JP4415561B2 - Inductance component manufacturing method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a manufacturing method of the inductance components used in various electronic devices.
[0002]
[Prior art]
In recent years, as electronic devices have become smaller and thinner, inductance components have become smaller and thinner, and in the high frequency region corresponding to higher speed and higher integration of LSIs such as CPUs, several A to several tens of A What can withstand a large current is desired.
[0003]
In response to such a demand, a conductor 30 is formed by cutting a metal plate such as copper or aluminum using a slitter as a lead wire that is the basis of a conventional inductance component, as shown in FIG. It has been proposed to use a flat insulating wire 32 on which a layer 31 is formed (see, for example, Patent Document 1).
[0004]
[Patent Document 1]
Japanese Patent Laid-Open No. 1-186714
[Problems to be solved by the invention]
However, in the above configuration, as shown in FIG. 24, burrs 33 are generated on the end face of the contact cross section, and even if the insulating layer 31 is formed in a state where the burrs 33 are formed, the insulating layer 31 is not formed on the burrs 33. Is not formed, causing dielectric breakdown.
[0006]
For this reason, as shown in FIG. 25, the burrs 33 of the conductor 30 formed by cutting the metal plate with a slitter are removed by etching, the cut surface is processed into a spherical shape, and the insulating layer 31 is also formed on the surface. It has been proposed to form.
[0007]
However, if the burrs 33 are etched to process the cut surface of the conductor 30 into a spherical shape, the thickness of the insulating layer 31 formed on the cut surface is reduced or the conductor 30 itself is exposed. Therefore, sufficient reliability cannot be obtained in terms of insulation.
[0008]
An object of the present invention is to provide a method of manufacturing an inductance component that eliminates the above-described conventional drawbacks and can provide sufficient reliability in terms of insulation despite being formed by stamping a metal plate. Is.
[0009]
[Means for Solving the Problems]
In order to solve the above problems, the present invention uses a step of punching a metal plate to form a coil portion in which terminals are integrally formed at least at both ends, and a mold for chamfering from the vertical direction of the coil portion. And forming a recess in the middle part of the cut surface of the coil part and pressing until the wall surface below the cut surface of the coil part protrudes outwardly, A step of chamfering the lower side, a step of applying a resin material from the upper surface of the coil portion excluding the terminal portion, filling the recess until the resin material overflows and semi-curing the resin material, and Inverting the coil part and applying the resin material also to the lower surface of the coil part and completely curing the resin material to form an insulation layer That.
[0010]
By adopting this manufacturing method , the concave portion of the cut surface becomes a reservoir for the resin material forming the insulating layer, and the insulating layer is necessarily formed thick and surely on the upper and lower cut surfaces. In this respect, it is possible to provide an inductance component with sufficient reliability.
[0011]
DETAILED DESCRIPTION OF THE INVENTION
The invention according to claim 1 of the present invention uses a step of punching a metal plate to form a coil portion in which terminals are integrally formed at least at both ends, and a mold for chamfering from the vertical direction of the coil portion. The upper side of the cut surface of the coil part is pressed by forming a recess in the middle part of the cut surface of the coil part and pressing until the wall surface below the cut surface of the coil part protrudes outward. And chamfering the lower side, applying a resin material from the upper surface of the coil part excluding the terminal part, filling the concave part until the resin material overflows, and semi-curing the resin material, by inverting the coil portion is the inductance component manufacturing method of having a step of forming an insulating layer by completely curing the resin material with applying the lower surface to the resin material also in the coil portion, the manufacturing Can recess of the cut surface by a method of forming a thick and reliable insulating layer on the cut surface becomes reservoir of resin material for forming the insulating layer, it is possible to improve the insulation properties At the same time, the binding strength of the insulating layer to the coil portion can be increased and peeling can be prevented.
[0012]
Further, the concave portion of the cut surface of the coil portion is formed by chamfering the upper and lower corners of the cut surface, so that the effect of deburring the cut surface can be obtained.
[0013]
Then, as the recess formed on the cut surface of the coil portion, and than also pressing until projecting downward from the upper wall surface forming a recess outside the resin material in forming the insulating layer by the manufacturing method It hits the lower part of the wall surface forming the concave part and flows into the concave part, so that the resin material is surely filled into the concave part, and as a result, a thick insulating layer can be reliably formed on the upper and lower wall surfaces of the concave part. .
[0014]
The insulating of the invention according to claim 1, constituted by embedding a coil portion in the magnetic body Then, the cutting face of the coil portion at the time of embedding with improved characteristics as an inductance component by using a magnetic material Layer breakage can be reduced.
[0015]
The configuration Then incorporate magnetic material coil unit, which also with improved characteristics as an inductance component by magnetic, insulating layer of the cut surface of the coil portion to be in contact during incorporation of the magnetic body is formed thickly Therefore, damage to the insulating layer can be reduced.
[0016]
And if the structure which clamped the coil part with the magnetic body is used , while also improving the characteristic as an inductance component by the magnetic body, the insulation at the upper side and the lower side part of the cut surface of the coil part contacting the magnetic body is also achieved. It can be surely secured.
[0017]
Furthermore, the insulator coil unit, configured Then placed on either plate-like body of dielectric or magnetic material, sufficiently secure the insulation between such other conductors and electronic components placed on the plate-like body can do.
[0018]
In addition, when the inductance component according to claim 1 is combined with another electronic component so as to form a predetermined circuit and used in the electronic device, the improvement in the reliability of the inductance component is directly reflected in the electronic device. become.
[0019]
Hereinafter, a method for manufacturing an inductance component of the present invention and a configuration example of the manufactured inductance component will be described with reference to the drawings. First, the manufacturing method of the inductance component of this invention is demonstrated using FIGS.
[0020]
First, a metal plate 1 made of copper or silver is cut by a press die 2 as shown in FIG. 1 to form a coil portion 3 having a predetermined shape as shown in FIG. At this time, it is assumed that the coil unit 3 is integrally formed with terminals at least at both ends thereof. As shown in FIG. 2, burrs 5 are formed on the lower side of the cut surface 4 of the coil portion 3.
[0021]
In the case where the burr 5 is formed in this way, even if an insulating layer to be described later is formed, it is difficult to form an insulating layer in the portion of the burr 5, and the coil part 3 lacks insulation. As shown in FIG. 4, the coil portion 3 is pressed by a chamfering die 6 and chamfered portions 7 are formed at the upper and lower corners of the cut surface 4 of the coil portion 3 as shown in FIG.
[0022]
By performing this chamfering process, a recess 8 is formed in the middle part of the cut surface of the coil part 3 as shown in FIG. In addition, the recess 8 is formed in such a manner that the wall surface below the cut surface 4 forming the recess 8 protrudes outward. This is because the burr 5 at the time of cutting described above is formed on the lower side of the cut surface 4 and the chamfering process including the burr 5 results in the above-described configuration.
[0023]
Next, as shown in FIG. 6, a resin material 9 such as an epoxy resin or a polyimide resin for forming an insulating layer is applied to the upper surface of the coil portion 3. At this time, the resin material 9 is applied so as to be formed also on the cut surface 4 of the coil portion 3, and the recess 8 of the cut surface 4 is sufficiently filled so as to overflow from the recess 8.
[0024]
Thereafter, the resin material 9 applied to the upper surface of the coil portion 3 is made into a semi-cured state, and then the coil portion 3 is reversed, and the resin material 9 is applied to the lower surface of the coil portion 3 as shown in FIG. the resin material 9 is formed on the whole, is to produce a formed inductance component of the insulating layer 10 so by fully cured.
[0025]
The insulating layer 10 is preferably not formed on the terminals at both ends of the coil portion 3, which is advantageous when mounting the inductance component on the printed wiring board. Further, the resin material 9 may be formed by printing, spraying, or transferring other than application.
[0026]
As described above, a concave portion 8 is provided in the intermediate portion of the cut surface 4 of the coil portion 3 formed by punching the metal plate 1, and the insulating layer 10 is formed so that the concave portion 8 is also filled with the resin material 9. By this, the concave portion 8 becomes a reservoir portion of the resin material 9 having fluidity, and the insulating layer 10 having a desired thickness can be reliably formed also in the chamfered portion 7 on the upper side or the lower side of the cut surface 4, Compared with an insulating layer formed on a cut surface formed into a spherical shape by a conventional deburring process, the insulating property can be improved.
[0027]
As the shape of the inductance component manufactured as described above, various shapes can be considered depending on its use and purpose. For example, a linear inductance component having terminals 11 at both ends as shown in FIG. 8, a meandering inductance component having terminals 11 at both ends as shown in FIG. 9, and a terminal 11 at both ends as shown in FIG. Spiral inductance components, ring-shaped inductance components having terminals 11 at both ends as shown in FIG. 11, frame-shaped inductance components having terminals 11 at both ends as shown in FIG. 12, and further, as shown in FIG. An inductance component having terminals 11 at both ends and bending a ring-like continuous body to form a coil 12 of several turns is conceivable.
[0028]
The ones shown here are merely representative examples that can be put into practical use, and various other types are conceivable. For example, the configuration shown in FIG. In place of the continuum, a frame-like continuum is bent.
[0029]
Even if only the coil part 3 punched from the metal plate on which the insulating layer 10 is formed as described above performs a sufficient function as an inductance component depending on the application, in order to further improve the characteristics as the inductance component, a magnetic material is used. A combination with these is required.
[0030]
A typical example will be described below with reference to FIGS. This example assumes a choke coil used in a power circuit of an electronic device. As shown in FIG. 14A, a metal plate made of copper is punched to use three ring-shaped continuous bodies 13 and a terminal-integrated coil portion 3 in which terminals 11 are integrally formed at both ends of the continuous body 13. . The coil portion 3 is chamfered on the cut surface 4 and has a recess 8 in the middle portion of the cut surface. A resin material 9 is applied so that the recess 8 is also filled with the insulating layer 10. Is formed. The insulating layer 10 is not formed on the bent portion 14 of the ring-shaped continuous body 13.
[0031]
This is to prevent the insulating layer 10 from being broken due to the difference in expansion and contraction between the outer side and the inner side of the bent portion 14 when the ring-shaped continuous body 13 is bent.
[0032]
As shown in FIG. 14 (b), such a portion is bent using the bent portion 14 so that the center points overlap with each other to form a coil portion 3 of several turns, and the terminal 11 is located with respect to the center of the coil portion 3. Thus, the shape protrudes radially outward.
[0033]
The coil portion 3 configured as described above is embedded in the magnetic body 15 as shown in FIG. For this magnetic body 15, 3.3 parts by weight of a silicone resin is added to and mixed with a soft magnetic alloy powder, and a composite magnetic body is used as a rectifying powder through a mesh. The metal magnetic powder is a soft magnetic alloy powder of Fe (50) Ni (50) having an average particle diameter of 13 μm manufactured by a water atomization method.
[0034]
By using such a magnetic body 15, each grain of soft magnetic alloy powder is covered with an insulating resin, and can have excellent saturation magnetic flux density and small eddy current loss. It will be possible to cope with. The composition of the metal magnetic powder includes Fe, Ni and Co in a total of 90% by weight or more, and by making the filling rate of the metal magnetic powder 65 to 90% by volume, the composite has high saturation magnetic flux density and high magnetic permeability. It can be a magnetic material. Further, when the average particle size of the metal magnetic powder is 1 to 100 μm, it is effective for reducing eddy current.
[0035]
The magnetic body 15 can be the same effect even if it is a ferrite magnetic body or a composite of a ferrite magnetic powder and an insulating resin. The resistance is higher than that of the metal magnetic powder, but the resistance prevents the generation of eddy currents. It is possible to cope with high frequencies.
[0036]
In the manufacture of this inductance component, semi-hardened magnetic pellets formed so as to follow the shape of the coil part 3 are arranged above and below the coil part 3 having the terminals 11, and these are applied with a pressure of 3 ton / cm ² . The heat treatment is performed at 150 ° C. for about 1 hour to completely cure the semi-cured magnetic material, and the coil portion 3 is embedded in the magnetic material 15. The terminals 11 protruding from the magnetic material 15 are connected to the terminals 11 of the magnetic material 15. An inductance component as shown in FIG. 16 is formed by bending from the side surface along the bottom surface.
[0037]
The terminal 11 protruding from the magnetic body 15 is formed with a surface layer 17 of solder or Sn or Pb for preventing oxidation and improving wettability of the Ni underlayer 16 and Ni underlayer as an anti-oxidation. Is done.
[0038]
In addition, the magnetic body 15 is formed in a square shape, and the top surface should be flat so that it can be easily attracted to the nozzle during automatic mounting. When the mounting direction and terminal polarity are indicated, the corner is dropped. It can also be.
[0039]
By embedding the coil portion 3 in the magnetic body 15 in this way, the inductance characteristics as an inductance component can be remarkably improved, the coil portion 3 can be protected, and further advantageous for automatic mounting. Can do. In addition, when the magnetic pellets are arranged vertically and pressed during the manufacturing process, even if the insulating layer 10 of the coil portion 3 causes friction with the magnetic pellets, the insulating layer 10 is firmly attached to the cut surface 4 of the coil portion 3. Is formed, and the insulating property is excellent.
[0040]
In addition, as shown in FIG. 17 and FIG. As the coil portion 3, the same one embedded in the magnetic body 15 is used. As the magnetic body, a T-shaped magnetic body 18 made of ferrite or the like having a cylindrical portion formed at the center of the upper surface of the plate-like body, and a coil on the side surface Using a cap-like magnetic body 20 made of ferrite or the like provided with a notch portion 19 for drawing out the terminal 11 of the portion 3, the cylindrical portion of the T-shaped magnetic body 18 is assembled so as to fit the hollow portion of the coil portion 3, The T-shaped magnetic body 18 incorporating the coil portion 3 is covered with a cap-shaped magnetic body 20, and the joining surfaces of the magnetic bodies 18 and 20 are bonded with an adhesive.
[0041]
Even with this configuration, the inductance part can be excellent in inductance characteristics, and the coil part 3 can be used even if some rubbing occurs when the coil part 3 is incorporated into the magnetic body 18 or when the magnetic body 20 is incorporated. Since the insulating layer 10 is firmly formed on the cut surface 4, it is possible to prevent the insulating layer 10 from being damaged or peeled off, and the insulating reliability is high.
[0042]
Still another inductance component will be described with reference to FIGS. The coil part 3 is the same as that of the above-mentioned two configurations, and two plate-like magnetic bodies 21 and 22 are used as magnetic bodies, and the coil part 3 is interposed between the two magnetic bodies 21 and 22. It is set as the structure which pinched | interposed. The magnetic bodies 21 and 22 and the coil portion 3 are integrated by being bonded with an adhesive.
[0043]
Instead of bonding with an adhesive, a resin material may be filled around the coil portion 3 to integrate the magnetic bodies 21 and 22 and the coil portion 3 together.
[0044]
Even in this configuration, the inductance characteristics can be improved as an inductance component, and depending on the configuration, the exposed coil portion 3 is completely covered with the insulating layer 10, so that some conductor is attached to the coil portion 3. Even if they come into contact with each other, sufficient insulation can be maintained.
[0045]
Further, another inductance component will be described with reference to FIG. The coil section 3 used here has terminals 11 at both ends shown in FIG. 9, and the meandering coil section in which the insulating layer 10 is also formed in the recess 8 of the cut surface 4 of the coil section 3 except for the terminals 11. 3. The coil portion 3 is configured to be bonded on a plate-like body 23 made of an insulator, a dielectric material or a magnetic material using an adhesive or the like.
[0046]
The insulator is selected as the plate-like body 23 because the plate-like body 23 can be a printed wiring board, and the inductance component is coupled to the surface of the printed wiring board to form another circuit pattern. A predetermined circuit can be configured with various electronic components to be mounted.
[0047]
In addition, the dielectric is selected as the plate-like body 23 because it is a laminated body of a thin dielectric layer and a metal layer, and a capacitor is built in, and by providing a coil portion 3 on the surface, an LC composite component or filter is selected. A circuit can be constructed.
[0048]
The reason why the magnetic body is selected as the plate-like body 23 is to improve the characteristics as an inductance component.
[0049]
Regardless of which plate member 23 is selected, other electronic components, conductors, and the like are often provided close to the coil portion 3, but in such a case, the coil portion 3 excluding the terminal 11 is also provided. Since the insulating layer 10 is firmly provided, the insulation reliability can be high.
[0050]
Various examples of the combination of the coil part 3 and the magnetic body have been shown. However, these are only those using one coil part 3, but multiple coils are used by using two or more coil parts 3. It can also be an inductance component or an inductance component such as a transformer. That is, two or more coil portions 3 are embedded in the magnetic body 15, embedded in the magnetic bodies 18, 20, sandwiched between the magnetic bodies 21, 22, or coupled to the plate-like body 23. As a result, the above-described multiple inductance component or an inductance component such as a transformer having another function can be obtained.
[0051]
As an example of such a multi-inductance component, an application example to an electronic device using a double choke coil as an example will be described with reference to FIG.
[0052]
FIG. 22 shows a power supply circuit of a multi-phase electronic device. An integrating circuit is formed by a choke coil 24 and a capacitor 25. The integrating circuit includes an input power supply 26, a switching element 27, and an output side such as a CPU. A load 28 is connected to constitute a power supply circuit.
[0053]
As the choke coil 24, one having a configuration in which two terminal-integrated coil portions 3 are embedded in the magnetic body 15 is used, and a phase control of a plurality of DC / DC converters is performed by the two coil portions 3. And run in parallel. With this circuit configuration, high frequency and large current can be achieved, and in particular, by mounting the choke coil 24 of the present invention, the insulation reliability is excellent.
[0054]
The inductance component according to the present invention is not limited to the multiphase power supply circuit described above, and can be used for a power supply circuit of an electronic device that can cope with other high frequency and high current. Representative examples of electronic devices include personal computers and mobile phones.
[0055]
【The invention's effect】
As described above, the method of manufacturing an inductance component according to the present invention includes a step of forming a coil portion in which a metal plate is punched and terminals are integrally formed at least at both ends, and a die for chamfering from the vertical direction of the coil portion. And forming a recess in the middle part of the cut surface of the coil part, and pressing until the wall surface below the cut surface of the coil part protrudes outward, thereby cutting the cut surface of the coil part A step of chamfering the upper side and the lower side, and a step of applying a resin material from the upper surface of the coil portion excluding the terminal portion, filling the concave portion until the resin material overflows, and semi-curing the resin material And applying the resin material to the lower surface of the coil portion by reversing the coil portion, and completely curing the resin material to form an insulating layer. Due to the process, is formed by a resin material is filled chamfered thicker the cut surface insulating layer for forming the insulating layer in a recess formed in an intermediate portion of the cut surface of the coil portion, and the insulating layer by the recess The binding force with respect to the coil portion can be increased, and the coil portion can be hardly peeled off, and the insulation can be highly reliable.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing a state in which a coil portion is formed by punching from a metal plate in an embodiment of an inductance component of the present invention. FIG. 2 is a cross-sectional view of a main part of the coil portion formed by punching the same. 3 is a cross-sectional view of the main part showing a state in which the coil part formed by punching is chamfered. FIG. 4 is a cross-sectional view of the main part in a state where the chamfering is performed. FIG. FIG. 6 is a cross-sectional view of the main part showing a state in which an insulating layer is formed on the upper surface of the coil part. FIG. 7 is a state in which an insulating layer is formed on both surfaces of the coil part. FIG. 8 is a perspective view showing a linear inductance component as an example of the inductance component of the present invention. FIG. 9 is a perspective view showing the meandering inductance component. FIG. Perspective view [Fig. 11] FIG. 12 is a perspective view showing the frame-shaped inductance component. FIG. 13 is a perspective view of the inductance component formed by bending the ring-like continuous body to form a coil of several turns. (A) Plan view of the coil part before bending of the inductance part constituted by the ring-like continuum (b) Perspective view after the bending [FIG. 15] Inductance part with the coil part embedded in the magnetic body FIG. 16 is a perspective view of the inductance component. FIG. 18 is a perspective view of the inductance component after assembling. FIG. ] An exploded perspective view of an inductance component formed by sandwiching the coil portion with a magnetic material [FIG. 20] A perspective view of an inductance component after the assembly [FIG. 21] FIG. 22 is a circuit diagram showing an example in which the inductance component is used in a power circuit of an electronic device. FIG. 23 is formed by punching from a conventional metal plate. FIG. 24 is a cross-sectional view of the main part showing the problem caused by the burr. FIG. 25 is a cross-sectional view of the main part showing the state where the burr is removed.
DESCRIPTION OF SYMBOLS 1 Metal plate 2 Press die 3 Coil part 4 Cutting surface 5 Burr 6 Chamfering die 7 Chamfering part 8 Recess 9 Resin material 10 Insulating layer 11 Terminal 12 Coil 13 Ring-shaped continuous body 14 Bending part 15 Magnetic body 18, 20, 21, 22 Magnetic body 23 Plate-like body 24 Choke coil 25 Capacitor 26 Input power supply 27 Switching element 28 Load

Claims (1)

A step of forming a coil part in which terminals are integrally formed at least at both ends by punching a metal plate, and a chamfering mold from the vertical direction of the coil part, A step of chamfering the upper and lower sides of the cut surface of the coil portion by forming a recess and pressing until the wall surface below the cut surface of the coil portion protrudes outward; and the terminal portion A step of applying a resin material from the upper surface of the coil portion except for filling and filling the concave portion until the resin material overflows and semi-curing the resin material; and reversing the coil portion to lower the coil portion And the step of applying the resin material and completely curing the resin material to form an insulating layer.

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