KR101111999B1

KR101111999B1 - Power inductor and method for manufacturing the same

Info

Publication number: KR101111999B1
Application number: KR1020100074593A
Authority: KR
Inventors: 김송자; 서영진; 유영각
Original assignee: (주) 세노텍
Priority date: 2010-08-02
Filing date: 2010-08-02
Publication date: 2012-02-24

Abstract

PURPOSE: A power inductor and a manufacturing method thereof are provided to prevent a coil from being separated from an electrode by winding the coil around a winding guide unit which is formed in an area facing the electrode. CONSTITUTION: An electrode(100) is connected to an external terminal and provides an electric signal. A winding guide unit(110) is formed in the end facing electrodes. A coil is wound around the winding guide unit of the electrode and the end of the coil is connected to the electrode. An inductor body surrounds a part of the electrode and the coil. The electrodes include an anode and a cathode.

Description

Power inductor and its manufacturing method {POWER INDUCTOR AND METHOD FOR MANUFACTURING THE SAME}

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a power inductor and a method of manufacturing the same. A surface-mount power inductor and a method of manufacturing the same, which can simplify the manufacture of the inductor by changing the internal terminal structure and reduce the loss with a high inductance value and a low resistance value. To provide.

Recently, due to the miniaturization of electronic devices, components mounted on printed circuit boards are also made light and small. In addition, due to the development of communication, the use frequency is gradually extended to the high frequency region, which tends to deteriorate components and printed circuit boards in electronic devices.

In particular, since the electromagnetic noise in the high frequency region causes communication disturbances or obstacles, a small power inductor is required to improve communication sensitivity of a wireless communication device. The power inductor is a passive device used as a filter to prevent sudden changes in current and filter out electrical noise in electronic products, oscillation circuits, and current storage devices of power circuits.

In other words, the power inductor is a product that functions to stabilize the current, act as a current driver and prevent surge current suppression in the communication circuit, and the characteristics of the resistance and the allowable current versus the inductance value, which are electrical characteristics, are very important. Especially in the case of electrical characteristics, the current value should be large and the resistance value should be made small.

Since the power inductor is mounted on the surface of the printed circuit board as described above, it is effective to manufacture a surface mount type (SMD).

The prior art of such a power inductor is a magnetically reinforced inductor of Publication No. 10-2009-0101751. This allows the coil to be vertically connected by vertically connecting the core having the convex and concave portions, the coil wound on the core, and the upper and lower convex portions of the core to keep the inductance value the same and to reduce the inductor or increase the inductance value in the same size inductor. It has a closed gyro to be disposed. In this way, the inductor can be miniaturized by reinforcing the magnetic path.

In addition, Korean Patent No. 10-0655418 discloses an integrated winding winding inductor. The present invention relates to a winding integrated inductor having high surface resistance and improved mechanical strength, and includes a coil, an electrode connected to an end of the coil, and a magnetic body in which the coil and the electrode are integrated. In this case, the mixed magnetic material, the insulation filler and the lubricant are used as the magnetic body, and the mold is molded through the mold. Forming a coupling hole in the magnetic body can increase the coupling force between the magnetic body and the electrode.

However, this combines the ends of the pre-wound coils with the electrodes by welding or soldering. Therefore, the coil winding step and the coil and electrode coupling step must be performed separately. At this time, due to the small size of the inductor, the diameter of the coil is also very small. Therefore, the process of disposing the small end of the coil in the space between the electrodes and joining it in the form of welding or soldering is very difficult process. In addition, in order to integrate the welded or soldered electrode and the coil into the magnetic body, a magnetic body molding process should be performed. However, since only a part of the electrode and the coil are joined by welding or soldering, they may be separated during movement or the coil may be shaken inside the electrode so that the molding of the magnetic body may not be performed smoothly. This caused a problem that the defective rate of the final product is increased.

Accordingly, the present invention has been made to solve the above problems, and by winding the coil to the winding guide by changing the shape of the electrode to install the winding guide to improve the coupling force between the coil and the electrode, for the magnetic body forming process Provided are a power inductor and a method of manufacturing the same, which can prevent a coil from shaking or a phenomenon in which a coil and an electrode are separated during a transfer and molding process.

Electrodes connected to an external terminal according to the present invention for receiving an electrical signal; A winding guide portion formed at an end portion region of the electrodes; A coil wound around the winding guide portion of the electrode and having an end connected to the electrode; And an inductor body surrounding a portion of the electrode and the coil such that the coil wound therein is located.

A portion of the electrode is bent and fixed to at least a side and an upper surface of the inductor body.

The electrodes may include a positive electrode and a negative electrode, and these electrodes may be manufactured in a bar shape, and the positive electrode and the negative electrode may be disposed on the same line or disposed on left and right sides based on one line.

A curved portion is formed on an opposite surface or a vertex region of the electrode, and the winding guide portion is formed in the curved portion region.

Coupling grooves for improving the coupling force between the electrode and the inductor body is formed on the electrode, characterized in that the embossed portion is formed on the electrode surface.

The winding guide portion is characterized in that it is formed in a circular shape by the shape of the curved portion.

The electrode and the winding guide portion is characterized in that it is manufactured integrally.

A magnetic material is used as the inductor body and is manufactured by mold molding, and when the height of the side surface of the inductor body is 100, it is effective that the side height of the inductor body without the electrode is 4 to 6%. It is characterized by.

In addition, the step of providing an electrode pattern plate formed with an electrode pattern having a winding guide portion protruding upwards according to the present invention; Winding a coil on the winding guide part, and electrically connecting the coil to the electrode; Forming an inductor body surrounding the coil region; And cutting the electrode pattern plate, bending the electrode protruding outside the inductor body, and fixing the electrode pattern plate to the outer surface of the inductor body.

The electrode pattern plate is manufactured by a press process, and the inductor body is characterized in that the manufacturing by mold molding.

As described above, in the present invention, a winding guide part is installed in an area adjacent to an electrode, and a coil is wound around the winding guide part to improve a coupling force between the coil and the electrode, and the coil is transported during the forming process for manufacturing the inductor body. And during shaping it can prevent the shaking of the coil or the phenomenon of separation between the coil and the electrode.

1 to 4 are views for explaining a power inductor and a method of manufacturing the same according to a first embodiment of the present invention.
5 to 8 are views for explaining a power inductor and a method of manufacturing the same according to a second embodiment of the present invention.
9 and 10 are diagrams for explaining a modification of the internal electrode of the power inductor according to the first embodiment of the present invention.

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. It will be apparent to those skilled in the art that the present invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, It is provided to let you know. Like numbers refer to like elements in the figures.

1 to 4 are diagrams for describing a power inductor and a method of manufacturing the same according to a first embodiment of the present invention. (A) is a top view, (b) is a rear view, (c) is a side view, (d) is a front view of an inverted state. (A) is a top view of an electrode pattern plate, (b) is a side view.

1 to 4, the power inductor according to the present exemplary embodiment includes an electrode 100 connected to an external terminal to receive an electrical signal, and a winding guide 110 formed at opposite end regions of the electrode. The coil 100 is wound around the winding guide part 110 of the electrode 100 a predetermined number of times, and the coil 200 having an end portion connected to the electrode 100 and the coil 200 wound therein are positioned. ) And the inductor body 300 surrounding the coil 200.

A portion of the electrode 100 is exposed to the outside of the inductor body 300, and a portion of the exposed electrode 100 is bent in close contact with the inductor body 300.

The electrode 100 includes a positive electrode 101 and a negative electrode 102 as shown in FIGS. 1 and 2.

The positive electrode 101 and the negative electrode 102 are manufactured in the form of a bar as shown in FIG. At this time, the positive electrode 101 and the negative electrode 102 are located on the same straight line. In addition, it is effective that the opposite surface of the two electrodes 100 (that is, the tip of the electrode 100) is manufactured in a half arc shape. As a result, a circular space is formed by the positive electrode 101 and the negative electrode 102 as shown in the drawing, and the diameter of the circle is effectively 2 to 4φ.

In addition, the winding guide part 110 protruding in the upper side direction is formed in the half arc area of the two electrodes 100 as shown in FIG. That is, the first winding guide part 111 is formed on the positive electrode 101, and the second winding guide part 112 is formed on the negative electrode 102. At this time, in the present embodiment, it is preferable that the winding guide 110 is formed in a half arc shape along the shape of the electrode 100. Of course, the present invention is not limited thereto, and the winding guide unit 110 may be manufactured in the form of a protrusion. In addition, the winding guide unit 110 of the present embodiment is to induce the winding of the coil 200 can be a variety of shapes that can be carried out the winding of the coil 200.

To this end, the winding guide 110 may be manufactured in a plurality of protrusions. The winding guide part 110 is manufactured in a thin plate shape, and a part of the plate is connected to one end of the electrode 100. Although not shown, a departure prevention part may be provided in an upper region of the winding guide part 110 to prevent the coil 200 from escaping when the coil 200 is wound. As a result, the upper region of the winding guide unit 110 extends toward the outer side of the electrode 100. That is, the winding guide 110 may be manufactured in the form of '' '. At this time, the height of the winding guide portion 110 protruding from the electrode 100 is effective to be 0.5 to 0.9mm. Preferably it is effective that it is 0.60 to 0.75 mm. At this time, the lower than the height has a disadvantage that the winding of the coil 200 is difficult. In addition, if the height is higher than the height of the inductor body 300 has to be increased because there is a disadvantage that can not reduce the size of the product.

The first and second winding guides 111 and 112 described above are manufactured in a substantially circular shape, and the diameter (ie, the outer diameter) of the circle is effectively 2? To 6 ?. At this time, the winding guide 110 is manufactured to a predetermined thickness. Therefore, the winding guide 110 arranged in a circular shape has an inner diameter and an outer diameter. Accordingly, the inner diameter is preferably 0.1 φ to 1 φ.

Through this, the coil 200 wound on the winding guide unit 110 may be manufactured in a circular shape. Of course, for this purpose, the winding guide 110 may be formed at an inner side (ie, the center of the electrode) instead of the end of the electrode 100.

Of course, in the present embodiment, since the coil is wound in a circular shape by the first and second winding guides 111 and 112 formed on the electrode 100, the end portion of the electrode 100, that is, the curved portion has no shape. You may not. That is, ends of each of the first and second electrodes 101 and 102 may have a planar shape. Of course, various shapes in which the first and second electrodes 101 and 102 are spaced apart from each other are possible.

Here, it is effective that the electrode 100 and the winding guide unit 110 are integrally manufactured. Of course, the present invention is not limited thereto, and the winding guide unit 110 may be attached to the electrode 100 after the electrode 100 and the winding guide unit 110 are separately manufactured. In this case, the winding guide 110 may be made of the same material as the electrode 100 or made of a different material. In this case, the winding guide 110 may be made of an insulator material or a ferrite-based material. Of course, it may be made of the same material as the inductor body (300).

Of course, the electrode 100 is not limited thereto, and as described above, in order to increase the coupling force with the inductor body 300 described above, curved portions are formed on opposite surfaces of the two electrodes 100; In addition, a separate through groove may be formed to increase the bonding force.

In the present embodiment, the coil 200 is wound around the winding guide part 100. At this time, it is effective that the diameter of the coil 200 is 0.03 to 1mm. In addition, the coil 200 is effectively wound 5 to 20 times.

One end of the coil 200 is connected to one of the two electrodes 100 (101, 102) and the other end is connected to the other electrode. Of course, an end of the coil 200 may be connected to the winding guide part 100.

In this case, the connection between the coil 200 and the electrode 100 may be performed by welding or soldering. In the case of welding, after the coating of the end of the coil 200 is peeled off, it may be bonded by micro welding.

The coil 200 described above is positioned at the center region of the inductor body 300. As a result, the inductor body 300 may prevent the coil 200 from being exposed. In addition, the electrode 100 is exposed on the outer surface of the inductor body 300, and the electrode 100 is bent and adhered to the surface of the inductor body 300, thereby enabling the expression mounting process.

In this case, the inductor body 300 may be manufactured using a magnetic material. Of course, the inductor body 300 may include a magnetic powder, a binder and an epoxy. In addition, it may further include an insulating filler and a lubricant. In addition, it is effective that the inductor body 300 is manufactured by compression molding.

As shown in FIG. 4, the inductor body 300 may be manufactured in a hexahedral form. In addition, one side of the inductor body 300 is provided with an electrode groove 310 to be in close contact with the electrode 100. In this case, the electrode groove 310 is formed on the side and the top surface of the inductor body 310. As a result, the electrode 100 may be disposed on the surface of the inductor body 300.

Hereinafter, a method of manufacturing the power inductor having the above-described configuration will be described.

First, as shown in FIG. 2, an electrode pattern plate 1000 on which an electrode 100 pattern having a winding guide part 110 is formed is prepared. This forms the electrode 100 by pressing a metal plate, and forms the winding guide 110 in the end region of the electrode 100.

In this case, the electrode pattern plate 1000 forms a H-shaped groove, and the electrode 100 is formed in a region other than the groove. The electrode 100 is located on the same line. As described above, the winding guide 110 is positioned in an upper end region of the electrodes 100 (101, 102) in a substantially circular band shape. In this case, the electrode pattern plate 1000 has a connection body 1100 to which the other end of the electrode 100 is connected. In the final step, the connection area between the connection body 1100 and the electrode 100 is cut to separate the electrode 100.

Here, it is effective that the width of one electrode region (that is, H-shaped width) is 5 to 9 mm, and the width between the electrode region and the electrode region is preferably 0.5 to 1.5 mm.

Subsequently, as shown in FIG. 3, the coil 200 is wound around the winding guide unit 110 of the electrode 100. At this time, the winding of the coil 200 solves the problem that the coil 200 is broken by adjusting the rotation speed (RPM) of the winding machine. At this time, by adjusting the rotational speed of the winding machine to 500 to 2000 RPM it can prevent the winding of the winding.

At this time, the coil 200 is electrically connected to the electrode 100.

Subsequently, as shown in FIG. 4, the electrode 100 wound around the coil 200 in the winding guide part 110 flows into the extrusion apparatus for manufacturing the inductor body 300. Thereafter, the inductor body 300 is manufactured such that the coil 200 is positioned at the center thereof through extrusion molding.

In this case, the inductor body 300 is made of a hexagonal body, a portion of the electrode 100 protrudes out of the inductor body 300. In addition, an electrode groove 310 is formed in side and upper surfaces of the inductor body 300 from which the electrode 100 protrudes.

Subsequently, as described above, the connecting body 1100 of the electrode pattern plate 1000 is separated from the electrode 100 to form a molded body for manufacturing an individual product. That is, the cut line region of the electrode pattern plate 1000 is cut to produce a power inductor molded product of a single product.

Subsequently, as shown in FIG. 1, the electrode 100 is bent to be in close contact with the inductor body 300 to fabricate a chip-type power inductor.

The inductor body 300 is manufactured in a square shape, and at this time, the length of one side is effective to 5.0 to 7.0mm. Of course, it can be manufactured smaller or larger than this depending on the diameter and number of turns of the coil 200 therein. In addition, an electrode groove 310 is formed on the surface of the inductor body 300, and the electrode 100 is bent into the groove. As a result, the electrode 100 may be prevented from protruding largely out of the inductor body 300 as shown in the drawing. In this case, it is effective to make the width of the electrode groove 310 larger than the width of the electrode 100. For example, when the width of the electrode 100 is 3mm, it is effective that the width of the electrode groove 310 is 3.2mm. In addition, the electrode groove 310 is preferably formed on the upper side of the inductor body (300).

In addition, in the present embodiment, the electrode 100 may be attached and fixed to the inductor body 300 by a separate adhesive means. In addition, based on the side surface of the inductor body 300 where the electrode 100 is located, the electrode 100 is not located at the entire side surface, but is located only at a partial region of the side surface. In this case, when the height of the side surface of the inductor body 300 is 100, the height at which the electrode is positioned is effectively 94 to 96% based on the upper side (or the lower side) of the inductor body 300. Of course, the height at which the electrode is not located is preferably 4 to 6% based on the lower side (or upper side) of the inductor body 300.

This is because the electrode 100 is positioned at a height of 4 to 6% of the inside of the inductor body 300 based on the lower side of the inductor body 300, that is, the bottom surface, and the coil 200 is wound on the electrode 100. Refers to the presence. That is, for example, when the total thickness of the inductor body 300 is 1.15 mm, the electrode 100 protrudes about 0.25 mm from the bottom surface of the inductor body 300, and the protruding electrode is the inductor body 300. Is bent along the sides.

As a result, a surface mounted power inductor having a part of the first and second electrodes 101 and 102 disposed at both edges of the upper surface thereof is manufactured.

As described above, in the present embodiment, the winding guide unit 110 is positioned on the electrode 100, and the coil 200 is wound around the winding guide unit 110. Since the coil 200 wound from the outside is not obtained through this, the coil 200 may be prevented from being unwound during the moving process, and sagging of the coil 200 may be prevented.

The present invention is not limited to the above description, and the electrode having the winding guide part can be manufactured in various forms. Other embodiments will be described later in this regard. In the following description, the same content as the above description will be omitted.

5 to 8 are views for explaining a power inductor and a method of manufacturing the same according to a second embodiment of the present invention. (A) is a top view, (b) is a rear view, (c) is a side view, (d) is a front view of an inverted state. (A) is a top view of an electrode pattern plate, (b) is a side view.

5 to 8, the power inductor according to the present embodiment includes an electrode 400 having a winding guide part 410, a coil 500 wound around the winding guide part 410, and a coil 500. It includes an inductor body 600 surrounding the.

The electrode 400 includes a positive electrode 401 and a negative electrode 402 as shown. The electrode 400 is manufactured in the form of a bar extending in one direction. The positive electrode 401 and the negative electrode 402 are not arranged on the same straight line, but are arranged on the straight lines parallel to each other. As a result, adjacent vertex regions of the two electrodes 400; 401 and 402 face each other. The vertex regions facing the two electrodes 400 (401, 402) are manufactured in a circular shape, and a curved portion is formed in the vertex region of the electrode 400 for this purpose.

In addition, a winding guide 410 having a protrusion (or a protruding bar shape) protruding upward is positioned in the region of the electrode 400 corresponding to the curved portion.

The coil 500 is formed by winding the winding guide 410. As described above, one end of the coil 500 is connected to the positive electrode 401 and the other end is connected to the negative electrode 402.

In addition, the inductor body 500 is manufactured by molding (injection or powder press) molding so that the coil 500 is located in the central region of the body. In this embodiment, the electrodes 400 are alternately arranged. Therefore, when the positive electrode 401 is formed on the left side of one side of the inductor body 500, the negative electrode 402 is formed on the right side of the other side opposite to the one side. In addition, in the case of the electrode 400 bent in close contact with the upper surface of the inductor body 500, the positions of the positive electrode 401 and the negative electrode 402 may be alternately arranged. As a result, short circuits between the two electrodes 400 (401, 402) can be prevented, and the positions thereof can be changed in various ways when combined on the lower main board. This can increase the mounting utility of the power inductor chip. That is, it is possible to mount inductor chips of various angles. As described above, the electrode groove 510 is positioned in the inductor body 500.

Hereinafter, a method of manufacturing such an inductor will be described.

First, as shown in FIG. 6, a pattern of electrodes 400 is formed on the electrode pattern plate 2000 so as to be alternately arranged with respect to a reference line through a pressing process. At this time, a semi-circular curved portion is formed at the opposite edges (vertical areas) of the electrodes 400. The winding guide part 410 is formed in the curved area.

Subsequently, as shown in FIG. 7, the coil 500 is formed by winding an electric wire (or wire) on the outer surface of the winding guide part 410 formed on the first and second electrodes 401 and 402, respectively. To this end, one terminal of the coil 500 is connected to the first electrode 401. This can be done by welding or soldering. Next, winding is performed along the outer circumferential surface of the winding guide unit 410. In this case, the number of windings may vary. Subsequently, the coil 500 is cut and the other cut terminal is connected to the second electrode 402.

Subsequently, as shown in FIG. 8, the inductor body 600 surrounding the coil 500 is manufactured through mold molding. Then, the electrode pattern plate 2000 is cut along the cutting line of FIG. 8 to form a molded body.

Subsequently, as shown in FIG. 5, the electrode 400 protruding outward of the inductor body 600 is bent to closely adhere to the outer surface of the inductor body 600. As a result, an electrode 400 disposed in a diagonal direction on the surface of the inductor body 600 is formed.

As such, it may be variously changed according to the position of the terminal on the board using the electrode pattern of the present invention.

9 and 10 are views for explaining a modification of the internal electrode of the power inductor according to the first embodiment of the present invention.

As shown in FIG. 9, coupling holes 103 are formed in the positive electrode 101 and the negative electrode 102 of the electrode 100 to improve the coupling force between the inductor body 600 and the electrodes, respectively. The coupling hole 103 of the electrode 100 is connected to the inductor body 600 formed above and below the electrode 100 through the coupling groove 103 when the inductor body 600 is formed.

Of course, although one coupling groove 103 is formed in one electrode 100 in FIG. 9, the present invention is not limited thereto, and a larger number of coupling grooves 103 may be formed. In addition, the diameters of the coupling grooves 103 formed at this time may be the same or different from each other.

Through the coupling hole 103, the coupling force between the electrode 100 and the inductor body 600 may be improved.

As shown in FIG. 10, an embossed portion having a concave portion and a convex portion may be formed on a surface of the electrode 100. As such, by forming the embossed portion on the electrode 100, the coupling force between the electrode 100 and the inductor body 600 is improved. That is, the inductor body 600 may be manufactured in a form corresponding to the concave portion and the convex portion of the embossing portion so that the electrode 100 may not easily escape to the outside of the inductor body 600 by a force from the outside.

Of course, various other techniques may be applied, and electrodes 100 having various structures may be manufactured. For example, a part of the electrode 100 may be cut out, and a part of the cut out area may protrude above the surface or protrude below the surface. Through this, the coupling force between the inductor body 600 and the electrode 100 may be improved by the protrusion protruding upward and downward.

100, 400: electrode
110, 410: winding guide portion
200, 500: coil
300, 600: inductor body
1000, 2000: electrode pattern plate

Claims

Electrodes connected to an external terminal to receive an electrical signal;
A winding guide portion formed at an end portion region of the electrodes;
A coil wound around the winding guide portion of the electrode and having an end connected to the electrode; And
A part of the electrode and an inductor body surrounding the coil so that the coil wound therein is located,
The electrodes include a positive electrode and a negative electrode, these electrodes are manufactured in the form of a bar, the positive electrode and the negative electrode is located on the same line, or arranged on the left and right sides on one line,
A half arc-shaped curved portion is formed on an opposite surface or a vertex region of the electrode, and the winding guide portion is formed in the curved portion region.
The winding guide part is a power inductor, characterized in that formed in a circular shape by the shape of the curved portion.

The method of claim 1,
And a portion of the electrode is bent and fixed to at least a side and an upper surface of the inductor body.

delete

The method of claim 1,
And the electrode and the winding guide unit are integrally manufactured.

The method of claim 1,
And a coupling groove formed in the electrode to improve the coupling force between the electrode and the inductor body, or an embossing portion formed on the surface of the electrode.

The method of claim 1,
A magnetic material is used as the inductor body and is manufactured by mold molding, and when the height of the side surface of the inductor body is 100, it is effective that the side height of the inductor body without the electrode is 4 to 6%. Power inductor, characterized in that.

Providing an electrode pattern plate having a half arc-shaped curved portion formed on an opposing surface or a vertex region, the electrode pattern having an electrode pattern having a winding guide portion protruding above the curved portion region;
Winding a coil on the winding guide part, and electrically connecting the coil to the electrode;
Forming an inductor body surrounding the coil region; And
Cutting the electrode pattern plate, bending the electrode protruding out of the inductor body, and fixing the electrode pattern plate to the outer surface of the inductor body.

10. The method of claim 9,
The electrode pattern plate is manufactured by a press process, and the inductor body is manufactured by a die molding method of manufacturing a power inductor.