TW200428426A - Thin inductor and manufacturing method thereof - Google Patents

Abstract

The invention provides a thin inductor and manufacturing method thereof. The method comprises winding a coil around a thin iron core, soldering and fixing the ends of two coil sonto the supporting frame of the material tape pre-pressed, and then disposing it into the mold for molding and packaging, so as to obtain a thin inductor by stamping/breaking.

Description

200428426 V. Description of the invention (1) [Technical field to which the invention belongs] The present invention is a "thin inductor and its manufacturing method, especially one suitable for SMD type inductors; it is mainly used-thin" core winding Set the coil, and weld the ends of the two coils to the pre-punched tape holder frame, then place it in the mold to fill the plastic package, and then seal the tape frame and two outputs The extra part of the terminal is a shaped inductor. Among them, the two output terminals on the frame are provided with a first inside! Ϊ ϊ ΐ There is a second 'f-folded portion' on the outside to improve the thin inductor Those who have good taste and enhance the effectiveness of the inductor structure. [Previous technology] The conventional SMD type inductor and its manufacturing method, because the drum core is wound, "when a coil force is generated, the drum core needs to be subjected to a second force when the force is lighter" The drum-shaped iron core will loosen, and the solid iron ΐ ΐ 疋 ', and when the clamping force is heavy, although the drum-shaped iron core can be ξπ ::' 'Because the thickness of the upper and lower baffles is thin, It is fragile and may be damaged; In addition, the so-type inductor of Xi Youzhi is difficult to construct 15 degrees. Because: the lower end face of the drum core is often used as the salt of the inductor. Therefore, the lower seeding board is susceptible to 7 Sound, which causes cracks in the drum-shaped iron core;

Before welding J, 'silver plating and silver sintering must be applied first, especially when Z is too thin, and silver will be dissolved first. = Groove ί 200428426 V. Description of the invention (2) In addition, there are some customary methods using a base substrate Inductors, the output terminals are buckled on the two sides of the substrate by means of buckles. The upper ends of the buckles and the coil terminals are joined by solder joints, and then the solder joint connection points are bonded with an adhesive; however, the amount of adhesive is not easy. If it is too much, it needs to be wiped and removed, while if it is too little, then the strength is insufficient, and quality control is not easy; and the addition of the base substrate will also increase the overall thickness of the inductor, so there are also suboptimal points. [Summary of the invention] Therefore, the main purpose of the present invention and its manufacturing method ", and has the following advantages, characteristics and purposes · The invention can be directly made into a thinner overall thickness between 10 ^^ and 3 〇11111] Drum-shaped iron core; 02 03 04 Mounting and covering 05 The drum-shaped iron core of the present invention may have a thin upper and lower cymbals. The upper and lower index plates of the present invention have sufficient knots = reverse; the drum-shaped iron core and the two output terminals of the present invention are insulated. Therefore, the gel seal has the characteristics of excellent quality and strong structure. 1- Qiu Ϊ Ϊ: The output terminal of the moon has two first bends and has the first fold. The project is broken after sealing, and the quality is better. The convenience of the cattle is in the packaging of the eastern system =: To achieve the above-mentioned purpose and function &, the powder core of the drum-shaped iron core II: Γ: The technical means include: ingredients steps, It can be made into two steps: pulverization step, pulverization step, and granulation step. Among them: granulation, can be ground into a fine powder with a particle size u "; ancestral step, can be Jiangluobian mesh 100 # granules, And Sun ^ powder is then granulated into a particle size of Liquid, and

200428426 V. Description of the invention (3) " ~ --- Other sintering aids, etc., shrink the surface of the fine powder into spherical bodies by spray granulation. ^ In order to achieve the above-mentioned object and effect of the present invention, the technical means adopted in the manufacturing method of the drum-shaped core includes: "molding step, drying step, processing step, firing step, and impregnation step, etc., wherein: f, you can impregnate the fired drum-shaped iron core with vacuum. 入 入 Insert the adhesive with a lower amount of knife to allow the adhesive to fully infiltrate, and then dry and solidify at a high temperature to make the adhesive and drum-shaped. The core produces a solidified structure to obtain better structural strength. [Embodiment] The features, technical means, specific functions, and specific embodiments of the present invention are described in detail below with drawings and numbers: Please refer to Figures 1 to 5, the method of the present invention includes the following steps ： Step 1 'is the step of “forming a thin iron core”, using magnetic ferrite as a molding material to make a thin drum iron core 丨 〇, the drum iron core has a thin upper and lower baffle plate 11, 1 2 The drum-shaped iron core 10 is provided with a winding shaft center 13 at the center, and the drum-shaped iron core 10 has a preferred overall thickness of 丨 · min to 3.0 · mni, and preferably 1.0 to 1.05mm; Step 2 is a step of “winding the coil directly on the thin core”, clamping the thin drum core 10 and winding it directly on the winding core 13 with the coil 20; step 3, It is the step of “putting the wound coil core into the tape holder frame”, and putting the thin drum core 10 wound into the coil 20 into the tape holder frame 40

200428426 V. Description of the invention (4), and the tape holder frame 40 has at least a pair of output terminals 41, 42 as shown in Figure 2; 'Step 4, is "weld the output terminals of the coil to the tape Step on the bracket, the two coil ends 21 and 22 are respectively welded at high temperature to one of the two output terminals 41 and 42 with one of the first bent portions 4la, 42a and the second bent portions 41b, 4 2b being flat outside. Place, as shown in week 3;

Step 5 is the step of “filling the tape with the coil core into the mold and pouring it into the mold”. The coil 2 〇 and the thin drum core 10 which have been welded and fixed to the tape holder frame 4 〇 are placed together. In the mold, it is potted and encapsulated, and the two output terminals 4 丨, 4 2 are covered with insulating gel 50 and fixed on the outer side of the second bending portions 41b and 42b, and are located in front of and behind the insulating gel 50. , 52, and the surface height of the second bent portions 41b, 42b and the front and rear sides 51, 52 of the insulating gel 50 are almost flush with each other, as shown in FIG. 4; "Remove the inductor from the frame", punch out the strip frame of the tape holder frame 40 and the excess portions of the two output terminals 41,42, and make the surface height of the two output terminals 41,42 equal to the insulation gel 5 0 刖, rear side 5 1, 5 2 are also nearly flush, and take out the packaged inductor 1, as shown in Figure 5; Step 7, which is the step of "finishing the finished terminal plating", will be two 41, 42 are electroplated, which is the final product; by this, a thin inductor can be made and has a simplified Manufacturing process, simple structure, output terminals 41, 4 2 have better quality and stronger structure. As shown in Figures 1 and 1A, according to the method of the present invention, the tape holder frame 40 can be stamped from a copper tape and can be electroplated; therefore, 200428426

The method of the present invention may further include, before step 3, a step of "taking copper strips to make the required material." A copper strip is punched to make several pieces of material. '可 A ISI 姘 +, ^ 克 木The frame 40 is a strip-like structure, such as 1 material; ^ plus ... 1: break 4 with a frame for easy processing operations, can be pre-rolled at the ii ^ r ^ ^ ^ ^: 4 丨, 42 to form a pre-roll Broken wire (not shown in the figure). Of course, if the depth of the pre-broken wire is large, it is also feasible to use the die punching and can be broken by hand. It is hereby explained; Step 9 is the step of "plating" The strip structure of 8 is plated and has a surface plating layer. This step 9 can be increased or decreased as required.

As shown in Figures 1B, 1C, and 2, if the overall thickness of the drum core 10 of the present invention is to be between 1.0 mm and 3.0 mm, or even thinned to 1.0 to 1.0 5mm, and the drum-shaped iron core 10 wants to have thin upper and lower baffles 11, 12, it can be implemented by the following powder manufacturing process go and iron core manufacturing process 70. Among them: The powder manufacturing process 60 The best steps include: "Batching" step 61, which is the process of ferric oxide (Fe203), Ni〇,

CuO, ZnO and other main ingredients and additives are evenly mixed; "Making a block" step 62 is a continuation of the previous step, and the powder raw material is made into a spherical or cube with a smaller particle size, and the preferred particle size can be 1 mm 0 to 10mm 0, and 3.50 to 6.5mm must be the optimal particle size; "false firing" step 6 3, continuing from the previous step, the manufactured block is 90 0 ° C to 105 ° C

Page 8 200428426 V. Description of the invention (6) Exchange magnetic material and use to produce better magnetic pulverization "Step 6 4 is the continuation of the previous step, grinding the" sintered "product to a particle size of 1.2 // m 0 The following fine powders are between 0.1 / zm and 0.8 // m0; the second step is 65, following the previous step, pulverizing and granulating to a particle size of The granules of mesh 1 00 # and above, and also the powder, and then the solution and other sintering aids, etc., the surface of the fine powder sprayed out by spraying granules 3 is shrunk into a spherical body under high temperature to improve The powder has two properties, and the preferred particle size for granulation can be between 0 ## and 3〇〇 #; by this means, the powder required to thin the drum core 10 can be made by maneuvering. 9 'Further, the iron core manufacturing process 70 is a better step, including: "Shaping" step 71, the powder made in the powder manufacturing process 60 is processed into a green body to increase the density; 1 "Drying" step 7 2 is to continue the previous step to remove the water from the embryo body to adjust its mechanical strength; and processing "Step 7 3 is to continue the previous step to cut the embryo body into a circular groove And it becomes a drum-shaped iron core with a winding axis 丨 3 in the center and a semi-finished product 'and has thinner upper and lower baffles 11, 2 at this time. At this time, the overall thickness of the drum-shaped core 丨 〇 semi-finished product has reached 1.0 minute 3.〇_ between;

The "firing" step 74 is a continuation of the previous step, and the finished drum-shaped iron core 100 semi-finished product is 11000. (3 to 13 0 〇. (: Sintering; "impregnation" step 75), continuing from the previous step, impregnating the sintered drum-shaped iron 1 10 and vacuum impregnation, and incorporating a lower molecular weight adhesive, After the adhesive has been sufficiently infiltrated, it is further dried with 1000 to 300%, so that

200428426 V. Description of the invention (7) The adhesive is cured to strike only two π — the strength of the cured structure of the lucky father drum core 1 10; & by this, the overall thickness can be directly made up to 1. Omm 到3. The thin S-shaped iron cores between 0 and 10 mm and the thinner upper and lower baffles 11 and 12 also have sufficient structural strength. As shown in Figures 2 to 6, the structure of the thin inductor of the present invention includes a core-shaped iron core 10, a coil 20, two output terminals 41, 42, and an insulating colloid 50, among others.

★ The thin drum-shaped iron core 10 is made of magnetic ferrite and has thin upper and lower baffle plates 1 丨, 丨 2, the drum-shaped iron core 丨 〇 and a winding axis 13 ′ The best overall thickness can be between 10 and 30 mm, and [0 to 1.05 mm is the best; the two output terminals 41, 42 are connected to the tape support frame 40—and are made of a copper tape. Stamped, the two output terminals 4 丨, 4 2 have a first bent portion 41a, 42a 'inside and a second bent portion 41b, 427 inside; the coil 2 0' is directly wound around the winding On the bobbin center 丨 3, and the two coil ends 21, 2 2 are electrically welded to the two output terminals 4 丨, 4 2 at high temperature, respectively, and the flatness between the first bent portions 41a, 42a and the second bent portions 4lb, 42b is flat. The insulating gel 50 is tied to the drum core 丨 0, the coil 2 0, and the two output terminals 41, 42 and is filled with glue after being placed in the mold. The two output terminals 41 and 42 are filled with glue.

2. The outer side of the green folded part 4lb, 42b is located before and behind the insulating gel 50, and on the rear sides 51, 52; by this, the tape frame of the tape holder frame 4 and the two output terminals 41, 42 are redundant. Some parts are punched out, and the packaged inductor is taken out and then the two output terminals 4 1 and 4 2 are electrically mined to form a thin shape.

Page 10 200428426 V. Description of the invention (8) Inductor. As shown in Figures 3 and 6, the thin drum core 10 can be supported by two output terminals 41, 42 and a total of four pillars, and is encapsulated and covered by an insulating gel 50. Therefore, the manufactured inductor has Excellent quality and strong structure. In summary, the "thin inductor and its manufacturing method" of the present invention has clearly met the requirements for the establishment of an invention patent, and has applied for a patent application in accordance with the law. Spirit is what we want. The drawing numbers are explained as follows: Thin drum core 1 0 Winding shaft center 1 3 Coil end 2 1, 2 2 Output terminals 41, 42 First bend 41a, 42a Colloid front side 5 1 Upper and lower baffles 11, 12 Coil 2 0 Material holder frame 40 Second bending portion 41b, 42b Insulation gel 50 Back side of gel 52

Page 11 200428426 Brief description of the drawings Figure 1 is a schematic diagram of the steps of the method of the present invention; Figure 1 A is a three-dimensional schematic view of the belt structure of the tape of the present invention; Figure 1 B is' the manufacture of the powder of the present invention Schematic diagram; Figure 1C is a schematic diagram of the manufacturing process of the iron core of the present invention; Figure 2 is a partial exploded view of the inductor of the present invention (a); Figure 3 is a partial bird of the inductor of the present invention Volume exploded view (II); Figure 4 is a partially exploded view of the inductor of the present invention (III); Figure 5 is a partially exploded view of the inductor of the present invention (IV); Figure 6 is A-A cross-sectional view of Figure 5.

Claims (1)

200428426 VI. Scope of patent application 1 · A "thin inductor manufacturing method", which includes the following steps: (a) The step of making a thin core is made of magnetic ferrite as a molding material Drum-shaped iron core, and the drum-shaped iron core has a thin upper and lower seeding plate, and the center of the drum-shaped iron core is provided with a winding axis; (b) the step of directly winding a coil on the thin-shaped iron core is to clamp the drum-shaped iron core; Holding and winding the coil on the winding axis: · 浔 ν 之 (c) put the wound coil core into the tape holder frame, put the coiled drum core into the tape holder frame, The system has at least a pair of output terminals; 円 円 ## with bracket frame (d) The coil output terminals are firmly fixed to the system. The steps of welding the two coil ends to the two output ends at high temperature, respectively, (e) will be equipped with The coil of the core of the coil is installed inside; the steps are to put the Gu, Er, and two injection moldings that have been welded on the frame of the band into the mold, and fill it with plastic. The ring and drum core must be fixed. , The second bent part of the two output terminals are also insulated Cover the solid surface of the body; 之前 Before and after the body modification (f), punch out the tape frame and take out the inductor + the frame's tape frame and the two output terminals are extra ^. Inductor. , ° 卩 份 'to be broken off, and 2. If the "thin method" of the scope of application for patent application item 丨, where the method after step (h) < (g) The step of plating the final product terminal, add two output terminals to 200428426 It includes electroplating; by this, it is made—3. As in the Patent Application Scope Act "', where the method includes the following steps: Thin inductor. Before the manufacturer of the thin inductor (C), you can further (h) take the copper strip and punch it into a strip punch to form several sections of the strip to support the M strip. The imperial city is also a band-like surname hibiscus. (1) The electroplating step is to apply the electroplating method to the boat-like, ..., structure, and hypothesis. The strip structure of the step (h) is electroplated. Broken shape 5. The coil, the thinner one should have a second outer side; such as "the order of the patent application scope item 1", the method is thin in step Λ, the inductor is manufactured with a square material with a bracket frame 4. The two outputs, the : 'You can also-step into a pre-break line on it. &Amp; Sub 41, 42 breaks, pre-shock "!: Inductor", including-thin drum core,-two outputs Coils, and insulating colloids, etc .; where ... the shape of the iron 'series is formed by magnetic ferrite, and has upper and lower baffles, the center of the drum core and a winding axis; two output terminals, The coil is provided with a first bent portion on the inner side and an f-folded portion on the outer side, and the second bent portion is provided between the two first bent portions. The coil is directly wound. On the winding axis, and the ends of the two coils are respectively welded to the first bends of the two output terminals at high temperature; the insulating gel is attached to the drum core, the coil, and the two output terminals, etc. The second bending portion of the two output terminals is located on the front and rear sides of the insulating gel; 6. Scope of applying for patents This can be followed by punching out the excess part of the holder frame of the tape, and taking out the frame of the armor and the two output terminals, and then pressing the two output terminals, and then sealing the inductor, or It can be connected to 6. · For example, "to form a thin inductor" in the scope of the patent application No. 5 of this patent. The material tape holder frame can be punched by a copper tape thin inductor, in which the belt-shaped structure of the frame. The "table" has a number of sections of tape support. 7) For example, "the copper tape further has a surface plating layer. / Shaped inductor" in item 6 of the scope of patent application, of which 8 · as in item 5 of the scope of patent application 0 "之间。" The preferred overall thickness of the drum-shaped core can be cold-shaped inductor ", wherein, such as the scope of the patent application 5th item ° l 0mm to 3. 0_ between. The best overall thickness of the drum-shaped core is 4-inductor "', where the degree of dryness' can be between 1.0 mm and 1.05 mm. ι〇 · A method for manufacturing a powder of a thin inductor drum core ", the method includes the following steps: U) batching step, which is the main ingredients and additives such as ferric oxide (Fe203), NiO, CuO, ZnO Mix uniformly; (b) The step of making a block is a continuation of the previous step, and the powder material is made into a spherical or cube with a smaller particle size, and the preferred particle size can be between 0 and 10 mm 0; c) The sintering step is a continuation of the previous step, and the prepared block is set at 900 C to 1 050. 〇Fake firing; (d) the pulverization step, which is followed by the previous step, and the sintered semi-finished product is ground to a fine powder with a particle size of 1 2 # m 0 or less; (e) the granulation step 'system Continuing the previous step, the fine powder after pulverization 200428426 VI. Patent application scope ^:-K particles are made into granules with a mesh size of 100 # or more, that is, by dry powder and adhesive solution, and other Sintering aids the process of spraying and granulating, so that the surface of the sprayed fine powder shrinks into a spherical body under a high temperature environment; and other steps. 11. The "method for manufacturing powder of a thin inductor drum core" according to item 10 of the scope of patent application, wherein the block-shaped particle diameter prepared in step (b) is in a range of 3 · 5mm 0 to 6.5mm 0 The best. 1 2. According to the method for manufacturing a powder of a thin inductor drum core according to item 10 of the scope of patent application, wherein the particle size of the fine powder prepared in step (d) ranges from 0 · 1 // m to 〇 · 8 # m 0 is the best. 1 3. If the method for manufacturing powder of a thin inductor drum core according to item No. of the patent application range, wherein the preferred particle diameter of step (e) for granulation may be between 100 # and 300 #. 14. A "manufacturing method for a thin-shaped inductor drum core", which includes the following steps: (a) a molding step in which powder is molded into a green body to increase its density; (b) a drying step ， Continued from the previous step to remove the moisture from the embryo body to adjust its mechanical strength; (c) processing step ， continued from the previous step to cut the embryo body into a circular groove to become the center with a winding axis. Semi-finished drum core with thin upper and lower baffles; (d) firing step, which is continued from the previous step, the finished semi-finished drum core is 100 ° C to 130 ° C Sintering; (e) impregnation step, following the previous step, firing the drum-shaped iron Page 16 200428426 6. The scope of the patent application is then impregnated with vacuum, and a low molecular weight adhesive is added to make the adhesive fully penetrate into the capillary pores of the drum core, and then dried and cured at high temperature to make the adhesive adhere. Curing agent to obtain better drum core structure strength; etc. 15 · For example, the "method for manufacturing powder of a thin inductor drum core" in item 14 of the scope of patent application, wherein the drum core semi-finished product in step (c) has an overall thickness of 1.0 mm to 3.0 μm between. 16 · If the method for manufacturing a powder of a thin inductor drum core according to item 14 of the scope of patent application, wherein step (e) is a preferred drying and curing temperature, which may be 100 ° C to 300 ° ° C. 1 7-A "manufacturing method of a drum-shaped iron core", the method includes the following steps: (a) a molding step, which forms powder into a green body to increase the density; (b) a drying step, which Continue the previous step to remove the embryo's water to adjust its mechanical strength; (c) The processing step is to continue the previous step to cut the embryo into a circular groove to form a drum shape with a winding axis in the center. Iron core semi-finished product with thin upper and lower baffle plates; (d) firing step, following the previous step, firing the drum core semi-finished product at 1000 ° C to 1300 ° C (E) Impregnation step, which is the continuation of the previous step, the impregnated drum core is vacuum impregnated, and a lower molecular weight adhesive is added to make the adhesive fully participate in the capillary pores of the drum core. , And then dried at high temperature Page 17 200428426 6. Scope of patent application ^ ------Chemical treatment, and curing the adhesive to obtain better drum core structure strength; and other steps. 18, such as "Powder Manufacturing Method of Drum-shaped Iron Core" in the scope of the patent application No. 丨 7, in which the overall thickness of the drum-shaped core semi-finished product in step (c) can be between 1.0 mm and 3.0 mm. 19 · For example, the “powder manufacturing method of drum core” in the scope of patent application No. 丨 7, wherein step (e) is the preferred drying and curing temperature, which can be between 100 ° C and 300 ° C. 20 · —A "method for manufacturing iron core powder", the method includes the following steps: (a) the batching step, which is composed of main components such as ferric oxide (ρ e 2 〇 3), Ni 〇, CuO, ZnO and The additives are uniformly mixed; (b) the step of making a block is a continuation of the previous step, and the powder raw material is made into a spherical or cube with a smaller particle size, and the preferred particle size may be 丨 mn] 0 to 10 mm 0 {between; (c) a false firing step, which is continued from the previous step, and the prepared block is subjected to false firing at 90 0 C to 105 ° C; (d) a crushing step, Continuing from the previous step, the sintered semi-finished product is ground into a fine powder with a particle size of 1 · 2 // m 0 or less; (e) The granulation step is the continuation of the previous step, and the pulverized fine powder is re-used. Granulate into granules with a mesh size of 100 # or more, that is, dry powder and adhesive solution, and other sintering aids, etc., to make the surface of the fine powder sprayed in a high temperature environment by spray granulation. Shrink into a spherical body; and so on. 2 1 · As for "iron core's powder manufacturer" in the scope of patent application No. 10 Page 18 200428426 VI. Method of Patent Application Scope ", wherein the block size made in step (b) is most preferably between 3 · 5 m 0 and 6. 5 mm 0. 2 2. The method for manufacturing a powder of an iron core according to item 10 of the scope of patent application, wherein the particle size of the fine powder produced in step (d) ranges from 0 · 1 // m to 0.8 # m 0 之The best. 2 3. If the method of manufacturing a powder of iron core is described in item 10 of the scope of patent application, the preferred particle size for granulation in step (e) may be between 1 0 0 # and 3 0 0 #. Page 19