present invention. In the second embodiment, a method of integrally forming simultaneously with an air-core coil using a metal foil as an external electrode will be described. In the second embodiment, the molding die used in the first embodiment is used, and the description of the parts common to the first embodiment is omitted.

第１の実施例で用いた空芯コイル１と金属箔８をスポット溶接し、図７に示すようなコイル部材を得た。このコイル部材を図８に示すように、位置出しピン３ａを空芯コイル１の内径部分に挿入し、金属箔８がキャビティ４の底部側になるようにコイル部材を配置する。このとき、長円状に形成された空芯コイル１は位置出しピン３ａによって回転移動することなく適正に配置される。コイル部材を配置した後、第１の実施例で図４、図５を参照しながら説明した操作を行い、磁性体モールド樹脂でコイル部材を封止して硬化させた。磁性体モールド樹脂を硬化させて得た成形体を成形金型から取り出して、サンドブラストでバリ取りを行うとともに空芯コイル１の端部と金属箔８を露出させる。露出させた空芯コイル１の端部と金属箔８の両方に接続するように半田浴に成形体をディップして半田層９を形成し、図９に示すようなモールドコイルを得る。   The air-core coil 1 and metal foil 8 used in the first example were spot welded to obtain a coil member as shown in FIG. As shown in FIG. 8, the positioning pin 3 a is inserted into the inner diameter portion of the air-core coil 1, and the coil member is disposed so that the metal foil 8 is on the bottom side of the cavity 4. At this time, the air-core coil 1 formed in an oval shape is properly arranged without being rotated by the positioning pin 3a. After arranging the coil member, the operation described with reference to FIGS. 4 and 5 in the first embodiment was performed, and the coil member was sealed with a magnetic mold resin and cured. A molded body obtained by curing the magnetic mold resin is taken out from the molding die, deburred by sandblasting, and the end of the air-core coil 1 and the metal foil 8 are exposed. The molded body is dipped in a solder bath so as to be connected to both the exposed end portion of the air-core coil 1 and the metal foil 8 to form a solder layer 9 to obtain a molded coil as shown in FIG.

（第３の実施例）
図１０〜図１６を参照しながら、本発明のモールドコイルの製造方法の第３の実施例について説明する。第３の実施例は、キャビティの側面部に位置出しピンを設けた成形金型を用いる方法を示す。なお、第３の実施例では第１の実施例で用いた磁性体モールド樹脂と平角線を用い、第１の実施例と共通する部分の説明は割愛する。 (Third embodiment)
A third embodiment of the method for manufacturing a molded coil according to the present invention will be described with reference to FIGS. The third embodiment shows a method using a molding die provided with positioning pins on the side surface of the cavity. In the third embodiment, the magnetic mold resin and the rectangular wire used in the first embodiment are used, and the description of the parts common to the first embodiment is omitted.

まず、本実施例で用いる空芯コイルについて説明する。図１０に第３の実施例で用いる空芯コイルの斜視図を示す。第１の実施例で用いた平角線と芯材を用いて、外外巻きで１２ターン巻いた。さらに、平角線の両端部を同方向に引き出し、その端部を折り曲げ加工して図１０に示す空芯コイル１０を得た。   First, the air core coil used in the present embodiment will be described. FIG. 10 shows a perspective view of an air core coil used in the third embodiment. Using the rectangular wire and the core material used in the first example, 12 turns were wound by external and external winding. Furthermore, both ends of the flat wire were drawn out in the same direction, and the ends were bent to obtain an air-core coil 10 shown in FIG.

次に、第３の実施例で用いる成形金型について説明する。図１１に本発明の第３の実施例で用いる成形金型を示し、（ａ）は上面図、（ｂ）は正面図を示す。図１１に示すように、第３の実施例で用いる成形金型は上型１１と下型１２を有し、上型１１と下型１２を組み合わせることによってキャビティ１３が形成される。上型１１の側面部の一つに、キャビティ１３内に突出する位置出しピン１１ａを設ける。このとき、位置出しピン１１ａは、位置出しピン１１ａが設けられる側面部に対して対向する側面部方向にキャビティ１１内に突出し、その突出する方向の前後方向（キャビティ１３の水平方向）に移動できるようにする。本実施例では、第１の実施例と同様に、位置出しピン１１ａに芯材よりも径が２０μｍ小さい柱状の金属棒を用い、その中心がキャビティ１３の底部から１．０ｍｍの位置になるように上型１１に設けた。   Next, a molding die used in the third embodiment will be described. FIG. 11 shows a molding die used in the third embodiment of the present invention, where (a) shows a top view and (b) shows a front view. As shown in FIG. 11, the molding die used in the third embodiment has an upper die 11 and a lower die 12, and a cavity 13 is formed by combining the upper die 11 and the lower die 12. A positioning pin 11 a protruding into the cavity 13 is provided on one of the side surfaces of the upper mold 11. At this time, the positioning pin 11a protrudes into the cavity 11 in the direction of the side surface facing the side surface where the positioning pin 11a is provided, and can move in the front-rear direction of the protruding direction (the horizontal direction of the cavity 13). Like that. In the present embodiment, as in the first embodiment, a columnar metal rod having a diameter 20 μm smaller than the core material is used for the positioning pin 11 a, and the center thereof is positioned at 1.0 mm from the bottom of the cavity 13. The upper die 11 was provided.

次に、第１の実施例のモールドコイルの製造方法について説明する。図１２〜図１５に第３の実施例のモールドコイルの製造工程の主要部分を示す。図１６に本発明の実施例のモールドコイルの斜視図を示す。なお、図１２〜図１５は、各工程における上面図と正面図を示し、（ａ）が上面図、（ｂ）が正面図である。   Next, a method for manufacturing the molded coil of the first embodiment will be described. 12 to 15 show the main part of the manufacturing process of the molded coil of the third embodiment. FIG. 16 is a perspective view of a molded coil according to an embodiment of the present invention. In addition, FIGS. 12-15 shows the top view and front view in each process, (a) is a top view, (b) is a front view.

図１２に示すように、空芯コイル１０をキャビティ１３内に配置し、成形金型を１８０℃で予熱する。このとき、位置出しピン１１ａを空芯コイル１０の内径部分に挿入する。図１３に示すように、上型１１の開口部から空芯コイル１０の上に所定量秤量した磁性体モールド樹脂１４をキャビティ１３内に投入し、成形金型の予熱で磁性体モールド樹脂１４を溶融させる。   As shown in FIG. 12, the air-core coil 10 is placed in the cavity 13 and the molding die is preheated at 180 ° C. At this time, the positioning pin 11 a is inserted into the inner diameter portion of the air-core coil 10. As shown in FIG. 13, a magnetic mold resin 14 weighed in a predetermined amount from the opening of the upper mold 11 onto the air core coil 10 is put into the cavity 13, and the magnetic mold resin 14 is preheated by the molding die. Melt.

図１４に示すように、上型１１の開口部にパンチ１５をセットし、パンチ１５を用いて５ｋｇｆで５秒間加圧する。空芯コイル１０は位置出しピン１１ａのある部分を除いて、磁性体モールド樹脂１４に封止される。次に、パンチ１５からの加圧をやめてパンチ１５をフリー状態とした上で、図１５（ａ）に示すように、その端部がキャビティ１３の側面部の位置になるように位置出しピン１１ａを移動させる。さらに、図１５（ｂ）に示すように、パンチ１５を用いて１０ｋｇｆで２０秒間加圧する。このようにすると、位置出しピン１１ａのあった部分に磁性体モールド樹脂１４が充填される。その後、１８０℃で１０分間加熱放置して磁性体モールド樹脂１４を硬化させる。   As shown in FIG. 14, the punch 15 is set in the opening of the upper mold 11 and is pressurized with 5 kgf for 5 seconds using the punch 15. The air-core coil 10 is sealed with the magnetic molding resin 14 except for a portion where the positioning pin 11a is provided. Next, after the pressurization from the punch 15 is stopped and the punch 15 is brought into a free state, the positioning pin 11a is positioned so that the end thereof is positioned at the side surface of the cavity 13 as shown in FIG. Move. Further, as shown in FIG. 15B, the punch 15 is pressurized with 10 kgf for 20 seconds. In this way, the magnetic mold resin 14 is filled in the portion where the positioning pin 11a was present. Thereafter, the magnetic mold resin 14 is cured by heating at 180 ° C. for 10 minutes.

磁性体モールド樹脂１４を硬化させて得た成形体を成形金型から取り出してサンドブラストでバリ取りを行い、成形体の側面に空芯コイル１０の端部を露出させる。成形体の外部電極を形成する部分以外をエポキシ樹脂で被覆する。露出させた空芯コイル１０の端部と接続するようにめっきにより外部電極１６を形成して、図６に示すようなモールドコイルを得る。   The molded body obtained by curing the magnetic mold resin 14 is taken out of the molding die and deburred by sandblasting, and the end of the air-core coil 10 is exposed on the side surface of the molded body. The molded body is covered with an epoxy resin except for the portion where the external electrode is formed. The external electrode 16 is formed by plating so as to connect to the exposed end portion of the air-core coil 10 to obtain a molded coil as shown in FIG.

上記実施例では、長円状の空芯コイルを用いたが、それに限ることなく、略真円状でなければどのような形状でも実施できる。例えば、半円状、扇状、楕円状、略多角形状、またはそれらを組合せた形状で実施することができる。また、上記実施例では断面の形状が長円状の位置出しピンを１つ用いたが、それに限ることなく、用いる空芯コイルの形状に合わせて、断面の形状を変更、または複数の位置出しピンを使用しても良い。   In the above embodiment, an elliptical air-core coil is used. However, the present invention is not limited to this, and any shape other than a substantially perfect circle can be used. For example, it can be implemented in a semicircular shape, a fan shape, an elliptical shape, a substantially polygonal shape, or a combination thereof. In the above embodiment, one positioning pin having an oval cross-sectional shape is used. However, the present invention is not limited to this, and the cross-sectional shape is changed according to the shape of the air core coil to be used, or a plurality of positioning pins are used. A pin may be used.

本実施例では圧縮成形法を用いてモールドコイルを作成したが、その他のトランスファ成形法やインジェクション成形法などのプラスチック成形法を用いても実施できる。   In this embodiment, the molded coil is formed by using the compression molding method, but the present invention can also be carried out by using other plastic molding methods such as a transfer molding method and an injection molding method.

本発明の第１の実施例で用いるコイルを示す図である。It is a figure which shows the coil used in the 1st Example of this invention. 本発明の実施例で用いる成形金型を示す図であり、（ａ）は上面図、（ｂ）は（ａ）のＡ−Ａ断面図である。It is a figure which shows the molding die used in the Example of this invention, (a) is a top view, (b) is AA sectional drawing of (a). 本発明の第１の実施例の空芯コイルの配置を示す図である。It is a figure which shows arrangement | positioning of the air-core coil of 1st Example of this invention. 本発明の第１の実施例のモールドコイルの製造方法を説明する図である。It is a figure explaining the manufacturing method of the mold coil of the 1st Example of the present invention. 本発明の第１の実施例のモールドコイルの製造方法を説明する図である。It is a figure explaining the manufacturing method of the mold coil of the 1st Example of the present invention. 本発明の第１の実施例のモールドコイルを示す図である。It is a figure which shows the mold coil of the 1st Example of this invention. 本発明の第２の実施例で用いるコイル部材を示す図である。It is a figure which shows the coil member used in the 2nd Example of this invention. 本発明の第２実施例のコイル部材の配置を示す図である。It is a figure which shows arrangement | positioning of the coil member of 2nd Example of this invention. 本発明の第２の実施例のモールドコイルを示す図である。It is a figure which shows the mold coil of the 2nd Example of this invention. 本発明の第３の実施例で用いるコイルを示す図である。It is a figure which shows the coil used in the 3rd Example of this invention. 本発明の第３の実施例で用いる成形金型を示す図であり、（ａ）は上面図、（ｂ）は正面図である。It is a figure which shows the shaping die used in the 3rd Example of this invention, (a) is a top view, (b) is a front view. 本発明の第３の実施例の空芯コイルの配置を示す図であり、（ａ）は上面図、（ｂ）は正面図である。It is a figure which shows arrangement | positioning of the air-core coil of the 3rd Example of this invention, (a) is a top view, (b) is a front view. 本発明の第３の実施例のモールドコイルの製造方法を説明する図であり、（ａ）は上面図、（ｂ）は正面図である。It is a figure explaining the manufacturing method of the molded coil of the 3rd Example of this invention, (a) is a top view, (b) is a front view. 本発明の第３の実施例のモールドコイルの製造方法を説明する図であり、（ａ）は上面図、（ｂ）は正面図である。It is a figure explaining the manufacturing method of the molded coil of the 3rd Example of this invention, (a) is a top view, (b) is a front view. 本発明の第３の実施例のモールドコイルの製造方法を説明する図であり、（ａ）は上面図、（ｂ）は正面図である。It is a figure explaining the manufacturing method of the molded coil of the 3rd Example of this invention, (a) is a top view, (b) is a front view. 本発明の第３の実施例のモールドコイルを示す図である。It is a figure which shows the mold coil of the 3rd Example of this invention. 従来の空芯コイルの配置を示す上面図である。It is a top view which shows arrangement | positioning of the conventional air core coil.

符号の説明Explanation of symbols

１：空芯コイル、２：上型、３下型、３ａ：位置出しピン、３ｂ：支持ピン、４：キャビティ、５磁性体モールド樹脂、６：パンチ、７：外部電極、８：金属箔、９：半田層、１０：空芯コイル、１１：上型、１１ａ：位置出しピン、１２：下型、１３：キャビティ、１４：磁性体モールド樹脂、１５：パンチ、１６：外部電極 1: air core coil, 2: upper mold, 3 lower mold, 3a: positioning pin, 3b: support pin, 4: cavity, 5 magnetic mold resin, 6: punch, 7: external electrode, 8: metal foil, 9: Solder layer, 10: Air core coil, 11: Upper die, 11a: Positioning pin, 12: Lower die, 13: Cavity, 14: Magnetic molding resin, 15: Punch, 16: External electrode

Claims (4)

プラスチック成形法を用いて、磁性体粉末と樹脂とを混練させた磁性体モールド樹脂で空芯コイルを封止してなるモールドコイルの製造方法において、
形状が略真円状ではない該空芯コイルと、
複数の金型から形成されるキャビティと、該キャビティ内を垂直方向に移動可能な位置出しピンとを有する成形金型を用い、
該位置出しピンによって該キャビティ内の所定の位置へ該空芯コイルを配置し、
該キャビティ内に該磁性体モールド樹脂を該キャビティ内に充填し、その充填中に該位置出しピンを所定の位置まで移動させることを特徴とするモールドコイルの製造方法。 In a method for producing a molded coil, in which an air-core coil is sealed with a magnetic molding resin in which magnetic powder and resin are kneaded using a plastic molding method,
The air-core coil whose shape is not substantially circular,
Using a molding die having a cavity formed from a plurality of molds and a positioning pin movable in the vertical direction in the cavity,
The air core coil is arranged at a predetermined position in the cavity by the positioning pin,
A mold coil manufacturing method, wherein the cavity is filled with the magnetic mold resin in the cavity, and the positioning pin is moved to a predetermined position during the filling. 前記空芯コイルの形状が、半円状、扇状、長円状、楕円状、略多角形状、またはそれらを組合せた形状のいずれかであることを特徴とする請求項１に記載のモールドコイルの製造方法。   2. The molded coil according to claim 1, wherein the shape of the air-core coil is any one of a semicircle, a fan, an oval, an ellipse, a substantially polygon, or a combination thereof. Production method. プラスチック成形法を用いて、磁性体粉末と樹脂とを混練させた磁性体モールド樹脂で空芯コイルを封止してなるモールドコイルの製造方法において、
形状が略真円状ではない該空芯コイルと、
複数の金型から形成されるキャビティと、該キャビティ内を水平方向に移動可能な位置出しピンとを有する成形金型を用い、
該位置出しピンによって該キャビティ内の所定の位置へ該空芯コイルを配置し、
該キャビティ内に該磁性体モールド樹脂を該キャビティ内に充填し、その充填中に該位置出しピンを所定の位置まで下降させることを特徴とするモールドコイルの製造方法。 In a method for producing a molded coil, in which an air-core coil is sealed with a magnetic molding resin in which magnetic powder and resin are kneaded using a plastic molding method,
The air-core coil whose shape is not substantially circular,
Using a molding die having a cavity formed from a plurality of molds and a positioning pin that can move horizontally in the cavity,
The air core coil is arranged at a predetermined position in the cavity by the positioning pin,
A method for producing a mold coil, wherein the cavity is filled with the magnetic mold resin in the cavity, and the positioning pin is lowered to a predetermined position during the filling. 前記空芯コイルの形状が、半円状、扇状、長円状、楕円状、略多角形状、またはそれらを組合せた形状のいずれかであることを特徴とする請求項３に記載のモールドコイルの製造方法。   4. The molded coil according to claim 3, wherein the shape of the air-core coil is any one of a semicircle, a fan, an oval, an ellipse, a substantially polygon, or a combination thereof. Production method.
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