200428425 玖、發明說明: 【發明所屬之技術領域】 5 本發明是有關於一種電感 指一種在一線圈外部包覆一包 造方法。 7G件及其製造方法，特別是 覆體所組成之電感元件及製 【先前技術】 10 15 20 -般電感元件的構造設計’會隨所需求之特性盘規格 如頻率、t流、體積、電感值…等的差異而有所不同，二 圖U 2所示之習知電感㈣構造’是包含有由導磁材料如 鐵合金所製成之一包套體10,及一被包套在該包套 之線圈13。 該包套體10包括有可一下一上對應蓋合之_底座^ 與-頂板」2。該底座n具有—由其—頂面往下凹陷之容槽 =1’及-直立地設立在該容槽lu中央處之軸柱ιι〇。該 容槽111具有二側開口端112。該頂蓋12概略成平板狀， 具有二由其一頂面兩相反侧往下凹陷之間隔凹槽U卜該頂 盖12對應蓋合在該底座η上之製造方式，是採用在頂蓋 12與底座u接合處以•膠塗_結，而將該二構件黏ς 成一體。 該線圈η具有-由-長條扁平狀導線等半徑地沿一中 心軸線彎繞預定圈數而成之繞圈部131，及二分別由該繞圈 部m兩端往外延伸之延伸部132。組裝時該繞圈部ΐ3ΐ是 在頂蓋12黏合於底座η卩前，切應容置在該底座u之 容槽111内，並軸裝套合在底座u之軸極11()外部，而該 4 一延伸部132是一高一低地分別對應穿出該容槽lu之該 等側開口端112,接著便可藉由前述頂蓋12黏合在該底= 11頂面，而將線圈13固定限位在頂蓋12與底座u間。又 ，如圖2所示，該二延伸部132之外端，可視需要往上並 相向彎折地貼覆在頂蓋12之該二凹槽121内。 上述習知電感元件之製造過程中，除了該包套體之 底座11與頂蓋12所進行的點膠黏合加工，會造成其作業較 為麻煩不利於大量生產並增加成本以外，其線圈13套裝在 底座11之容槽111内的設置構造，由於線圈13以套合方式 奋置在底座11與頂蓋12間，難免會存在空隙，而兩側開口 端112更是一無法避免的導磁缺隙，因此除了通電運作時容 易產生振動與噪音外，並會造成較大的磁損，且電感的品 質因素（Quality Factor，簡稱Q值)會下降。 【發明内容】 因此，本發明之目的，即在提供一種包覆體與線圈間 完全不會存在空隙且方便於大量生產之電感元件及其製造 方法。 於是，本發明電感元件之製造方法所製造出的電‘感元 件，是具有一線圈及一包覆在該線圈外部之包覆體，該線 圈具有一由一長條導線彎繞預定圈數而成之繞圈部，及二 分別由该繞圈部兩端往外延伸之延伸部，該製造方法包含 .(A)將該線圈放置在一由導磁材料製成之底座上。將一 由‘磁材料製成之蓋板固定覆蓋在該線圈的繞圈部頂面。 (C)將该底座連同線圈與蓋板放置在由一上模與一下模對應 200428425 蓋合所界定出之一容裝空間，使線圈之二延伸部受夹持定 位。及（D)以流態包覆流體，射入並充滿該容裝空間内，以 凝結形成填充密滲於該底座上、蓋板外部與繞圈部中且包 覆於底座上和蓋板、繞圈部外部之一固態結覆層，而由該 結覆層、蓋板與底座共同組結成該包覆體。 【實施方式】 有關本發明之前述及其他技術内容、特點與功效，在 以下配合參考圖式之一較佳實施例的詳細說明中，將可清 楚的明白。 10 參閱圖3、4，本發明第一實施例之製造方法所製造出 的電感兀件2具有一線圈21，及一包覆在該線圈21外部之 包覆體22。該線圈21具有一由一長條扁平狀導線等半徑地 沿一中心軸線彎繞預定圈數而成之繞圈部211，及二分別由 该繞圈部211兩端往外延伸之延伸部212。該包覆體是 15 從上而下由、⑺覆層23、一蓋板25與一底座24無間隙地 結合一體所構成，該結覆層23並密填滲滿於線圈Μ中， 而將該線圈21之繞線部211固定包覆於包覆體22内部。該 結覆層23具有二由其頂面兩相反側往下凹陷之間隔凹槽 231。 9 20 如圖5所示本發明第一實施例藉以達成上述電感元件 製造=法之製造模具包含有—下模3,及—用來對應壓合在 該下模3頂面之上模*。 具有一橫向延伸之下基 31之一頂面往上同體延 該下模3呈水平長片狀板體， 壁31，及多數相鄰接地由該下基壁 6 200428425 伸的長方框形下圍壁32,藉以界定出多數開口朝上之下模 穴33，為使圖式較為清楚明瞭，本實施例中僅以該下模3 具有兩個下模穴33為例作說明，但設計上並不以此為限'。 每一下模穴33上皆可供放置該預先由導磁材料如鐵合 金粉末壓鑄所製成之底座24。該底座24具有一由其一頂面 往下凹陷之容槽241、一直立地設立在該容槽241中央處之 轴柱24·2，及二由其兩相反侧中央處往内凹陷之缺口 。 該容槽241具有二側開口端243。前述線圈21之繞圈部 211是容置在該底座24之容槽241内，並套合在該軸柱 242外部，設計上繞圈部21丨與軸柱242頂面約等高，而線 圈21之該二延伸部212是分別對應穿出該容槽24ι之該等 側開口端242。 配合參閱圖6在線圈21放置定位後，是接著將一由導 磁材料如鐵合金粉末壓鑄所製成之蓋板25由上往下水平置 入底座之容槽241内，並對應覆蓋在該線圈21之繞圈部21 與底座24之軸柱242頂面，該蓋板25形狀是對應於容槽 241中間部位之面積，而呈中間寬、兩端窄之片狀造型，也 就是說蓋板25蓋合後並未完全封閉於容槽241頂面，而是 在兩側開口端243處預留適當間隙。該蓋板25的形狀並不 以本貫施例所揭為限，在實施上只要能遮覆於繞圈部211 頂面即可，例如採用圓片狀。本實施例中，該轴柱242較 底座24的兩側壁244略低，而使組合該蓋板25時其兩弧 形侧緣251恰與該兩側壁244嵌合，而使蓋板25與底座24 構成封閉環路（cl0se 1〇〇p)。 7 200428425 母下圍壁32上皆可供前述線圈21之延伸部212跨 置其上’且每一下圍壁32具有平行之前、後壁段321、322 及二連接於耵、後壁段321、322兩末端間之側壁段323, 别述之下模穴33便是由該下圍壁32與下基壁31所共同界 定出，該前、後壁段321、322皆具有一前後延伸地由其一 頂面往下凹陷之下定位槽324、325，該二下定位槽324、 325具有與前述線圈21之延伸部212配合的長方橫截面， 使線圈21之二延伸部212可分別水平跨置在該二下定位槽 324、325上，該二側壁段323與前壁段321等高，且設計 上該後壁段322之高度較該前壁段321為往上突伸，使該 一下定位槽324、325為一低一高，此一設計是為了因應線 圈21在跨置a寸其一延伸部212是呈一高一低水平延伸狀態 〇 該上模4呈可與前述下模3對應蓋合之長片狀板體， 具有一 k向延伸之上基壁41、多數相鄰接地由該下基壁41 之一底面往下同體延伸的長方框形上圍壁42，及多數成對 地分別位於該等上圍壁42之兩相反内側面的突出部40。該 上基壁41具有一貫穿其頂、底面用來射入所述包覆體22 之結覆層23的射入孔411。每一上圍壁42具有平行之前、 後壁4又421、422 ’及二連接於前、後壁段421、422兩末端 間之側壁段423，並由該上圍壁42與上基壁41共同界定出 一開口朝下之上模穴43，且上圍壁42之形狀是與前述下模 3之下圍壁31形成可對應蓋合之互補形狀，亦即該上圍壁 42之該等側壁段423與前壁段421突出程度相同，僅該後 8 ^00428425 壁& 422之突出程度較小。每對突出部4()是分別突出在所 對應上圍^ 42之前、後側壁421、422相向面與該上基壁 41交接處附近’使每_突出部4()側視造型是呈[型截面。 5 10 一當前述下模3.之該等下圍壁32上皆放置有底座24、線 圈21與蓋板25時，可接著將上模4對應蓋合在下模3頂 面’此時藉上模4之該等上圍壁42，分別密抵壓合在下模 3之該等下圍壁32上，將每一線圈21之二延伸部犯分別 夾持定位於所對應上、下圍壁42、32之前壁段421、321 間與後壁段422、322間，此時並由上、下模4在每一上、 下圍壁42、32間，共同界定出一由上、下模穴43、33連 通而成之容裝空間5，該底座24、線圈21與蓋板乃便是 由下而上容置在該容裝空間5的一下端部内。 15 20 如圖7所不，在各底座24、線圈21與蓋板25容置定 位於上、下杈4、3間以後，接著以塑膠射出成型或金屬射 出成i的方式，將適當之材料，例如：在塑膠射出成型時 可使用塑膠包覆用流體為材料，在金屬射出成型時使用含 有鐵合金粉末所製成之流態膠質包覆用流體為材料，而將 射出流體由上模4之射入孔411射入，並經蓋板25兩側所 預留之間隙往下滲流而充滿該容裝空間5上端部内，以凝 結形成包覆於底座24上方及線圈21、蓋板25外部之固態 結覆層23。此處包覆流體由該等射入孔411射入上、下模4 、3間之容裝空間5上端部内，且密填滲滿於底座24之該 二缺口 240及繞圈部211的縫隙中，使各底座24、線圈21 之繞圈部211與蓋板25被事後凝結成固態之結覆層23所充 9 ^00428425 5 遵而結合成一體。該底座24藉由該二缺口 240内 :真滲滿包覆流體，而可加強底座24與結覆層23間的結 :力。且結覆層23在對應於上模4之該二突出部40處， =對應形成前述該二凹槽231。另外，該蓋板25於成型材 料射入時，亦具分散射入壓力的作用。 10 15 由於本貫施例中該線圈21之繞線部211是被蓋覆於鐵 :孟粉末壓鑄所製成之底座24與蓋板25間，已足以提供 導磁所需之結構，因此實施上該結覆層23只要利用塑膠射 i成1方式來構成即可，由於塑膠射出成型在產速及相關 、、/、、材料的成本節省等條件上，皆優於金屬射出成型方 式^因此結覆層23採取塑膠射出成型的花費，會較低於採 处、'屬射出成型。但是利用金屬射出來製成該結覆層時， ，使：體保覆體22導磁的組成材料具有變化性，可讓底座 24、盍板25相對於結覆層23採用不同特性的導磁材料。 20 接著更甚者，視射出成型所使用材料而定，可選擇地 供烤該等結合—體之底纟24、線圈21、蓋板Μ與結覆層 23 ’使結覆層23硬化定型，而所製成之電感元件2中之線 圈的繞圈部211，除了被蓋覆於導磁材料所製成之底座 與盖板25間，更藉由該結覆層23填充密渗的結合特性 合=圈部211、底座24、蓋板25間獲得無間隙的穩固結 電二二得—提的是，採用本實施例製造方法所製成之 用=，可藉由底座24、蓋板25相對於結覆層η採 導磁材料，使電感元件2能針對不同工作特 10 200428425 性需求，不受單一材料條件的限制，製造出具有複合式材 料之包覆體22，此類複合式材料所可提供之效果，可詳見 於本案發明人前所設計之公告第49379〇號「複合式電感器 」新型專利案。 * 5 此外，為了整體線圈21定位的需要，可在線圈21置· 入下杈3時，便藉由加工機台上所預設之二擋塊可見於 圖6、7)，阻擋於線圈21之該二延伸部212末端，以使後 續作業在射入結覆層23期間，避免線圈21之二延伸部212 受結覆層23的流動推擠影響而前後位移。 1〇 另，本實施例所製成之電感元件2的二延伸部212末 端，可另外進行彎製加工，而循凹槽231形狀往上並相向 彎折貼覆至包覆體22的頂面。 由本貝靶例上述製造方法可知，在製造過程中確實不 需要進行如習知方法所進行的黏合加工之組裝作業，因此 15 可降低製造成本並方便於大量生產，而且所製成的電感元 件2，由於其包覆體22藉結覆層23的充填密滲，使底座 24、盍板25配合結覆層23而能無間隙地將線圈21之繞圈 部211包覆其間，繞圈部211與包覆體22間不會存在空隙 ，因此可避免產生振動與噪音、減少磁損，及提升電感的q 2〇 值。而在製造過程中，該線圈21亦能被穩定地定位，使其 與模具内壁的距離充分隔開而固定，確保導磁體（包覆體U) 的規格厚度。 如圖8所不，本發明第二實施例之製造方法所欲製造 電感元件所採用的線圈21與前述實施例不同，線圈21是 11 200428425 由長條圓線狀導線繞而成，且該線圈21具有—由—長條· 圓線狀導線f繞預定圈數而成之繞圈部211、二分別由該繞 圈部211之兩端往外延伸的延伸部212，及二分別由該等延 伸部212之末端往下同向延伸的彎折部213。 · 參閱圖9、1〇，為了因應線圈21形狀的差異，本實施· 例之製造模具中，該下模3之下圍壁32的前、後側壁段 321、322，更分別具有分別由下定位槽324、325往下延伸 〜 之側定位槽326、327，使線圈21之該二彎折部213相向側· 可分別併抵於該二側定位槽326、327，而更能確保線圈21 · 之中心軸線的垂直穩定狀態。 當前述下模3之該等下圍壁32上皆放置有底座24、線 圈21與蓋板25時，可接著將上模4對應蓋合在下模3頂 面’即圖10所示狀態，藉上模4之該等上圍壁42分別密 ‘ 抵壓合在下模3之該等下圍壁32上，而將每一線圈21之 二延伸部212分別夾持定位於所對應上、下圍壁42、32之 前壁段421、321間與後壁段422、322間，該底座24與線 _ 圈21同樣是容置在該容裝空間5下端部内。 如圖11所示，在各底座24、線圈21、蓋板25容置定 位於上、下模4、3間以後’接著將含有鐵合金粉末所製成 之流態包覆用流體，由上模4之射入孔411射入並充滿該容 裝空間5上端部内，以凝結形成包覆於底座24、線圈21、 蓋板25上之固態結覆層23。 歸納上述，本發明之製造方法藉由鐵合金粉末所製成 之結覆層23 —體成型包覆在底座24、線圈21、蓋板25上 12 ’使所製成結合—驷—a进 空隙，而 覆體22與線圈21間，不會存在 達二::目:提升所製成的電感元件的品質，咖 能以僅為本發明之較佳實施例而已，當不 範圍及發明說之範圍’即大凡依本發明申請專利 應仍屬本發明專二 之簡單的等效變化與修飾，皆 4 乂明寻利涵蓋之範圍内。 【圖式簡單說明】 10 圖1疋一習知電感元件的立體分解圖； 圖2是該習知電感元件的組合剖視圖； —=_\是本發明之製造方法的第-較佳實關所製成之 一电感兀件的立體圖； 圖4是圖3中該電感元件側視剖面圖； 15 圖5疋一製造模具之簡略立I#八紐 隹， ^立體分解圖，說明本發明該 弟一較佳實施例之製造方法； 圖6是圖5中該製造模具的—組合右側剖視圖，說明 :線圈位於一底座與一蓋板間並受模具夾持 空間内； 20 圖7是-類似於圖6之視圖’說明該蓋板與線圈的頂 面與周圍被射入該容裝空間内之結覆層包覆· 之 圖8是本發明之製造方法的第二θ較佳是實施例所製成 一電感元件的立體圖； 圖9是一製造模具之簡略立體分Μ 肢刀解圖，說明本發明第 較佳實施例之製造方法； 13 200428425 圖ίο疋g 9中該製造模具的_組合右側剖視圖，說 -線圈位於一底座與一蓋板間並受模具夹持定位在 空間内；及 i 第圖11是一類似於圖10之視圖，說明該蓋板與線圈的 頂面與周圍被射入該容裝空間内之結覆層包覆。200428425 发明, Description of the invention: [Technical field to which the invention belongs] 5 The present invention relates to an inductor, which refers to a method of wrapping a package outside a coil. 7G parts and its manufacturing method, especially the inductive element and system made of the cover body [Previous Technology] 10 15 20-The general structural design of the inductive element will be based on the required characteristics of the disk specifications such as frequency, t current, volume, inductance The values of the conventional inductor ㈣ structure shown in Figure 2 U 2 include a sheathing body 10 made of a magnetically permeable material such as an iron alloy, and a sheathing body Set of coils 13. The cover body 10 includes a _ base ^ and-a top plate "2 which can be closed correspondingly. The base n has a trough = 1 ′ recessed from its top surface and a shaft post ιι set upright at the center of the trough lu. The receiving tank 111 has two open ends 112. The top cover 12 is roughly flat, and has two spaced recesses recessed downward from one top surface and two opposite sides. The top cover 12 is correspondingly manufactured on the base η. The joint with the base u is glued together to glue the two components together. The coil η has a winding portion 131 formed by bending a predetermined number of turns along a central axis, such as a long flat wire, and two extension portions 132 each extending outward from both ends of the winding portion m. When assembling, the winding part ΐ3ΐ is to be accommodated in the receiving groove 111 of the base u before the top cover 12 is adhered to the base η 卩, and the shaft is fitted to the outside of the shaft pole 11 () of the base u, and The four extensions 132 are corresponding to the open ends 112 on the sides of the slot lu corresponding to the high and low portions, and then the coil 13 can be fixed by bonding the top cover 12 to the bottom = 11 top surface. The limit is between the top cover 12 and the base u. In addition, as shown in FIG. 2, the outer ends of the two extending portions 132 may be bent upward and opposite to each other to be covered in the two grooves 121 of the top cover 12 as needed. In the manufacturing process of the above-mentioned conventional inductance element, in addition to the glue-bonding processing performed on the base 11 and the top cover 12 of the cover body, it will cause its operation to be more troublesome, which is not conducive to mass production and increase costs. The installation structure in the receiving groove 111 of the base 11 is because the coil 13 is nested between the base 11 and the top cover 12 in a nested manner. There will inevitably be a gap, and the open ends 112 on both sides are an unavoidable magnetic gap. Therefore, in addition to being prone to vibration and noise during power-on operation, it will cause large magnetic losses, and the quality factor (Q value) of the inductor will decrease. SUMMARY OF THE INVENTION Therefore, an object of the present invention is to provide an inductor element and a method for manufacturing the same, which have no gap between the cover and the coil and are convenient for mass production. Therefore, the electric inductive element manufactured by the manufacturing method of the inductive element of the present invention has a coil and a covering body covered on the outside of the coil, and the coil has a predetermined number of turns bent by a long wire. The completed winding portion and two extension portions respectively extending outward from both ends of the winding portion. The manufacturing method includes (A) placing the coil on a base made of a magnetically conductive material. A cover plate made of a 'magnetic material is fixedly covered on the top surface of the winding portion of the coil. (C) Place the base together with the coil and cover plate in a receiving space defined by the upper mold and lower mold corresponding to 200428425 cover, so that the extension of the coil is clamped and positioned. And (D) coating the fluid in a fluid state, injecting and filling the containing space, and forming a filling to infiltrate and densely infiltrate the base, the outside of the cover plate and the loop portion, and cover the base and the cover plate, A solid coating layer is formed on the outside of the winding part, and the coating layer is formed by the coating layer, the cover plate and the base. [Embodiment] The foregoing and other technical contents, features, and effects of the present invention will be clearly understood in the following detailed description of a preferred embodiment with reference to the accompanying drawings. 10 Referring to FIGS. 3 and 4, the inductor element 2 manufactured by the manufacturing method of the first embodiment of the present invention has a coil 21 and a covering body 22 covering the outside of the coil 21. The coil 21 has a winding portion 211 formed by a long flat wire and the like being bent along a central axis for a predetermined number of turns, and two extending portions 212 extending from both ends of the winding portion 211 outwardly. The covering body is composed of 15 from top to bottom, a cladding layer 23, a cover plate 25 and a base 24 combined with one another without a gap. The cladding layer 23 is tightly filled into the coil M, and The winding portion 211 of the coil 21 is fixed and covered inside the covering body 22. The covering layer 23 has two spaced grooves 231 recessed downward from two opposite sides of the top surface. 9 20 As shown in FIG. 5, the first embodiment of the present invention to achieve the above-mentioned inductance element manufacturing = manufacturing mold includes-the lower mold 3, and-corresponding to the mold on the top surface of the lower mold 3 *. It has a laterally extending one of the lower bases 31, the top surface of which is uniformly extended from the lower mold 3 into a horizontal long sheet-like plate body, a wall 31, and a plurality of adjacent grounds extending from the lower base wall 6 200428425. The lower surrounding wall 32 defines the majority of the openings that face upward and downward of the mold cavity 33. In order to make the figure clearer, this embodiment uses only the mold 3 with two mold cavity 33 as an example, but the design It is not limited to this. ' Each of the lower cavities 33 can be provided with a base 24 previously made of a magnetically permeable material such as iron alloy powder die-casting. The base 24 has a receiving groove 241 recessed downward from a top surface thereof, a shaft post 24 · 2 standing upright at the center of the receiving groove 241, and two notches recessed inward from the center of two opposite sides. The receiving groove 241 has two open ends 243. The winding portion 211 of the coil 21 is received in the receiving slot 241 of the base 24 and fits outside the shaft post 242. The winding portion 21 丨 is designed to be about the same height as the top surface of the shaft post 242, and the coil The two extensions 212 of 21 are corresponding to the open ends 242 of the sides respectively through the receiving slot 24m. With reference to FIG. 6, after the coil 21 is placed and positioned, a cover plate 25 made of a magnetically conductive material such as iron alloy powder is die-cast into the groove 241 of the base horizontally from top to bottom, and correspondingly covers the coil. The top surface of the winding portion 21 of the 21 and the shaft 242 of the base 24. The shape of the cover plate 25 corresponds to the area of the middle portion of the groove 241, and has a sheet shape with a wide middle and narrow ends, that is, the cover plate. After the 25 is closed, it is not completely closed on the top surface of the tank 241, but an appropriate gap is reserved at the open ends 243 on both sides. The shape of the cover plate 25 is not limited to the one disclosed in the present embodiment. In practice, the shape of the cover plate 25 can be covered on the top surface of the winding portion 211, for example, a disc shape is used. In this embodiment, the shaft post 242 is slightly lower than the two side walls 244 of the base 24, so that when the cover plate 25 is assembled, the two curved side edges 251 are just fitted into the two side walls 244, so that the cover plate 25 and the base 24 forms a closed loop (cl0se 100p). 7 200428425 The female lower surrounding wall 32 can be used to extend the extension 212 of the coil 21 above, and each lower surrounding wall 32 has parallel front and rear wall sections 321, 322 and two connected to the cymbals, rear wall sections 321, The side wall section 323 between the two ends of the 322, and the lower mold cavity 33 is defined by the lower surrounding wall 32 and the lower base wall 31. The front and rear wall sections 321 and 322 both have a front-to-back extension. One of the top surfaces is recessed downwardly to locate positioning grooves 324 and 325, and the two lower positioning grooves 324 and 325 have rectangular cross-sections that cooperate with the extending portion 212 of the coil 21, so that the two extending portions 212 of the coil 21 can be horizontal respectively. Straddled on the two lower positioning grooves 324 and 325, the two side wall sections 323 and the front wall section 321 are at the same height, and the height of the rear wall section 322 is designed to project upward from the front wall section 321, so that The lower positioning grooves 324 and 325 are one low and one high. This design is to respond to the coil 21 in a span of one inch and one of its extensions 212 is in a high and low horizontal extension state. The upper mold 4 is compatible with the aforementioned lower mold. 3 Corresponding to a long sheet-shaped plate body having a k-direction extending upper base wall 41, and most adjacent grounds are formed by one of the lower base walls 41 A rectangular long upper enclosure wall 42 extending downwards in the same body, and a plurality of protrusions 40 located on two opposite inner sides of the upper enclosure walls 42 in pairs, respectively. The upper base wall 41 has an injection hole 411 penetrating through the top and bottom surfaces of the upper base wall 41 for injecting into the coating layer 23 of the covering body 22. Each upper surrounding wall 42 has parallel front and rear walls 4 and 421, 422 'and two side wall sections 423 connected between the two ends of the front and rear wall sections 421, 422. The upper surrounding wall 42 and the upper base wall 41 A cavity 43 with an opening facing downward is defined together, and the shape of the upper surrounding wall 42 forms a complementary shape corresponding to that of the lower surrounding wall 31 of the aforementioned lower die 3, that is, the upper surrounding wall 42 The protruding degree of the side wall section 423 is the same as that of the front wall section 421, and only the protruding degree of the rear 8 ^ 00428425 wall & 422 is small. Each pair of protrusions 4 () are respectively protruding in front of the corresponding upper wall ^ 42, near the opposite side of the rear side wall 421, 422 and the upper base wall 41, so that each of the protrusions 4 () has a side view shape [ Type cross section. 5 10 Once the base 24, the coil 21 and the cover plate 25 are placed on the lower surrounding walls 32 of the aforementioned lower mold 3. Then, the upper mold 4 can be correspondingly covered on the top surface of the lower mold 3 'at this time. The upper surrounding walls 42 of the mold 4 are closely pressed against the lower surrounding walls 32 of the lower mold 3, respectively, and the two extensions of each coil 21 are clamped and positioned on the corresponding upper and lower surrounding walls 42 respectively. 32, the front wall sections 421, 321 and the rear wall sections 422, 322. At this time, the upper and lower molds 4 in each of the upper and lower surrounding walls 42, 32 jointly define a cavity formed by the upper and lower molds. The accommodating space 5 formed by connecting 43 and 33. The base 24, the coil 21 and the cover plate are accommodated in the lower end of the accommodating space 5 from bottom to top. 15 20 As shown in Figure 7, after the base 24, the coil 21 and the cover plate 25 are accommodated and positioned between the upper and lower branches 4, 3, and then the appropriate material is formed by plastic injection molding or metal injection into i. For example, the plastic coating fluid can be used as the material during plastic injection molding, and the fluid colloidal coating fluid made of iron alloy powder can be used as the material during metal injection molding, and the injection fluid is transferred from the upper mold 4 The injection hole 411 penetrates and percolates downward through the gaps reserved on both sides of the cover plate 25 to fill the upper end of the containing space 5 to form a condensation covering the base 24 and the coil 21 and the outside of the cover plate 25. Solid junction coating layer 23. Here, the coating fluid is injected into the upper ends of the accommodating space 5 between the upper and lower molds 4 and 3 through the injection holes 411, and the two gaps 240 and the gaps around the loop portion 211 that penetrate the base 24 are tightly filled. In each case, the base 24, the coiled portion 211 of the coil 21, and the cover plate 25 are charged with a solid coating layer 23 that is condensed afterwards. The base 24 can be filled with the covering fluid through the two gaps 240 to strengthen the bond between the base 24 and the cover layer 23. In addition, the bonding layer 23 is corresponding to the two grooves 231 at the two protruding portions 40 corresponding to the upper mold 4. In addition, when the cover material 25 is injected, the cover plate 25 also has a function of scattering the injection pressure. 10 15 Since the winding portion 211 of the coil 21 in this embodiment is covered between the base 24 and the cover plate 25 made of iron: Meng powder die-casting, it is enough to provide the structure required for magnetic permeability. The cladding layer 23 can be formed by using plastic injection molding method. Since plastic injection molding is superior to metal injection molding in terms of production speed and related cost savings, etc., therefore The cost of adopting plastic injection molding of the cladding layer 23 will be lower than that of the mining area, and it is a metal injection molding. However, when the bonding layer is made by metal injection, the magnetically permeable composition material of the body covering body 22 has variability, and the base 24 and the cymbal plate 25 can adopt different characteristics of magnetic permeability with respect to the covering layer 23 material. 20 Next, depending on the materials used for injection molding, these combinations can be optionally baked-the bottom of the body 24, the coil 21, the cover M and the cover layer 23 'to harden and shape the cover layer 23, In addition, the coil winding portion 211 of the coil in the manufactured inductive element 2 is not only covered between the base made of the magnetically permeable material and the cover plate 25, but also the bonding characteristics of the sealing layer 23 filling the infiltration. Closer = Obtain a stable and stable electric connection between the ring 211, the base 24, and the cover plate 25. It is mentioned that the use of the manufacturing method of this embodiment = can be achieved through the base 24, the cover plate 25 Compared with the cladding layer η, magnetically permeable material is used, so that the inductive element 2 can meet the requirements of different working characteristics 10 200428425, and is not limited by a single material condition, and a composite body 22 having a composite material is manufactured. Such a composite material The effect that can be provided can be found in the new patent case of “Composite Inductor” No. 4937900, which was previously designed by the inventor of this case. * 5 In addition, for the positioning of the entire coil 21, when the coil 21 is placed and inserted into the lower branch 3, the two stoppers preset on the processing machine can be seen in Figures 6 and 7), blocking the coil 21 The ends of the two extension portions 212 are used to prevent subsequent displacements of the extension portion 212 of the coil 21 from being pushed back and forth by the flow of the cover layer 23 during the injection into the cover layer 23 during subsequent operations. 10 In addition, the ends of the two extensions 212 of the inductive element 2 made in this embodiment may be additionally subjected to bending processing, and are bent upward and follow the shape of the groove 231 to cover the top surface of the covering body 22 . It can be known from the above-mentioned manufacturing method of this target that the assembly operation of the bonding process like the conventional method is not really needed in the manufacturing process, so 15 can reduce the manufacturing cost and facilitate mass production, and the manufactured inductor element 2 Since the covering body 22 is infiltrated by the filling and covering layer 23, the base 24 and the cymbal plate 25 cooperate with the covering layer 23 to cover the winding portion 211 of the coil 21 without gaps, and the winding portion 211 There is no gap with the cover 22, so vibration and noise can be avoided, magnetic loss can be reduced, and the q2 value of the inductance can be increased. In the manufacturing process, the coil 21 can also be stably positioned so that the distance from the inner wall of the mold is sufficiently separated and fixed to ensure the specification thickness of the magnet guide (the cover U). As shown in FIG. 8, the coil 21 used in the manufacturing method of the second embodiment of the present invention to manufacture the inductive element is different from the previous embodiment. The coil 21 is 11 200428425 wound by a long round wire, and the coil 21 has a winding portion 211 made of a long and circular wire f around a predetermined number of turns, two extension portions 212 extending outward from both ends of the winding portion 211, and two extensions respectively The end of the portion 212 is a bent portion 213 extending downward in the same direction. Referring to FIGS. 9 and 10, in order to cope with the difference in the shape of the coil 21, in the manufacturing mold of this embodiment, the front and rear side wall sections 321 and 322 of the surrounding wall 32 below the lower mold 3 have respectively The positioning grooves 324 and 325 extend downward to the side positioning grooves 326 and 327, so that the two bent portions 213 of the coil 21 face to the side. The two positioning grooves 326 and 327 can respectively and abut the positioning grooves 326 and 327 of the two sides, so that the coil 21 can be more ensured. · Vertical steady state of its central axis. When the base 24, the coil 21 and the cover plate 25 are placed on the lower surrounding walls 32 of the aforementioned lower mold 3, the upper mold 4 can then be correspondingly covered on the top surface of the lower mold 3 ', i.e., the state shown in FIG. The upper surrounding walls 42 of the upper mold 4 are closely pressed against the lower surrounding walls 32 of the lower mold 3, and the two extension portions 212 of each coil 21 are respectively clamped and positioned at the corresponding upper and lower circumferences. The walls 42 and 32 are between the front wall sections 421 and 321 and the rear wall sections 422 and 322. The base 24 and the wire ring 21 are also accommodated in the lower end of the accommodation space 5. As shown in FIG. 11, after each base 24, coil 21, and cover plate 25 are accommodated and positioned between the upper and lower molds 4, 3, and then, a fluid coating fluid made of an iron alloy powder is then placed by the upper molds. The injection hole 411 of 4 penetrates and fills the upper end of the containing space 5 to form a solid junction coating layer 23 covering the base 24, the coil 21, and the cover plate 25 by condensation. Summarizing the above, the manufacturing method of the present invention covers the base 24, the coil 21, and the cover plate 12 by forming the covering layer 23 made of iron alloy powder in a body shape 12 'to make the bonding— 驷 —a into the gap, And there will be no two between the cover 22 and the coil 21 :: Objective: to improve the quality of the manufactured inductive element, the coffee can only be the preferred embodiment of the present invention, and the scope and scope of the invention are not included. That is to say, those who apply for a patent in accordance with the present invention should still be the simple equivalent changes and modifications of the second aspect of the present invention, which are all within the scope covered by profit-seeking. [Brief description of the drawings] FIG. 1 is a perspective exploded view of a conventional inductance element; FIG. 2 is a sectional view of the conventional inductance element; — = _ \ is the first-best practice of the manufacturing method of the present invention A perspective view of a manufactured inductor element; FIG. 4 is a side sectional view of the inductor element in FIG. 3; 15 FIG. A manufacturing method of a preferred embodiment; FIG. 6 is a sectional view on the right side of the manufacturing mold of FIG. 5, illustrating: the coil is located between a base and a cover plate and is held by the mold clamping space; FIG. 7 is-similar to The view of FIG. 6 illustrates the top surface of the cover plate and the coil, and the surrounding layer coating which is shot into the containing space. FIG. 8 is the second preferred embodiment of the manufacturing method of the present invention. A perspective view of an inductive element is made; FIG. 9 is a schematic three-dimensional exploded view of a manufacturing mold illustrating a manufacturing method of the first preferred embodiment of the present invention; 13 200428425 FIG. Sectional view on the right, saying-the coil is located between a base and a cover The mold is clamped and positioned in the space; and FIG. 11 is a view similar to FIG. 10, illustrating that the top surface and surroundings of the cover plate and the coil are covered with a covering layer projected into the containing space.
14 200428425 【圖式之主要元件代表符號說明】 1 …， 電感元件 321 * · 前壁段 2卜… 線圈 322… 後壁段 211 * * 繞圈部 323 * * 側壁段 212 * * 延伸部 324〜325 下定位槽 213… 彎折部 326〜327 側定位槽 22，… 包覆體 33 *，， 下模穴 23 ·… 結覆層 4 ... 上模 231… 凹槽 40 * · · 突出部 24…♦ 底座 41 ♦ * 上基壁 240… 缺口 411… 射入孑L 241… 容槽 42 *… 上圍壁 242… 軸柱 421 * * 前壁段 243… 側開口端 422 * * 後壁段 244 · ♦ 側壁 423 ♦ · 側壁段 25 蓋板 424〜425 上定位槽 251… 弧形側緣 43 *… 上模穴 3 * * - 下模 5 * * 容裝空間 31'** 下基壁 6 擋塊 32 ·… 下圍壁14 200428425 [Description of the main symbols of the drawings] 1…, inductive element 321 * · front wall section 2… coil 322… rear wall section 211 * * coil section 323 * * side wall section 212 * * extension 324 ~ 325 Lower positioning groove 213 ... Bending portion 326 ~ 327 Side positioning groove 22, ... Covering body 33 *, Lower mold cavity 23 ... Bonding layer 4 ... Upper mold 231 ... Groove 40 * ... Protrusion 24… ♦ Base 41 ♦ * Upper base wall 240… Notch 411… Injection into 孑 L 241… Receiving slot 42 *… Upper surrounding wall 242… Shaft 421 * * Front wall section 243… Side open end 422 * * Rear wall section 244 · ♦ Side wall 423 ♦ · Side wall section 25 Cover plate 424 ~ 425 Upper positioning groove 251 ... Curved side edge 43 * ... Upper mold cavity 3 * *-Lower mold 5 * * Capacity space 31 '** Lower base wall 6 Stop 32 · ... under the wall
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