JP6323588B2 - Surface mount inductor and manufacturing method thereof - Google Patents
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本発明は、表面実装インダクタと、その製造方法とに関する。 The present invention relates to a surface mount inductor and a method for manufacturing the same.
特許文献１に示すように、磁性体粉末と樹脂とを混練した磁性体樹脂で巻線を封止したインダクタが、従来から広く利用されている。磁性体樹脂で巻線を封止したモールドコイルに、エポキシ樹脂などの熱硬化性樹脂とＡｇなどの金属粒子を分散させた導電性ペーストを塗布したり、金属端子を接着したりして、プリント基板等に実装するための電極を形成し、表面実装インダクタとなる。 As shown in Patent Document 1, an inductor in which a winding is sealed with a magnetic resin obtained by kneading magnetic powder and resin has been widely used. Printed by applying a conductive paste in which a thermosetting resin such as epoxy resin and metal particles such as Ag are dispersed to a molded coil whose winding is sealed with a magnetic resin, or by bonding a metal terminal. An electrode for mounting on a substrate or the like is formed to form a surface mount inductor.
導電性ペーストは高価であり、広い面積に塗布するとコストが嵩んでしまう。そのため、比較的大型な表面実装インダクタの場合は、外部端子には金属板が多用されている。そのような表面実装インダクタの製造方法として、例えば、特許文献２や特許文献３に示されるような方法が知られている。 Conductive paste is expensive, and costs increase when applied to a large area. Therefore, in the case of a relatively large surface mount inductor, a metal plate is frequently used for the external terminal. As a method for manufacturing such a surface mount inductor, for example, methods as disclosed in Patent Document 2 and Patent Document 3 are known.
特許文献２には、端末を引き出して磁性体樹脂に巻線を埋設してモールドコイルを成形し、金属板を予め所定の形状に折り曲げた金属端子をモールドコイルに貼り付けて、巻線端末と金属端子とをはんだ付けや溶接等で電気的に接続する表面実装インダクタの製造方法が記載されている。
特許文献３には、巻線端末と金属板とをはんだ付けや溶接等で電気的に接続した後に、巻線とその接続部を含む金属板の一部とを共に磁性体樹脂に埋設してモールドコイルを成形し、モールドコイルから露出している金属板をモールドコイルの外装に沿って折り曲げて金属端子とする表面実装インダクタの製造方法が記載されている。
In Patent Document 2, a terminal is pulled out, a winding is embedded in a magnetic resin, a molded coil is formed, a metal terminal in which a metal plate is bent in a predetermined shape is pasted on the molded coil, A method for manufacturing a surface-mount inductor in which a metal terminal is electrically connected by soldering or welding is described.
In Patent Document 3, after electrically connecting a winding terminal and a metal plate by soldering or welding, the winding and a part of the metal plate including the connection portion are both embedded in a magnetic resin. A method for manufacturing a surface mount inductor is described in which a mold coil is formed and a metal plate exposed from the mold coil is bent along the exterior of the mold coil to form metal terminals.
特許文献２に記載の表面実装インダクタの製造方法では、モールドコイルを作成後に金属端子を配置するため、金属端子の厚み分だけ表面実装インダクタの外形が大きくなるという問題や、金属端子は、接着剤によりモールドコイルに固定されるが、この接着剤の強度がプリント基板等への実装時のはんだ付け時の熱などにより劣化して、金属端子が脱落しやすくなるという問題がある。
また、特許文献３に記載の表面実装インダクタの製造方法では、金属端子と巻線端末との接続部がモールドコイル内に埋設されてしまうため、接続状態を目視で確認できないという問題がある。
In the method for manufacturing a surface mount inductor described in Patent Document 2, since the metal terminal is arranged after the mold coil is formed, the problem that the outer shape of the surface mount inductor increases by the thickness of the metal terminal, However, there is a problem in that the strength of the adhesive deteriorates due to heat at the time of soldering when mounted on a printed circuit board or the like, and the metal terminal is likely to drop off.
Moreover, in the manufacturing method of the surface mount inductor described in Patent Document 3, the connection portion between the metal terminal and the winding terminal is embedded in the molded coil, and thus there is a problem that the connection state cannot be visually confirmed.
本発明の表面実装インダクタは、絶縁被覆された導線を巻回した巻線を、磁性体粉末と熱硬化性樹脂を混練して所定の形状に仮成形した複数の仮成形体で挟み、加温とともに加圧する表面実装インダクタであって、前記表面実装インダクタの外装に、一対の金属端子が、厚み方向を埋設されて配置され、前記巻線の端末は、前記表面実装インダクタの底面から引き出されて、前記金属端子の外面上に、太さ方向を前記金属端子に埋設して配置されていることを特徴とする。 The surface-mount inductor according to the present invention includes a winding wound with an insulation-coated conductive wire, sandwiched between a plurality of temporary molded bodies obtained by kneading magnetic powder and a thermosetting resin into a predetermined shape, and heating A surface mount inductor that pressurizes together with a pair of metal terminals embedded in the exterior of the surface mount inductor, the end of the winding being pulled out from the bottom surface of the surface mount inductor The thickness direction is embedded in the metal terminal on the outer surface of the metal terminal.
また、本発明の表面実装インダクタの製造方法は、磁性体粉末と熱硬化性樹脂を混練して所定の形状に仮成形体を成形する工程と、絶縁被覆された巻線の巻線端末を引き出して前記複数の仮成形体で挟み、前記仮成形体の外面に一対の金属端子を配置し、前記巻線端末を前記金属端子外面上に配置し、加温とともに加圧する工程と、を具えたことを特徴とする。 In addition, the method for manufacturing a surface mount inductor according to the present invention includes a step of kneading magnetic powder and a thermosetting resin to form a temporary molded body into a predetermined shape, and pulling out a winding terminal of the insulation-coated winding. And sandwiching the plurality of temporary molded bodies, placing a pair of metal terminals on the outer surface of the temporary molded body, placing the winding terminal on the outer surface of the metal terminals, and pressurizing with heating. It is characterized by that.
本発明の表面実装インダクタによれば、接着剤を使用せずに表面実装インダクタを製造することができ、しかも、金属端子の一部が樹脂に埋設されているので、金属端子の脱落の虞がない。また、金属端子と巻線端末との接続部が表面実装インダクタの表面に露出しているので、接続状態を容易に目視確認することができる。 According to the surface mount inductor of the present invention, the surface mount inductor can be manufactured without using an adhesive, and a part of the metal terminal is embedded in the resin. Absent. Further, since the connection portion between the metal terminal and the winding terminal is exposed on the surface of the surface mount inductor, the connection state can be easily visually confirmed.
以下、本発明の表面実装インダクタの一実施例を、図面を用いて説明する。
図１は、本発明の表面実装インダクタの構造を説明するための、底面側を上方にした状態を示す分解斜視図であり、図２は金属端子の展開図を示す。
Hereinafter, an embodiment of a surface mount inductor according to the present invention will be described with reference to the drawings.
FIG. 1 is an exploded perspective view showing a state in which the bottom side is directed upward for explaining the structure of the surface mount inductor according to the present invention, and FIG. 2 is a development view of metal terminals.
表面実装インダクタ１０は、磁性体粉末とエポキシ樹脂等の熱硬化性樹脂とを混練した磁性体樹脂を加圧成形（以降、仮成形と称する）した仮成形体２０、３０と、仮成形体２０、３０に挟まれた絶縁被覆された導線を巻線した巻線４０と、巻線４０の両端末４１ａ、４１ｂがそれぞれ接続される薄い板状の金属板をパンチング等により打ち抜いて所定の形状に折り曲げた一対の金属端子５０ａ、５０ｂとからなる。 The surface mount inductor 10 includes temporary molded bodies 20 and 30 obtained by pressure molding (hereinafter referred to as temporary molding) of a magnetic resin obtained by kneading a magnetic powder and a thermosetting resin such as an epoxy resin, and the temporary molded body 20. , 30 is wound into a predetermined shape by punching a thin plate-like metal plate to which the ends 40a and 41b of the winding 40 are respectively connected, and a winding 40 wound with an insulation-coated conductive wire sandwiched between 30 It consists of a pair of bent metal terminals 50a, 50b.
仮成形体２０は、外形が直方体、内側が円筒形のポット形状で、内側底面の中央には凸部２１が設けられて、縦断面がＥ字形状をなし、外壁にはその一部が切り欠かれた開口部２２ａ、２２ｂが設けられている。 The temporary molded body 20 is a pot shape having a rectangular parallelepiped outer shape and a cylindrical shape on the inner side, and a convex portion 21 is provided at the center of the inner bottom surface. The vertical cross section has an E shape, and a part of the outer wall is cut. Notched openings 22a and 22b are provided.
仮成形体３０は、平面視略四角形の板状で、角部３１ａ、３１ｂが面取りされている。
巻線４０は、外形が円筒形となるように巻回され、巻線の両端末が巻線の外形より外側の巻線の中心軸方向に引き出されている。
The temporary molded body 30 is a plate having a substantially rectangular shape in plan view, and corners 31a and 31b are chamfered.
The winding 40 is wound so that the outer shape becomes a cylindrical shape, and both ends of the winding are drawn out in the direction of the central axis of the winding outside the outer shape of the winding.
図２に示すように、金属端子５０ａは、底面５１と、底面５１に対して９０°折り曲げられる側面からなる断面がＬ字形状の金属板であり、側面５２には、底面５１と同じ方向に９０°折り曲げられる舌状の埋設部５３とが設けられている。底面５１の端には、切欠部５４ａが設けられている。金属端子５０ａと金属端子５０ｂとは対称形であり、金属端子５０ｂには金属端子５０ｂと同様に切欠部５４ｂが設けられている。 As shown in FIG. 2, the metal terminal 50 a is a L-shaped metal plate having a bottom surface 51 and a side surface that is bent by 90 ° with respect to the bottom surface 51, and the side surface 52 has the same direction as the bottom surface 51. A tongue-like embedded portion 53 that is bent by 90 ° is provided. A cutout 54 a is provided at the end of the bottom surface 51. The metal terminal 50a and the metal terminal 50b are symmetrical, and the metal terminal 50b is provided with a notch portion 54b, like the metal terminal 50b.
本発明の表面実装インダクタの組み立て方法を、図３（ａ）〜（ｆ）の順に説明する。 A method for assembling the surface mount inductor according to the present invention will be described in the order of FIGS.
（ａ）巻線端末４１ａ、４１ｂが、開口部２２ａ、２２ｂに位置するように、巻線４０を仮成形体２０に収納する。 (A) The winding 40 is accommodated in the temporary molded body 20 so that the winding terminals 41a and 41b are positioned in the openings 22a and 22b.
（ｂ）仮成形体３０の両側面に、それぞれ金属端子５０ａ、５０ｂを、角部３１ａと切欠部５４ａ、角部３１ｂと切欠部５４ｂとが、それぞれ一致するように装着する。 (B) The metal terminals 50a and 50b are mounted on both side surfaces of the temporary molded body 30 so that the corner portion 31a and the cutout portion 54a and the corner portion 31b and the cutout portion 54b coincide with each other.
（ｃ）金属端子の切欠部５４ａ、５４ｂから巻線端末４１ａ、４１ｂがそれぞれ導出するように、仮成形体３０と仮成形体２０を重ねる。 (C) The temporary molded body 30 and the temporary molded body 20 are overlapped so that the winding terminals 41a and 41b are led out from the notches 54a and 54b of the metal terminals, respectively.
（ｄ）（ｅ）仮成形体から露出している巻線端末４１ａ、４１ｂを、仮成形体３０から引き出された根元部４２で折り曲げ、金属端子５０ａ、５０ｂの上面の中央に載置する。以降、図３（ｅ）の状態を、本成形前の表面実装インダクタ１０’’と称する。 (D) (e) The winding terminals 41a and 41b exposed from the temporary molded body are bent at the root portion 42 drawn from the temporary molded body 30, and placed at the center of the upper surface of the metal terminals 50a and 50b. Hereinafter, the state of FIG. 3E is referred to as a surface-mount inductor 10 ″ before the main molding.
（ｆ）本成形前の表面実装インダクタ１０’’を、金型内で、加温とともに加圧する（以降、本成形と称する）と、端子接続前の表面実装インダクタ１０’が得られる。 (F) When the surface-mount inductor 10 ″ before the main molding is pressurized with heating in the mold (hereinafter referred to as the main molding), the surface-mount inductor 10 ′ before the terminal connection is obtained.
このようにして得られた端子接続前の表面実装インダクタ１０’を浸漬はんだすると、巻線端末の絶縁被覆が除去されるととともに巻線端末と金属端子とが電気的に接続されて、表面実装インダクタ１０が得られる。 When the surface-mounted inductor 10 ′ before terminal connection obtained in this way is immersed and soldered, the insulation coating on the winding terminal is removed, and the winding terminal and the metal terminal are electrically connected to each other. The inductor 10 is obtained.
図４（ａ）は、本成形前の表面実装インダクタ１０’’の縦断面図（図３（ｅ）においてＡ−Ａで示す）であり、図４（ｂ）は、本成形後の表面実装インダクタ１０’の同じ位置の縦断面図（図３（ｆ）においてＡ−Ａで示す）である。 4A is a longitudinal sectional view (indicated by AA in FIG. 3E) of the surface-mount inductor 10 ″ before the main molding, and FIG. 4B is a surface mounting after the main molding. It is a longitudinal cross-sectional view (it shows by AA in FIG.3 (f)) of the same position of inductor 10 '.
図４（ａ）に示すように、本成形前の表面実装インダクタ１０’’は、金属端子５０ａ，５０ｂの上にそれぞれ巻線端末４１ａ、４１ｂが載置されており、仮成形体の内部には、巻線４０と仮成形体２０、３０との間の空隙６０、開口部２２ａ、２２ｂの空隙（図示せず）などが存在している。
図４（ｂ）に示すように、本成形後の表面実装インダクタ１０’は、加圧により仮成形体２０と仮成形体３０とが崩れて空隙６０を埋めて一体になるとともに、金属端子５０ａ、５０ｂの埋設部５３は、モールドコイル１１内部に埋設される。また、金属端子５０ａ、５０ｂは、その厚み分がモールドコイル１１に減り込み、巻線端末４１ａ、４１ｂは、その直径分がそれぞれの金属端子５０ａ、５０ｂに減り込む。そして、加温により熱硬化性樹脂が完全に硬化し、その結果、表面に凹凸のない表面実装インダクタ１０が得られる。
As shown in FIG. 4A, the surface-mount inductor 10 ″ before the main molding has winding terminals 41a and 41b mounted on the metal terminals 50a and 50b, respectively, There are a gap 60 between the winding 40 and the temporary molded bodies 20 and 30, a gap (not shown) between the openings 22 a and 22 b, and the like.
As shown in FIG. 4 (b), the surface-mounted inductor 10 ′ after the main molding collapses the temporary molded body 20 and the temporary molded body 30 by pressurization, fills the gap 60, and is integrated with the metal terminal 50a. , 50 b is embedded in the molded coil 11. Further, the thickness of the metal terminals 50a and 50b is reduced to the molded coil 11, and the diameter of the winding terminals 41a and 41b is reduced to the respective metal terminals 50a and 50b. Then, the thermosetting resin is completely cured by heating, and as a result, the surface mount inductor 10 having no unevenness on the surface is obtained.
図５は、根元部４２付近（図３（ｆ）のにおいてＢ−Ｂで示す）の縦断面の拡大図である。
図５に示すように、根元部４２付近では、折り曲げられた巻線端末の上部（図中Ｃで示す）を樹脂が埋めるため、スプリングバックの影響を軽減することができる。
FIG. 5 is an enlarged view of a longitudinal section in the vicinity of the root portion 42 (indicated by BB in FIG. 3F).
As shown in FIG. 5, in the vicinity of the root portion 42, the resin fills the upper part of the bent winding terminal (indicated by C in the figure), so that the influence of the springback can be reduced.
金属端子は、巻線端末が減り込み易いように、ある程度薄い方がよく、また、金属端子の材質は、変形して巻線端末が金属端子に減り込み易いように、燐青銅板よりはタフピッチ銅板、調質硬度は、例えば、１／２Ｈ以下の比較的柔らかくて薄いものを用いるのが好適である。 The metal terminal should be thin to some extent so that the winding end can be easily reduced, and the material of the metal terminal is tougher than the phosphor bronze plate so that the winding end can be easily reduced due to deformation. For the copper plate and the tempered hardness, for example, it is preferable to use a relatively soft and thin material of 1 / 2H or less.
図６は、上記した方法で製造した表面実装インダクタの縦断面写真である。表面実装インダクタは、横６ｍｍ×縦６ｍｍ×高さ３ｍｍ、巻線に用いる導線の直径は０．３２ｍｍ、燐青銅製の金属端子の厚みは０．０８ｍｍであり、本成形の圧力は１０Ｋｇ／ｃｍ２である。 FIG. 6 is a vertical cross-sectional photograph of a surface-mount inductor manufactured by the method described above. The surface mount inductor is 6mm wide x 6mm long x 3mm high, the wire diameter used for the winding is 0.32mm, the thickness of the phosphor bronze metal terminal is 0.08mm, and the pressure of this molding is 10Kg / cm 2 .
図６に示すように、巻線端末が金属端子に減り込み、金属端子はその厚み方向が表面実装インダクタに埋設されていることがわかる。 As shown in FIG. 6, it can be seen that the winding terminal is reduced to the metal terminal, and the thickness direction of the metal terminal is embedded in the surface mount inductor.
上記した表面実装インダクタは、金属端子の一部はモールドコイルに埋設されているため、金属端子の脱落の虞もなく、表面実装インダクタの外装で金属端子と巻線端末の接続部が接続されているため、接続状態を目視で確認可能である。
また、巻線端末は金属端子に減り込み、金属端子はモールドコイルに減り込んでいるので、表面実装インダクタの外形が金属端子により大きくなることがない。
さらに、巻線端末を折り曲げた根元部も樹脂に埋設されているので、巻線端末のスプリングバックによる、巻線端末と金属端子とを電気的に接続する前の巻線端末の位置ずれ、基板実装時のはんだの再溶融時による巻線端末と金属端子との接続外れを抑制することがきる。
In the surface mount inductor described above, a part of the metal terminal is embedded in the molded coil, so there is no risk of the metal terminal falling off, and the connection part between the metal terminal and the winding terminal is connected by the exterior of the surface mount inductor. Therefore, the connection state can be visually confirmed.
Further, since the winding terminal is reduced to the metal terminal and the metal terminal is reduced to the molded coil, the outer shape of the surface mount inductor is not increased by the metal terminal.
Furthermore, since the root part where the winding terminal is bent is also embedded in the resin, the position of the winding terminal before the electrical connection between the winding terminal and the metal terminal due to the spring back of the winding terminal, the substrate It is possible to suppress disconnection between the winding terminal and the metal terminal due to remelting of the solder during mounting.
なお、本成形により、磁性体樹脂の中の樹脂が金属端子の底面の外面まで滲み出て、底面の一部を被覆してしまい、実装不良の原因となることがある。そのような場合は、バレル研磨等で、滲み出た樹脂を除去しても行ってもよい。
また、舌部の形状は種々選択可能である。たとえば、先端部が幅広な形状にしたり、また、孔を設けたりすることにより、さらに金属端子が脱落し難い表面実装インダクタとすることができる。
In addition, by this shaping | molding, resin in magnetic body material oozes out to the outer surface of the bottom face of a metal terminal, may coat a part of bottom face, and may cause mounting defect. In such a case, the exuded resin may be removed by barrel polishing or the like.
The shape of the tongue can be selected variously. For example, by making the tip portion wide or providing a hole, it is possible to provide a surface-mount inductor in which the metal terminal is more difficult to drop off.
１０、１０’、１０’’ 表面実装インダクタ
１１ モールドコイル
２０、３０ 仮成形体
２１ 引出部
２２ａ、２２ｂ 開口部
３１ａ、３１ｂ 面取部
４０ 巻線
４１ａ、４１ｂ 巻線端末
４２ 根元部
５０ａ、５０ｂ 金属端子
５１ 底面
５２ 側面
５３ 埋設部
５４ 切欠部
10, 10 ′, 10 ″ surface-mount inductor 11 Mold coil 20, 30 Temporary molded body 21 Lead portions 22a, 22b Openings 31a, 31b Chamfered portion 40 Winding 41a, 41b Winding terminal 42 Root portion 50a, 50b Metal Terminal 51 Bottom surface 52 Side surface 53 Buried part 54 Notch
Claims (1)
一対の金属端子のそれぞれが、巻線の端末を引き出すための切欠部を有する底面部と、該底面部から折り曲げられた側面部と、該側面部から折り曲げられ、該表面実装インダクタの内部に埋設された埋設部とを備え、該底面部が該表面実装インダクタの外装の底面に厚み方向を埋設されて配置され、
該巻線の端末は、該表面実装インダクタの外装の底面に位置する該金属端子の切欠部から該表面実装インダクタの外装の底面側に引き出され、該金属端子の該底面部の外面上に配置され、該金属端子の切欠部から引き出された根元部分が該表面実装インダクタの外装の底面に埋設され、該金属端子の外面上に配置された部分の太さ方向が該金属端子と共に該表面実装インダクタの外装の底面に埋設されたことを特徴とする表面実装インダクタ。 A surface-mount inductor in which a winding wound with a conductive wire covered with insulation is sandwiched between a plurality of temporary molded bodies kneaded with magnetic powder and a thermosetting resin and temporarily molded into a predetermined shape, and pressurized with heating. Because
Each of the pair of metal terminals has a bottom surface portion having a cutout portion for pulling out a terminal of the winding, a side surface portion bent from the bottom surface portion, a bent portion from the side surface portion, and embedded in the surface mount inductor. An embedded portion, and the bottom surface portion is disposed with the thickness direction embedded in the bottom surface of the exterior of the surface mount inductor,
The end of the winding is drawn from the notch portion of the metal terminal located on the bottom surface of the outer surface of the surface mount inductor to the bottom surface side of the outer surface of the surface mount inductor, and disposed on the outer surface of the bottom surface portion of the metal terminal The root portion drawn out from the notch of the metal terminal is embedded in the bottom surface of the outer surface of the surface mount inductor, and the thickness direction of the portion disposed on the outer surface of the metal terminal is the surface mount together with the metal terminal. A surface mount inductor characterized in that it is embedded in the bottom surface of the exterior of the inductor.
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