JP5874133B2 - Inductance element manufacturing method - Google Patents

Inductance element manufacturing method Download PDF

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JP5874133B2
JP5874133B2 JP2013046130A JP2013046130A JP5874133B2 JP 5874133 B2 JP5874133 B2 JP 5874133B2 JP 2013046130 A JP2013046130 A JP 2013046130A JP 2013046130 A JP2013046130 A JP 2013046130A JP 5874133 B2 JP5874133 B2 JP 5874133B2
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coil body
magnetic core
terminal portion
center line
inductance element
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JP2014175437A (en
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川瀬　恭一
恭一 川瀬
松井　和彦
和彦 松井
小島　章伸
章伸 小島
慶一 荒木
慶一 荒木
英一郎 松山
英一郎 松山
誠作 今井
誠作 今井
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Alps Green Devices Co Ltd
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Description

本発明は、磁性粉末とバインダー樹脂とが加圧されて成形された圧粉成形体の磁性コアにコイル体が埋め込まれたインダクタンス素子の製造方法に関する。 The present invention is a magnetic powder and a binder resin process for the preparation of an inductance element which coil body is embedded in the magnetic core of the pressurized molded green compact.

以下の特許文献１ないし３に記載されたインダクタンス素子は、圧粉成形体の磁性コアにコイル体が埋め込まれている。圧粉成形体の磁性コアは、磁性粉末とバインダー樹脂とから成るコア材料が金型内に供給され、加熱され加圧されてコア形状に成形されるものであり、磁性粉末の密度を高くでき、高いインダクタンスを得ることが可能である。   In the inductance elements described in the following Patent Documents 1 to 3, a coil body is embedded in a magnetic core of a powder compact. The magnetic core of the green compact is a core material consisting of magnetic powder and a binder resin that is supplied into a mold, heated and pressurized to be molded into a core shape, which can increase the density of the magnetic powder. It is possible to obtain a high inductance.

特許文献１に記載されたインダクタは、平角銅線が、厚さ方向を巻き中心線に向けた状態で、巻き中心線に沿って重ねられるように巻かれたコイルが使用されている。コイルが圧粉成形体の内部に埋め込まれて磁性コアが成形されるが、平角銅線の両端部は磁性コアから外部に突出している。磁性コアが成形された後に、平角銅線の両端部が磁性コアの裏面に向けて折り曲げられて、端子部が形成される。   The inductor described in Patent Document 1 uses a coil wound so that a flat copper wire is overlapped along the winding center line in a state where the thickness direction is directed to the winding center line. The coil is embedded inside the green compact to form the magnetic core, but both ends of the flat copper wire protrude from the magnetic core to the outside. After the magnetic core is molded, both end portions of the flat copper wire are bent toward the back surface of the magnetic core to form the terminal portion.

特許文献１に記載されたインダクタは、磁性コアから突出した平角銅線の端部を折り曲げて端子部を形成するため、磁性コアの裏面と端子部との間に隙間が発生しやすく、インダクタの薄型化と小型化に適したものではない。また、磁性コアから突出した平角銅線の端部を折り曲げるときに、この端部の基部から磁性コアに大きな応力が作用し、平角銅線が突出している部分で磁性コアが損傷しやすく、または内部に亀裂が生じやすくなる。   The inductor described in Patent Document 1 forms a terminal portion by bending an end portion of a flat copper wire protruding from the magnetic core, so that a gap is easily generated between the back surface of the magnetic core and the terminal portion. It is not suitable for thinning and miniaturization. Also, when bending the end of the flat copper wire protruding from the magnetic core, a large stress acts on the magnetic core from the base of this end, and the magnetic core is easily damaged at the portion where the flat copper wire protrudes, or Cracks are likely to occur inside.

特許文献２に記載された圧粉成形体の製造方法は、銅線によりコイルが巻かれるとともに、銅線の端部が折り曲げられて一対の端子部が形成される。コイルならびに一対の端子部がプレス機に設置されるとともに、磁性粉末とバインダー樹脂とから成るコア材料が供給され、コイルならびに端子と共にコア材料が圧縮され且つ加圧されて圧粉成形体の磁性コアが成形される。成形後のインダクタンス素子は、コイルと端子部が共に磁性コアの内部に埋め込まれたものとなり、端子部の表面のみが磁性コアの裏面に露出する。   In the method for manufacturing a green compact described in Patent Document 2, a coil is wound with a copper wire, and ends of the copper wire are bent to form a pair of terminal portions. A coil and a pair of terminal portions are installed in a press, and a core material made of magnetic powder and a binder resin is supplied, and the core material is compressed and pressed together with the coil and terminals to form a magnetic core of a compacted body. Is formed. In the formed inductance element, both the coil and the terminal portion are embedded in the magnetic core, and only the surface of the terminal portion is exposed on the back surface of the magnetic core.

この製造方法で成形されたインダクタンス素子は、コイルと端子部がコア材料と共に加圧されて磁性コアが形成されるため、小型化と薄型化が可能であり、また、磁性コアの成形後に端子部を折り曲げる必要がないため、折り曲げ作業により磁性コアに損傷や亀裂を与えることがない。   The inductance element formed by this manufacturing method can be reduced in size and thickness because the coil and the terminal are pressed together with the core material to form the magnetic core, and the terminal is formed after the magnetic core is formed. Therefore, the magnetic core is not damaged or cracked by the bending operation.

しかし、特許文献２に記載されたコイルを形成している銅線は、断面が正方形であるため、銅線を折り曲げた一対の端子部は、コイルの巻き中心線に沿う方向での断面二次モーメント（Ｉ）が大きくなり、コイルの巻き中心線に沿う向きでの曲げ剛性（ＥＩ：Ｅは縦弾性係数）が非常に大きくなる。そのため、コイルと端子部がコア材料とともに巻き中心線に沿う方向へ加圧されて磁性コアが成形された後に、端子部が前記巻き中心線方向へ戻ろうとするスプリングバック力が大きく作用する。そのため、成型後の磁性コアの内部に、スプリングバック力による大きな応力が作用し、磁性コアの内部に亀裂が発生しやすくなる。   However, since the copper wire forming the coil described in Patent Document 2 has a square cross section, the pair of terminal portions obtained by bending the copper wire has a secondary cross section in the direction along the winding center line of the coil. The moment (I) is increased, and the bending rigidity (EI: E is a longitudinal elastic modulus) in the direction along the winding center line of the coil is greatly increased. Therefore, after the coil and the terminal portion are pressed together with the core material in the direction along the winding center line to form the magnetic core, a springback force that causes the terminal portion to return to the winding center line direction acts greatly. Therefore, a large stress due to the springback force acts inside the magnetic core after molding, and cracks are likely to occur inside the magnetic core.

次に、特許文献３に記載されたインダクタの製造方法は、鉄系金属磁性粉末とエポキシ樹脂を混合して得た封止材を予備成形した２個の予備成形体が使用される。空心コイルと空心コイルから延び出ている両端部が２個の予備成形体の間に収納され、予備成形体が加熱され圧縮成形されて、磁性コアが成形される。   Next, in the inductor manufacturing method described in Patent Document 3, two preforms obtained by preforming a sealing material obtained by mixing an iron-based metal magnetic powder and an epoxy resin are used. The air core coil and both ends extending from the air core coil are accommodated between two preforms, and the preform is heated and compression-molded to form a magnetic core.

特許文献３に記載された製造方法は、断面が長方形状の導電性帯体が、その帯体の幅方向がコイルの巻き中心線と平行に向けられた状態で円筒状に巻かれてコイル体が形成されている。そして、磁性コアを成形するときに、コイルを形成している導電性帯体に対して加圧力が幅方向に作用する。そのため、導電性帯体が幅方向へ座屈変形しやすくなり、その変形力で磁性コアに亀裂などが発生しやすい。さらに、変形した導電性帯体の面間に隙間が形成されやすく、この隙間内に磁性粉が入り込んで、コイルの絶縁性が劣化する問題も発生しやすい。   The manufacturing method described in Patent Document 3 is a coil body in which a conductive strip having a rectangular cross section is wound in a cylindrical shape with the width direction of the strip directed parallel to the winding center line of the coil. Is formed. And when shape | molding a magnetic core, a pressurizing force acts on the electroconductive strip which forms the coil in the width direction. For this reason, the conductive band is easily buckled and deformed in the width direction, and cracks and the like are easily generated in the magnetic core by the deformation force. Furthermore, a gap is easily formed between the surfaces of the deformed conductive band, and a problem that the magnetic powder enters the gap and the insulation of the coil deteriorates easily occurs.

絶縁性の劣化などの課題は磁性コアが小型化されて圧粉成形体の体積が小さくなると、特に顕著になる。したがって、特許文献３に記載された製造方法は、小型の磁性コアに適したものではない。   Issues such as deterioration of insulation become particularly significant when the magnetic core is downsized and the volume of the green compact is reduced. Therefore, the manufacturing method described in Patent Document 3 is not suitable for a small magnetic core.

特開２００６−１３０６６号公報JP 2006-13066 A 特開２００５−２９４４６１号公報JP 2005-294461 A 特開２０１２−１６０５０７号公報JP 2012-160507 A

本発明は、上記従来の課題を解決するものであり、コイル体から延びる端子部のスプリングバック力を弱くして、圧粉成形体である磁性コアの内部に亀裂が生じにくくし、さらに小型化と薄型化が可能なインダクタンス素子の製造方法を提供することを目的としている。 The present invention solves the above-described conventional problems, weakens the spring back force of the terminal portion extending from the coil body, makes it difficult for cracks to occur inside the magnetic core, which is a powder compact, and further reduces the size. and its object is to provide a manufacturing method of the inductance element which can be thinned with.

本発明は、磁性粉末とバインダー樹脂を有するコア材料を加圧して成形した圧粉成形体の磁性コアの内部にコイル体を埋め込むインダクタンス素子の製造方法において、
幅方向の寸法が厚さ方向の寸法よりも大きく断面が長方形で長尺状の導電性帯体を使用し、
前記導電性帯体で、厚さ方向を巻き中心線と平行に向けて巻き中心線方向へ重ねられるように巻かれた前記コイル体と、前記コイル体から前記巻き中心線と直交する方向に延び出る一対の端部とを形成し、それぞれの前記端部を厚さ方向に曲げて前記巻き中心線と平行な向きとし、さらにその先部を厚さ方向に曲げて、前記コイル体を形成する導電性帯体と平行に対向する一対の端子部を形成し、
前記コイル体を形成する導電性帯体の厚さ方向と、前記端子部を構成する導電性帯体の厚さ方向を、共に加圧方向に向けて、前記コア材料とそれぞれの前記端子部とを前記巻き中心線と平行な方向へ加圧して前記コア材料で前記磁性コアを形成し、前記端子部の板面が前記磁性コアの表面とほぼ同一面となるように前記コイル体を前記磁性コアに埋め込むことを特徴とするものである。 The present invention relates to a method for manufacturing an inductance element in which a coil body is embedded in a magnetic core of a powder compact formed by pressing a core material having magnetic powder and a binder resin.
Use a conductive strip that is longer in the width direction than the thickness in the thickness direction and rectangular in cross section,
The coil body wound in such a manner that the thickness direction is parallel to the winding center line, and the coil body is overlapped in the winding center line direction, and extends from the coil body in a direction perpendicular to the winding center line. Forming a pair of protruding end portions, bending each of the end portions in the thickness direction to be parallel to the winding center line, and further bending the tip portion in the thickness direction to form the coil body. Forming a pair of terminal portions facing in parallel with the conductive band;
The core material and each of the terminal portions are arranged such that the thickness direction of the conductive band forming the coil body and the thickness direction of the conductive band forming the terminal portion are both directed in the pressing direction. Is pressed in a direction parallel to the winding center line to form the magnetic core with the core material, and the coil body is made to be magnetic so that the plate surface of the terminal portion is substantially flush with the surface of the magnetic core. It is characterized by being embedded in the core.

本発明のインダクタンス素子の製造方法では、前記磁性コアを形成した後に、アニール処理を行うことが可能である。   In the method for manufacturing an inductance element according to the present invention, annealing can be performed after the magnetic core is formed.

本発明のインダクタンス素子の製造方法は、金属製帯体で形成された端子部の厚さ方向が、圧粉成形体を加圧する際の加圧方向に向けられている。端子部は加圧方向に向けて剛性が低くなるため、磁性コアが成形された後の端子部のスプリングバック力が弱くなり、端子部に隣接する部分で磁性コアに亀裂が発生しにくくなる。 Manufacturing method of the inductance element of the present invention, it thickness direction of the terminal portion formed by a metal strip member is directed to the pressing direction at the time of pressurizing the powder compact. Since the rigidity of the terminal portion decreases in the pressurizing direction, the springback force of the terminal portion after the magnetic core is formed is weakened, and cracks are less likely to occur in the magnetic core adjacent to the terminal portion.

また、コイル体も、金属製帯状体の厚み方向が加圧方向と平行に向けられているため、磁性コアを圧縮成形した後のコイル体を構成する金属製帯体のスプリングバック力が弱くなり、コイル体を構成する金属製帯体の間の接着が剥がれようとする力も発生しにくい。そのため、アニール処理により、金属製帯体の間の接着力が低下しても金属製帯体の面間に隙間が発生しにくい。   In addition, since the thickness direction of the metal strip is directed parallel to the pressing direction, the spring back force of the metal strip constituting the coil body after compression molding of the magnetic core is weakened. Further, it is difficult to generate a force for peeling off the adhesion between the metal strips constituting the coil body. Therefore, even if the adhesive force between the metal strips decreases due to the annealing treatment, a gap is hardly generated between the surfaces of the metal strips.

本発明の実施の形態のインダクタンス素子に使用されるコイル体が巻き成形された直後の状態を示す斜視図、The perspective view which shows the state immediately after the coil body used for the inductance element of embodiment of this invention was wound-molded, コイル体に端子部が曲げ成形された状態を示す斜視図、The perspective view which shows the state by which the terminal part was bending-formed by the coil body, 磁性コアを圧粉成形する過程を示す側面図、Side view showing the process of compacting the magnetic core, インダクタンス素子の底面図、Bottom view of the inductance element, インダクタンス素子の断面図であり、図２のＶ−Ｖ線の断面図、FIG. 4 is a cross-sectional view of an inductance element, a cross-sectional view taken along line VV in FIG. コイル体の断面図であり、図２のＶＩ−ＶＩ線の断面図、FIG. 4 is a cross-sectional view of the coil body, a cross-sectional view taken along line VI-VI in FIG.

本発明の実施の形態のインダクタンス素子１は、圧粉成形体である磁性コア２０にコイル体１０が埋め込まれている。   In the inductance element 1 according to the embodiment of the present invention, a coil body 10 is embedded in a magnetic core 20 that is a powder compact.

図１と図２に示すように、コイル体１０は、金属製帯体１１を巻いて形成されている。図１と図６に示すように、金属製帯体１１は、対向する板面１１ａ，１１ａと、対向する側端面１１ｂ，１１ｂとを有し、断面が長方形の帯状体である。金属製帯体１１は、板面１１ａ，１１ａによって幅方向の寸法Ａが決められ、側端面１１ｂ，１１ｂによって厚さ方向の寸法Ｂが決められている。   As shown in FIGS. 1 and 2, the coil body 10 is formed by winding a metal strip 11. As shown in FIGS. 1 and 6, the metal strip 11 is a strip-like body having plate surfaces 11 a and 11 a facing each other and side end surfaces 11 b and 11 b facing each other and having a rectangular cross section. The metal strip 11 has a dimension A in the width direction determined by the plate surfaces 11a and 11a, and a dimension B in the thickness direction determined by the side end faces 11b and 11b.

幅方向の寸法Ａは厚さ方向の寸法Ｂよりも十分に大きく、寸法Ａは寸法Ｂの２倍以上であり、好ましくは４倍以上、さらに好ましくは６倍以上である。   The dimension A in the width direction is sufficiently larger than the dimension B in the thickness direction, and the dimension A is twice or more than the dimension B, preferably four times or more, more preferably six times or more.

金属製帯体１１は銅で形成されており、図６に示すように、金属製帯体１１の表面に被覆層１２が形成されている。被覆層１２は絶縁樹脂層の表面にナイロンなどの融着層が重ねられた２層構造である。   The metal strip 11 is made of copper, and a coating layer 12 is formed on the surface of the metal strip 11 as shown in FIG. The covering layer 12 has a two-layer structure in which a fusion layer such as nylon is superimposed on the surface of the insulating resin layer.

図１ないし図３にコイル体１０の巻き中心線Ｏが示されている。コイル体１０は、金属製帯体１１の板面１１ａが巻き中心線Ｏとほぼ垂直となり、厚さ方向を決めている側端面１１ｂが巻き中心線Ｏと平行となる向きで、板面１１ａどうしが巻き中心線Ｏに沿って重なるように巻かれている。図１と図２および図４に示すように、コイル体１０は、金属製帯体１１が楕円形となるように巻かれている。   A winding center line O of the coil body 10 is shown in FIGS. In the coil body 10, the plate surfaces 11a of the metal strip 11 are substantially perpendicular to the winding center line O, and the side end surfaces 11b defining the thickness direction are parallel to the winding center line O, and the plate surfaces 11a are in contact with each other. Are wound along the winding center line O. As shown in FIGS. 1, 2, and 4, the coil body 10 is wound so that the metal strip 11 has an elliptical shape.

図６に示すように、金属製帯体１１を巻いて形成されたコイル体１０は、加熱されるとともに巻き中心線Ｏと平行な向きの加圧力Ｆ１によって加圧される。この加熱加圧処理により、被覆層１２の表面の融着層が溶融し、金属製帯体１１の板面１１ａどうしが離れないように接着される。   As shown in FIG. 6, the coil body 10 formed by winding the metal strip 11 is heated and pressurized with a pressure F <b> 1 in a direction parallel to the winding center line O. By this heat and pressure treatment, the fusion layer on the surface of the coating layer 12 is melted and bonded so that the plate surfaces 11a of the metal strip 11 are not separated from each other.

図１に示すように、コイル体１０が楕円状に巻かれた状態で、コイル体１０から金属製帯体１１の第１の端部１３と第２の端部１６とが突出している。ここで、端部１３，１６とは、金属製帯体１１のうちのコイル体１０として巻かれていない両端部分を意味している。   As shown in FIG. 1, the first end 13 and the second end 16 of the metal strip 11 protrude from the coil body 10 with the coil body 10 wound in an elliptical shape. Here, the end portions 13 and 16 mean both end portions of the metal strip 11 that are not wound as the coil body 10.

図２に示すように、第１の端部１３は、第１の折れ線１４ａによって谷折り方向へほぼ直角に曲げられ、第２の折れ線１４ｂによって山折り方向へほぼ直角に曲げられ、第３の折れ線１４ｃと第４の折れ線１４ｄのそれぞれにおいて谷折り方向へほぼ直角に折り曲げられる。第２の端部１６は、第１の折れ線１７ａにおいて山折れ方向へほぼ直角に折り曲げられ、第２の折れ線１７ｂと第３の折れ線１７ｃおよび第４の折れ線１７ｄにおいて、谷折り方向へほぼ直角に折り曲げられている。   As shown in FIG. 2, the first end portion 13 is bent at a substantially right angle in the valley fold direction by the first fold line 14 a, bent at a substantially right angle in the mountain fold direction by the second fold line 14 b, Each of the bent line 14c and the fourth bent line 14d is bent at a substantially right angle in the valley folding direction. The second end portion 16 is bent substantially perpendicularly to the mountain fold direction at the first fold line 17a, and substantially perpendicular to the valley fold direction at the second fold line 17b, the third fold line 17c, and the fourth fold line 17d. It is bent.

第１の端部１３は、第４の折れ線１４ｄよりも先の部分が第１の端子部１５であり、第２の端部１６は、第４の折れ線１７ｄよりも先の部分が第２の端子部１８である。   The first end portion 13 has a first terminal portion 15 ahead of the fourth broken line 14d, and the second end portion 16 has a second portion ahead of the fourth bent line 17d. This is a terminal portion 18.

図２と図５に示すように、第１の端子部１５は、コイル体１０として巻かれている金属製帯体１１の板面１１ａからやや離れた位置にあり、第１の端子部１５を形成している金属製帯体１１の板面１１ａと、コイル体１０を構成している金属製帯体１１の板面１１ａとがほぼ平行に対向している。   As shown in FIGS. 2 and 5, the first terminal portion 15 is located slightly away from the plate surface 11 a of the metal strip 11 wound as the coil body 10, and the first terminal portion 15 is The plate surface 11a of the formed metal strip 11 and the plate surface 11a of the metal strip 11 constituting the coil body 10 are opposed substantially in parallel.

図２に示すよう、第２の端子部１８も、コイル体１０として巻かれている金属製帯体１１の板面１１ａからやや離れた位置にあり、第２の端子部１８を形成している金属製帯体１１の板面１１ａと、コイル体１０を構成している金属製帯体１１の板面１１ａとがほぼ平行に対向している。   As shown in FIG. 2, the second terminal portion 18 is also located slightly away from the plate surface 11 a of the metal strip 11 wound as the coil body 10, and forms the second terminal portion 18. The plate surface 11a of the metal strip 11 and the plate surface 11a of the metal strip 11 constituting the coil body 10 are opposed substantially in parallel.

そして、第１の端子部１５の図２において上に向けられている板面１１ａと、第２の端子部１８の図２において上に向けられている板面１１ａが、ほぼ同一面に位置し、その面は、巻き中心線Ｏと垂直な面である。   The plate surface 11a of the first terminal portion 15 facing upward in FIG. 2 and the plate surface 11a of the second terminal portion 18 facing upward in FIG. 2 are located on substantially the same plane. The surface is a surface perpendicular to the winding center line O.

図３に、磁性コア２０を圧粉成形体として成形する工程が示されている。
図３に示すプレス機３０は、金型本体３１の内部に下型３２が設けられ、その上方にキャビティ３４が形成されている。図２に示すコイル体１０がキャビティ３４の内部に挿入され、第１の端子部１５の表面の板面１１ａと第２の端子部１８の表面の板面１１ａが、下型３２の上面に当接するように位置決めされる。 The process of shape | molding the magnetic core 20 as a compacting body is shown by FIG.
The press machine 30 shown in FIG. 3 has a lower mold 32 provided inside a mold body 31 and a cavity 34 formed above the lower mold 32. The coil body 10 shown in FIG. 2 is inserted into the cavity 34, and the plate surface 11 a on the surface of the first terminal portion 15 and the plate surface 11 a on the surface of the second terminal portion 18 contact the upper surface of the lower mold 32. Positioned to touch.

その後、磁性粉末とバインダー樹脂とから成るコア材料が、キャビティ３４の内部に供給される。磁性粉末は磁性合金粉末であり、例えば、Ｆｅを主体とし、Ｎｉ、Ｓｎ、Ｃｒ、Ｐ、Ｃ、Ｂ、Ｓｉなどの各種金属が含まれたＦｅ基非結晶金属ガラス合金の粉末であり、水アトマイズ法により粉末化されたものである。バインダー樹脂は、シリコーン樹脂やエポキシ樹脂などである。   Thereafter, a core material made of magnetic powder and binder resin is supplied into the cavity 34. The magnetic powder is a magnetic alloy powder, for example, an Fe-based amorphous metal glass alloy powder mainly composed of Fe and containing various metals such as Ni, Sn, Cr, P, C, B, and Si. Powdered by the atomizing method. The binder resin is a silicone resin or an epoxy resin.

前記コア材料は、前記磁性粉末が前記バインダー樹脂でコーティングされた混合粉末である。あるいは、磁性粉末と粉末状のバインダー樹脂とが単に混合されたものであってもよい。   The core material is a mixed powder in which the magnetic powder is coated with the binder resin. Alternatively, the magnetic powder and powdered binder resin may be simply mixed.

コア材料がキャビティ３４内に充填されると、キャビティ３４の上方から上型３３が挿入され、下型３２と上型３３とでコア材料が加圧力Ｆ２で加圧されて、圧粉成形体である磁性コア２０が形成される。この圧粉成形では、バインダー樹脂が磁性粉末どうしを結合するための結合剤として機能する。このとき、キャビティ３４を、必要に応じて後述するアニール処理時の温度と同じ程度の温度で加熱してもよい。   When the core material is filled into the cavity 34, the upper mold 33 is inserted from above the cavity 34, and the core material is pressurized with the pressurizing force F2 by the lower mold 32 and the upper mold 33. A certain magnetic core 20 is formed. In this compacting, the binder resin functions as a binder for binding the magnetic powders. At this time, the cavity 34 may be heated at a temperature approximately equal to the temperature at the annealing process described later, if necessary.

図２ないし図４に示すように、圧粉成形体である磁性コア２０は、上面２１と下面２２を有しさらに４つの側面を有する立方体形状である。図２と図４に示すように、コイル体１０から延びる金属製帯体１１の端部１３，１６で形成された第１の端子部１５と第２の端子部１８は、その表面の板面１１ａが、磁性コア２０の下面２２に露出し、それぞれの端子部１５，１８の板面１１ａが磁性コア２０の下面２２とほぼ同一面となる。   As shown in FIGS. 2 to 4, the magnetic core 20, which is a powder compact, has a cubic shape having an upper surface 21 and a lower surface 22 and four side surfaces. As shown in FIGS. 2 and 4, the first terminal portion 15 and the second terminal portion 18 formed by the end portions 13 and 16 of the metal strip 11 extending from the coil body 10 are plate surfaces on the surface thereof. 11 a is exposed to the lower surface 22 of the magnetic core 20, and the plate surface 11 a of each terminal portion 15, 18 is substantially flush with the lower surface 22 of the magnetic core 20.

また、図２に示すように、金属製帯体１１の第１の端部１３の折れ線１４ｃと折れ線１４ｄとの間の部分の板面１１ａが、磁性コア２０の１つの側面２３に現れる。また、第２の端部１６の折れ線１７ｃと折れ線１７ｄとの間の部分の板面１１ａも、磁性コア２０の側面２３に現れる。それぞれの板面１１ａと側面２３とがほぼ同一面である。   Further, as shown in FIG. 2, the plate surface 11 a of the portion between the fold line 14 c and the fold line 14 d of the first end 13 of the metal strip 11 appears on one side surface 23 of the magnetic core 20. Further, the plate surface 11 a of the portion between the fold line 17 c and the fold line 17 d of the second end portion 16 also appears on the side surface 23 of the magnetic core 20. Each plate surface 11a and the side surface 23 are substantially the same surface.

図３に示すように、キャビティ３４内では、下型３２と上型３３との間で、磁性粉末とバインダー樹脂とから成るコア材料が加圧力Ｆ２で加圧されると同時に、コイル体１０ならびに第１の端子部１５と第２の端子部１８も加圧力Ｆ２を受けて加圧される。   As shown in FIG. 3, in the cavity 34, a core material made of magnetic powder and a binder resin is pressurized between the lower mold 32 and the upper mold 33 with the applied pressure F2, and at the same time, the coil body 10 and The first terminal portion 15 and the second terminal portion 18 are also pressurized by receiving the applied pressure F2.

第１の端子部１５と第２の端子部１８を構成している金属製帯体１１は、板面１１ａが巻き中心線Ｏと垂直な面となり、第１の端子部１５と第２の端子部１８を構成している金属製帯体１１の厚さ方向が、加圧力Ｆ２が作用する方向に向けられている。図６に示すように、金属製帯体１１は、幅方向の寸法Ａに比べて厚さ方向の寸法Ｂが十分に小さくなっている。よって、金属製帯体１１の断面では、加圧力Ｆ２が作用する方向での断面二次モーメント（Ｉ）が極小となり、第１の端子部１５と第２の端子部１８は、加圧力Ｆ２が作用する方向での曲げ剛性（ＥＩ）が極小となる。   In the metal strip 11 constituting the first terminal portion 15 and the second terminal portion 18, the plate surface 11a is a surface perpendicular to the winding center line O, and the first terminal portion 15 and the second terminal The thickness direction of the metal strip 11 constituting the portion 18 is directed to the direction in which the pressing force F2 acts. As shown in FIG. 6, the metal strip 11 has a dimension B in the thickness direction that is sufficiently smaller than a dimension A in the width direction. Therefore, in the cross section of the metal strip 11, the second moment (I) in the direction in which the applied force F2 acts is minimized, and the first terminal portion 15 and the second terminal portion 18 have the applied pressure F2. The bending rigidity (EI) in the acting direction is minimized.

そのため、図３に示すキャビティ３４の内部で圧粉成形体の成形が完了し、下型３２と上型３３との加圧力Ｆ２が解除された後に、第１の端子部１５と第２の端子部１８がコア体１０から離れようとする向きのスプリングバック力がきわめて弱くなる。第１の端子部１５と第２の端子部１８のスプリングバック力が磁性コア２０の内部に与える応力が最小になるため、端子部１５，１８と対面している部分で磁性コア２０に内部亀裂が発生する可能性が低くなる。   Therefore, after the molding of the green compact is completed inside the cavity 34 shown in FIG. 3 and the pressure F2 between the lower mold 32 and the upper mold 33 is released, the first terminal portion 15 and the second terminal The springback force in the direction in which the portion 18 tries to leave the core body 10 becomes extremely weak. Since the stress applied to the inside of the magnetic core 20 by the springback force of the first terminal portion 15 and the second terminal portion 18 is minimized, an internal crack is formed in the magnetic core 20 at the portion facing the terminal portions 15 and 18. Is less likely to occur.

図４に示すように、第１の端子部１５と第２の端子部１８は、コイル体１０を形成している金属製帯体１１の板面１１ａに一部が対面する対面領域Ｄを有している。図５に示すように、対面領域Ｄでは、端子部１５，１８とコイル体１０との隙間δが狭くなり、加圧成形後に端子部１５，１８がコイル体１０から離れようとするスプリングバック力により、隙間δの狭い領域に位置している磁性コア２０に内部応力が発生しやすくなっている。しかし、端子部１５，１８は厚さ方向が巻き中心線Ｏと平行に向けられてスプリングバック方向の曲げ剛性（ＥＩ）が低くなっているので、隙間δの部分で磁性コア２０に大きな亀裂などが生じにくくなる。   As shown in FIG. 4, the first terminal portion 15 and the second terminal portion 18 have a facing region D that partly faces the plate surface 11 a of the metal strip 11 forming the coil body 10. doing. As shown in FIG. 5, in the facing region D, the gap δ between the terminal portions 15 and 18 and the coil body 10 is narrowed, and the springback force that causes the terminal portions 15 and 18 to move away from the coil body 10 after pressure molding. As a result, internal stress is easily generated in the magnetic core 20 located in the narrow region of the gap δ. However, since the terminal portions 15 and 18 have the thickness direction parallel to the winding center line O and the bending rigidity (EI) in the springback direction is low, the magnetic core 20 has a large crack in the gap δ. Is less likely to occur.

さらに、図４に示すように、端子部１５，１８とコイル体１０との対面領域Ｄの面積が、それぞれの端子部１５，１８の面積の５０％以下となっていると、隙間δの狭い領域が可能な限り狭くなり、この領域において磁性コア２０の部分に亀裂などがさらに生じにくくなる。   Furthermore, as shown in FIG. 4, when the area of the facing region D between the terminal portions 15 and 18 and the coil body 10 is 50% or less of the area of the terminal portions 15 and 18, the gap δ is narrow. The region becomes as narrow as possible, and cracks and the like are less likely to occur in the magnetic core 20 in this region.

磁性コア２０が圧粉成形された後に、アニール処理に移行する。このアニール処理は、３５０℃〜４５０℃程度の温度に加熱して行われるものであり、磁性コア２０の内部歪みを緩和し、磁歪を低減するための工程である。図６に示すように、コイル体１０を形成している金属製帯体１１は、コイル体１０を成形するときに加圧力Ｆ１を与えて上下に圧縮させた状態で、絶縁層１２の表面のナイロンなどの融着層で接着されている。そのため、アニール処理で、前記融着層が加熱されると接着力が低下し、コイル体１０を形成している金属製帯体１１の板面１１ａどうしを巻き中心線Ｏ方向へ引きはがそうとするスプリングバック力が作用する。 After the magnetic core 20 is compacted, the annealing process is performed. This annealing process is performed by heating to a temperature of about 350 ° C. to 450 ° C., and is a process for relaxing the internal strain of the magnetic core 20 and reducing the magnetostriction. As shown in FIG. 6, the metal strip 11 forming the coil body 10 is compressed on the surface of the insulating layer 12 in a state where the coil body 10 is compressed up and down by applying a pressing force F <b> 1. Bonded with a fusion layer such as nylon. Therefore, when the fusion layer is heated in the annealing process, the adhesive strength is reduced, and the plate surfaces 11a of the metal strip 11 forming the coil body 10 are wound and peeled in the direction of the centerline O. The springback force is applied.

しかし、コイル体１０を構成する金属製帯体１１は、スプリングバック方向である巻き中心線Ｏと平行な方向に断面の厚さ寸法Ｂが向けられているため、スプリングバック方向の断面二次モーメント（Ｉ）が極小となり、スプリングバック方向の剛性（ＥＩ）が極小となる。そのため、スプリングバック力により、コイル体１０を構成する金属製帯体１１どうしが剥がれるのを抑制しやすくなる。よって、コイル体１０を構成する金属製帯体１１の板面１１ａの間に磁性粉末が入り込むのを抑制でき、金属製帯体１１どうしの絶縁を保つことが可能になる。   However, since the metal strip 11 constituting the coil body 10 has the cross-sectional thickness dimension B oriented in a direction parallel to the winding center line O in the spring back direction, the secondary moment of inertia in the spring back direction. (I) is minimized, and rigidity (EI) in the springback direction is minimized. Therefore, it becomes easy to suppress peeling of the metal strips 11 constituting the coil body 10 due to the springback force. Therefore, it is possible to suppress the magnetic powder from entering between the plate surfaces 11a of the metal strip 11 constituting the coil body 10, and it is possible to maintain the insulation between the metal strips 11.

コイル体１０ならびに端子部１５，１８は、断面が長方形の金属製帯体１１で形成されているため、幅寸法Ａを大きくすることで、断面積を十分に大きく確保することが可能である。そのため、コイル体１０の抵抗値を小さくでき、コイル体１０に必要とされる電流量を十分に与えることが可能である。しかも、金属製帯体１１は、長方形の断面の厚さ寸法Ｂの方向が、スプリングバック力が作用する加圧方向ならびに巻き中心線Ｏと平行な方向に向けられているため、端子部１５，１８のスプリングバック力による磁性コア２０の損傷や、コイル体１０を構成している金属製帯体１１のスプリングバック力による層間の剥がれを抑制しやすくなっている。   Since the coil body 10 and the terminal portions 15 and 18 are formed of the metal strip 11 having a rectangular cross section, it is possible to secure a sufficiently large cross sectional area by increasing the width dimension A. Therefore, the resistance value of the coil body 10 can be reduced, and the amount of current required for the coil body 10 can be given sufficiently. Moreover, since the metal strip 11 has the rectangular cross section having the thickness dimension B oriented in the direction in which the spring back force acts and the direction parallel to the winding centerline O, the terminal portion 15, It is easy to suppress damage to the magnetic core 20 due to the 18 springback force and peeling between layers due to the springback force of the metal strip 11 constituting the coil body 10.

図５に示すように、アニール処理の後に、磁性コア２０の外面の全域に保護樹脂層４１がコーティングされる。第１の端子部１５と第２の端子部１８が存在している部分で、前記保護樹脂層４１と、さらに、第１の端子部１５および第２の端子部１８の表面に形成されている被覆層１２が除去されて露出部４１ａが形成される。そして、保護樹脂層４１の表面に金などによる低抵抗金属層がめっき処理により形成され、端子導通部４２が形成される。端子導通部４２は一対形成され、第１の端子部１５と第２の端子部１８に個別に導通したものとなる。   As shown in FIG. 5, a protective resin layer 41 is coated on the entire outer surface of the magnetic core 20 after the annealing treatment. In the portion where the first terminal portion 15 and the second terminal portion 18 exist, the protective resin layer 41 is formed on the surfaces of the first terminal portion 15 and the second terminal portion 18. The covering layer 12 is removed to form an exposed portion 41a. Then, a low resistance metal layer made of gold or the like is formed on the surface of the protective resin layer 41 by plating, and the terminal conductive portion 42 is formed. A pair of terminal conducting portions 42 are formed and are individually conducted to the first terminal portion 15 and the second terminal portion 18.

１ インダクタンス素子
１０ コイル体
１１ 金属製帯体
１１ａ 板面
１１ｂ 側端面
１３ 第１の端部
１５ 第１の端子部
１６ 第２の端部
１８ 第２の端子部
２０ 磁性コア
３０ プレス機
３２ 下型
３３ 上型
３４ キャビティ
Ｄ 対面領域
Ｆ１，Ｆ２ 加圧力
Ｏ 巻き中心線 DESCRIPTION OF SYMBOLS 1 Inductance element 10 Coil body 11 Metal strip 11a Plate surface 11b Side end surface 13 1st end part 15 1st terminal part 16 2nd end part 18 2nd terminal part 20 Magnetic core 30 Press machine 32 Lower mold | type 33 Upper die 34 Cavity D Facing area F1, F2 Pressure O Winding center line

Claims (3)

磁性粉末とバインダー樹脂を有するコア材料を加圧して成形した圧粉成形体の磁性コアの内部にコイル体を埋め込むインダクタンス素子の製造方法において、
幅方向の寸法が厚さ方向の寸法よりも大きく断面が長方形で長尺状の導電性帯体を使用し、
前記導電性帯体で、厚さ方向を巻き中心線と平行に向けて巻き中心線方向へ重ねられるように巻かれた前記コイル体と、前記コイル体から前記巻き中心線と直交する方向に延び出る一対の端部とを形成し、それぞれの前記端部を厚さ方向に曲げて前記巻き中心線と平行な向きとし、さらにその先部を厚さ方向に曲げて、前記コイル体を形成する導電性帯体と平行に対向する一対の端子部を形成し、
前記コイル体を形成する導電性帯体の厚さ方向と、前記端子部を構成する導電性帯体の厚さ方向を、共に加圧方向に向けて、前記コア材料とそれぞれの前記端子部とを前記巻き中心線と平行な方向へ加圧して前記コア材料で前記磁性コアを形成し、前記端子部の板面が前記磁性コアの表面とほぼ同一面となるように前記コイル体を前記磁性コアに埋め込むことを特徴とするインダクタンス素子の製造方法。 In the method of manufacturing an inductance element in which a coil body is embedded in the magnetic core of a compacted body formed by pressing a core material having magnetic powder and a binder resin,
Use a conductive strip that is longer in the width direction than the thickness in the thickness direction and rectangular in cross section,
The coil body wound in such a manner that the thickness direction is parallel to the winding center line, and the coil body is overlapped in the winding center line direction, and extends from the coil body in a direction perpendicular to the winding center line. Forming a pair of protruding end portions, bending each of the end portions in the thickness direction to be parallel to the winding center line, and further bending the tip portion in the thickness direction to form the coil body. Forming a pair of terminal portions facing in parallel with the conductive band;
The core material and each of the terminal portions are arranged such that the thickness direction of the conductive band forming the coil body and the thickness direction of the conductive band forming the terminal portion are both directed in the pressing direction. Is pressed in a direction parallel to the winding center line to form the magnetic core with the core material, and the coil body is made to be magnetic so that the plate surface of the terminal portion is substantially flush with the surface of the magnetic core. A method for manufacturing an inductance element, wherein the inductance element is embedded in a core. 前記磁性コアを形成した後に、アニール処理を行う請求項２記載のインダクタンス素子の製造方法。 The method of manufacturing an inductance element according to claim 2 , wherein after the magnetic core is formed, an annealing process is performed. それぞれの前記端子部を、前記コイル体を形成する前記導電性帯体の板面から離れた位置に形成し、前記端子部の板面を金型の表面に当接させた状態で加圧を行って、前記端子部と前記コイル体を形成する前記導電性帯体の板面との間に前記磁性コアを介在させる請求項１または２記載のインダクタンス素子の製造方法。 Each of the terminal portions is formed at a position away from the plate surface of the conductive band forming the coil body, and pressure is applied in a state where the plate surface of the terminal portion is in contact with the surface of the mold. The method of manufacturing an inductance element according to claim 1 or 2 , wherein the magnetic core is interposed between the terminal portion and a plate surface of the conductive band forming the coil body.
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