201106392 六、發明說明： 【發明所屬之技術領域】 本發明係關於一種電感器之製造方法，該電感器具備於 磁心内埋設線圈之捲繞部之結構，該磁心係使含有磁性粉 末及黏合劑之材料粉末經壓縮成形者硬化而得者。 【先前技術】 關於此種電感器之製造方法’於專利文獻丨（日本專利第 3108931號）中揭示有「一種電感器之製造方法’其特徵在 於包含以下步驟：藉由成形模對含有用以黏合磁性粉末之 熱固性樹脂之黏合劑的摻有黏合劑之磁性粉末進行加壓預 成形，而形成第1壓胚；於上述成形模上設置具有端子部 之線圈；以上述線圈為基準而於上述第丨壓胚之相反側的 成形模上設置第2壓胚；該第2壓胚係與上述摻有黏合劑之 磁性粉末相同之摻有黏合劑之磁性粉末、或者對與上述摻BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing an inductor having a structure in which a winding portion of a coil is embedded in a core, the magnetic core containing magnetic powder and a binder The material powder is obtained by hardening the compression molded person. [Prior Art] A method of manufacturing such an inductor is disclosed in the patent document 日本 (Japanese Patent No. 3108931), which is characterized in that "the method of manufacturing an inductor" is characterized in that it comprises the following steps: a magnetic powder containing a binder of a binder of a thermosetting resin bonded to a magnetic powder is subjected to pressure pre-forming to form a first preform; a coil having a terminal portion is provided on the molding die; and the above-mentioned coil is used as a reference a second indenter is disposed on the forming die on the opposite side of the first pressing embryo; the second indenter is the same as the magnetic powder doped with the binder, and the magnetic powder is doped with the binder, or
又，於專利文獻2(日本專利第367〇575號）中揭Moreover, it is disclosed in Patent Document 2 (Japanese Patent No. 367〇575)
其包含如下步驟：第】壓 緣材料之強磁性金屬粒子 線圈封入鐵粉心時，使用 147456.doc 201106392 組入有上内衝頭之上衝頭及組入有下内衝頭之下衝頭，於 上述下内衝頭上升至成形空間内之狀態下，將上述磁性粉 末填充於上述成形空間内之後，使包含上述上内衝頭之上 述上衝頭下降直至與上述磁性粉末接觸為止，之後使上述 上内衝頭與上述下内衝頭同步下降，其後使包含上述上内 衝頭之上述上衝頭進一步下降而進行壓縮成形，藉此形成 下部芯；線圏配置步驟’係於上述成形空間β，在上述下 β〜之上面载置上述線圏；線圈埋入步驟，係將上述磁性 籾末再-人填充至上述成形空間内，以便填埋上述線圈；及 第2壓縮成形步驟，係於上述下部芯與上述線圈積層之方 向上施加壓力，使其等壓縮成形」。 進而，於專利文獻3(曰本專利第3654254號）中揭示有 「-種線圈零件之製造方法，其具備外裝部形成步驟，係 將含有熱固性樹脂之黏合劑與磁性粉末於上述熱固性樹脂 未完全硬化之非加熱狀態下混合，對加壓成形為背面部具 有中腳部及外腳部之形狀之壓胚進行再加壓成形，以覆蓋 具有貫通孔之線圈部’同時進行加熱使上述熱固性樹脂完 全硬化，從而形成内包有上述線圈部之外裝部；使上述壓 胚之背面部為強硬度部’使中腳部及外腳部為弱硬度部， 亚且藉由上述壓胚之背面部支撐上述線圈部之上下表面， 使再加壓成形時之加壓力高於上述壓胚之加壓成形時之加 壓力’且使内包上述線圈部之上述外裝部之内包厚度尺寸 形成為小於上述線圈部之貫通孔的直徑，同時使上述外裝 部之上面部及下表面部之密度形成為大於上述外裝部之中 147456.doc 201106392 間部之密度」。 又，此種電感器於個人電腦等電子機器中之需求較高， 已有具有各種尺寸及特性者在銷售。為了於此種市場中臝 得銷售競爭’重要的是提供品質為同等以上且廉價之電感 器。 為提供此種電感器，工時及材料費用之降低不可或缺， 關於工時降低之對策可列舉：（1)使用1台成形裝置而於短 〇 日守間内進行所需之壓縮成形。另一方面，關於材料費用降 低之對策可列舉：（2)可使用廉價之圓線線圈（使用剖面圓 形之線材而形成之線圈，具有圓形之捲繞部及自其兩端抽 出之直線狀之2個抽出部者，參照圖3)作為線圈。 然而，專利文獻1及2所揭示之製造方法不適於採取上述 對策（2)，又，專利文獻3所揭示之製造方法並不適於採取 上述對策（1)及（2)之兩者。 即’專利文獻1所揭示之製造方法係如下者：使第2壓胚 〇 (摻有黏合劑之磁性粉末、或該摻有黏合劑之磁性粉末經 加壓預成形而成者）對接於第丨壓胚，實施加壓成形直至消 除第1壓胚及第2壓胚間之連接部分中之界面為止，使其等 一體化。因此，若使用上述圓線線圈作為線圈，於加壓成 '形時會將捲繞部向上方或下方壓縮，伴隨該壓縮，各抽出 部上易被施加使其上下位置及左右位置發生變動之應力。 即，特別是若使用利用低剛性之線材（例如直徑為〇 8 mm 以下之線材）而形成之圓線線圈，則各抽出部會因上述應 力而易於產生位置偏移、變形或龜裂等，且由於該等原因 147456.doc 201106392 而易於導致特性變化等之品質降低。 又專利文獻2所揭示之製造方法係如下者：於第丨壓縮 成形步驟所形成之下部芯的上面載置線圈之後，以填埋該 線圈之方式填充磁性粉末’並將其壓縮成形(第2壓縮成形 步驟）。因此，若使用上述圓線線圈作為線圈，於第2壓縮 成形時係將捲繞部向下方壓縮，伴隨該壓縮，各抽出部上 易被施加使其上下位置及左右位置發生變動之應力。即， 特別是若使用利用低剛性之線材（例如直徑為〇8聰以下 之線材）而形成之圓線線圈，則各抽出部會因上述應力而 易於產生位置偏移' 變形或龜裂等’ 1由於該等原因而易 於導致特性變化等之品質降低。 進而，專利文獻3所揭示之製造方法係預先準備經加壓 成形之2個壓胚’並對該等壓胚進行再力口壓成开)以便覆蓋 線圈。因此，為預先準備2個壓胚而需要2台以上之成形裝 置，與專利文獻1及2所揭示之製造方法相較，壓縮成形繁 雜且亦費時。而且’若使用上述圓線線圈作為線圈，則加 壓成形時係將捲繞部向上方及下方壓縮，伴隨該壓縮，各 抽出部上易被施加使其上下位置及左右位置發生變動之應 力。即’特別是若使用利用低剛性之線材（例如直徑為〇 8 mm以下之線材）而形成之圓線線圈，則各抽出部會因上述 應力而易於產生位置偏移、變形或龜裂等，且由於該等原 因而易於導致特性變化等之品質降低。 、 如此，〃由於專利文獻1〜3所揭示之製造方法均不適於採 取上述對策(2) ’故而使用廉價之圓線線圈作為線圈以實 147456.doc 201106392 電感器之低價化的做法極其困難。 [先前技術文獻] [專利文獻] [專利文獻1]曰本專利第3108931號 [專利文獻2]曰本專利第3670575號 [專利文獻3]日本專利第3654254號 【發明内容】 Ο ◎ [發明所欲解決之問題] 本發明之目的在於提供一種適於使用廉價之圓線線圈作 為線圈而實現電感器之低價化的電感器之製造方法。 [解決問題之技術手段] 為達成該目的，本發明之電感器之製造方法至少包含如 下步驟：使用含有磁性粉末及黏合劑之材料粉末、與具有 捲繞部及自§玄捲繞部之兩端抽出之同一高度之2個抽出部 之圓線線圈’而得埋設有該圓線線圈之捲繞部及各抽出部 之捲繞部側之一部分的最終壓縮體；於將材料粉末之粒子 密度設為未壓縮密度D1，且以滿足未壓縮密度中壓缩 密度D2<高壓縮密度D3<最終壓縮密度D4之關係之方式而 分別設定目標之中壓縮密度D2、高壓縮密度d3及最終壓 縮密度D4之數值或數值範圍時，上述步驟包含如下步驟. (S1)將未壓縮密度D1之材料粉末向下方壓縮成形，而开>成 一次壓縮體，該一次壓縮體係一體地具有具備可與圓線線 圈之捲繞部之下表面相向之高壓縮密度D3部分> 〈下壁、及 以包圍該下壁之方式而設置之中壓縮密度D2之周辟 、， θ 2，並且 147456.doc 201106392 具有藉由下壁與周壁而劃分之凹部；（S2)以捲繞部位於下 壁之间壓縮遂、度D3部分之上，且各抽出部位於中壓縮密度 D2之周壁之上之方式’將圓線線圈之捲繞部插入至一次壓 縮體之凹部内；（S3)將投入至一次壓縮體上及圓線線圈之 捲繞部之内側之材料粉末向下方壓縮成形，而形成除了具 有上述下壁及周壁以外，還一體地具有設置於周壁及線圈 上之中壓縮密度D2之上壁、及設置於圓線線圈之捲繞部之 内側之中壓縮密度D2之中心部的二次壓縮體；以及（S4)將 二次壓縮體向上方及下方壓縮成形，而形成最終壓縮密度 D 4之最終塵縮體。 根據該製造方法，於上述步驟之二次壓縮過程（步驟s3) 中，係於位於一次壓縮體之中壓縮密度〇2之周壁上之圓線 線圈之各抽出部之上側將材料粉末壓縮成中壓縮密度一 次壓縮體之周壁為中壓縮密度，並且此處所壓縮之$料粉 末係以沿剖面圓形之各抽出部之外側曲面而避開其等之方 式流動，故各抽出部不易被施加使其上下位置及左右位置 發生變動之應力。又，於上述步驟之最終壓縮過程（步驟 S4)中，係於圓線線圈之各抽出部之下側及上側將二次壓 縮體之中壓縮密度D2之周壁及上壁壓縮成最終壓縮密度 D4 ’該周壁及上壁同為中壓縮密度⑴，並且此處所壓縮 之周壁及上壁之粒子係以沿剖面圓形之各抽出部之外側曲 面而避開其等之方式流動’故各抽出部不易被施加使其上 下位置及左右位置發生變動之應力。 即，二次壓縮過程（步驟S3)中圓線線圈之各抽出部上不 147456.doc 201106392 易被施加使其上下位置及左右位置發生變動之應力，且最 終壓縮過程（步驟S4)中圓線線圈之各抽出部上亦不易被施 加使其上下位置及左右位置發生變動之應力，故即使使用 • 利用低剛性之線材（例如直徑為0.8 mm以下之線材）所形成 . 之圓線線圈之情形時，亦可抑制於上述步驟中圓線線圈之 各抽出部產生位置偏移、變形或龜裂等，並且亦可抑制由 於該等原因而導致之特性變化等之品質降低。即，可提供 0 一種使用廉價之圓線線圈作為線圈而實現電感器之低價 化、並且品質為先前者之同等以上之電感器。 [發明之效果] 根據本發明，可提供一種適於使用廉價之圓線線圈作為 線圈而實現電感器之低價化之電感器之製造方法。 本發明之上述目的及其以外之目的、構成特徵、及作用 效果，藉由以下說明及隨附圖式而可明瞭。 【實施方式】 〇 [第1實施形態] ▲圖1〜圖6係顯示本發明（電感器之製造方法實施形 態。该第1實施形態包含如下步驟： al.使用含有磁性粉末及黏合劑之材料粉末、與具有捲繞 部及自該捲繞部之兩端抽出之同一高度之2個抽出部之 圓線線圈，而獲得埋設有該圓線線圈之捲繞部及各抽 出部之捲繞部側之-部分之最終壓縮體的步驟； A對最終壓縮體進行硬化處理而獲得心之步驟； a3.對磁心進行清洗而去除無需物之步驟；及 147456.doc 201106392 a4_於磁心上形成端子之步驟。 <步驟al> 於上述步驟al中，如圖1(A)所示，使用具備下模1〇及上 模20之成形裝置。 下模10具有下内柱銷11、配置於下内柱銷11周圍之下内 套筒12、及配置於下内套筒12周圍之下外套筒13。下内柱 銷11之俯視輪廓係較下述圓線線圈CO之捲繞部COa之内徑 略小之圓形。又，下内套筒12之俯視輪廓係與下述最終壓 縮體CB3之俯視輪廓大略一致之矩形。進而，於下外套筒 13之上面形成有可插入下述圓線線圈c〇之各抽出部c〇b之 特定深度的細槽1 3 a。 另一方面，上模20具有上内柱銷21、配置於上内柱銷21 周圍之上内套同22、及配置於上内套筒21周圍之上外套筒 23。上内柱銷21之仰視輪廓係較下述圓線線圈c〇之捲繞 部COa之外徑略大之圓形。又，上内套筒22之仰視輪廓係 較下内套筒12之俯視輪廊略小之矩形。進而，上外套筒23 之下部係形成為可向下外套筒13之細槽丨3 a内插入之升》 狀。 於上述步驟al中，首先如圖1(A)所示，使下内柱銷11與 下内套筒12下降，並於因該下降而形成之高度模穴中 投入材料粉末MP。 材料粉末MP含有磁性粉末及塗佈於該磁性粉末之至少 部分表面之黏合劑。磁性粉末包含顯示強磁性之周知金 屬、例如高導磁合金（Fe-Ni合金）、超導磁合金（Fe_m_M。 147456.doc -10- 201106392 否金）鐵鋁矽合金（Fe-Si-Al合金）、肥粒鐵、Fe-Co合金、 A1 5 金、pe_Cr合金、Fe Si合金、合金、^、The method comprises the following steps: when the strong magnetic metal particle coil of the crimping material is sealed into the iron powder core, the 147456.doc 201106392 group is used with the upper inner punch and the lower punch and the lower inner punch. After the inner punch is lifted into the molding space, the magnetic powder is filled in the molding space, and then the upper punch including the upper inner punch is lowered until it comes into contact with the magnetic powder. And lowering the upper inner punch and the lower inner punch, and then lowering the upper punch including the upper inner punch to perform compression molding to form a lower core; the wire arrangement step is a molding space β on which the coil is placed on the lower surface β~; a coil embedding step of filling the magnetic matrix into the molding space to fill the coil; and a second compression molding step And applying pressure to the lower core and the coil laminated layer to be compression-molded. Further, a method for producing a coil component is disclosed in Patent Document 3 (Japanese Patent No. 3654254), which comprises an exterior portion forming step of bonding a thermosetting resin-containing binder and a magnetic powder to the thermosetting resin. The mixture is completely hardened and mixed in a non-heated state, and is subjected to re-press molding to press-form the preform having the shape of the middle leg portion and the outer leg portion on the back surface portion to cover the coil portion having the through hole and simultaneously heating to make the thermosetting property. The resin is completely cured to form an outer portion of the coil portion; the back portion of the preform is made of a strong portion; the middle portion and the outer portion are weak portions, and the back surface of the preform is The portion supports the upper and lower surfaces of the coil portion, and the pressing force at the time of re-press molding is higher than the pressing force at the time of press forming of the preform, and the inner thickness of the outer portion of the coil portion is formed to be smaller than The diameter of the through hole of the coil portion is such that the density of the upper surface portion and the lower surface portion of the exterior portion is formed to be larger than the outer portion 147456.doc 201106392 Ministry of density. " Moreover, such inductors are in high demand in electronic equipment such as personal computers, and are already available in various sizes and characteristics. In order to compete for sales in such a market, it is important to provide inductors of the same quality and cheaper. In order to provide such an inductor, the reduction in man-hours and material costs is indispensable, and measures for reducing the number of man-hours are as follows: (1) The required compression molding is performed in a short day and a day using one molding device. On the other hand, measures against the reduction in material cost include (2) an inexpensive round wire coil (a coil formed by using a circular wire having a circular cross section, a circular winding portion and a straight line drawn from both ends thereof) The two extraction parts of the shape are referred to as Fig. 3) as a coil. However, the manufacturing methods disclosed in Patent Documents 1 and 2 are not suitable for the above-described countermeasure (2), and the manufacturing method disclosed in Patent Document 3 is not suitable for taking both of the above measures (1) and (2). That is, the manufacturing method disclosed in Patent Document 1 is such that the second preform (the magnetic powder doped with the binder or the magnetic powder doped with the binder is preformed by pressurization) is attached to the first The embryo is pressed and subjected to press molding until the interface between the first bead and the second bead is removed, and the like is integrated. Therefore, when the above-mentioned round wire coil is used as the coil, when the press is formed into a shape, the winding portion is compressed upward or downward, and with the compression, each of the drawing portions is easily applied to change the vertical position and the left and right positions. stress. In other words, in particular, when a round wire coil formed of a low-rigidity wire (for example, a wire having a diameter of 〇8 mm or less) is used, each of the extracting portions is liable to cause positional displacement, deformation, cracking, or the like due to the stress. And for these reasons 147456.doc 201106392, it is easy to cause deterioration in quality such as characteristic changes. Further, the manufacturing method disclosed in Patent Document 2 is as follows: after the coil is placed on the upper surface of the lower core formed in the second compression forming step, the magnetic powder is filled in such a manner as to fill the coil, and compression molding is performed (second Compression forming step). Therefore, when the above-described round wire coil is used as the coil, the winding portion is compressed downward in the second compression molding, and the pressure is easily applied to the respective extraction portions so that the vertical position and the left and right positions are changed. In other words, in particular, when a round wire coil formed of a low-rigidity wire (for example, a wire having a diameter of 〇8 or less) is used, each of the extracting portions is liable to cause a positional shift, such as deformation or cracking, due to the stress. 1 For these reasons, it is easy to cause deterioration in quality such as characteristic changes. Further, in the manufacturing method disclosed in Patent Document 3, two preforms which are press-formed are prepared in advance and the pressure-embedding is further pressed to open the coil to cover the coil. Therefore, two or more molding apparatuses are required to prepare two blanks in advance, and the compression molding is complicated and time consuming as compared with the production methods disclosed in Patent Documents 1 and 2. Further, when the above-described round wire coil is used as the coil, the winding portion is compressed upward and downward during press forming, and the pressure is applied to each of the drawing portions so that the vertical position and the left and right positions are easily changed. In other words, in particular, when a round wire coil formed of a low-rigidity wire (for example, a wire having a diameter of 〇 8 mm or less) is used, each of the extracting portions is liable to cause positional displacement, deformation, cracking, or the like due to the stress. Further, due to these reasons, it is easy to cause deterioration in quality such as a change in characteristics. In this way, the manufacturing methods disclosed in Patent Documents 1 to 3 are not suitable for the above-mentioned countermeasures (2). Therefore, it is extremely difficult to use a cheap round wire coil as a coil to 147456.doc 201106392. . [PRIOR ART DOCUMENT] [Patent Document 1] Japanese Patent No. 3108931 [Patent Document 2] Japanese Patent No. 3670575 [Patent Document 3] Japanese Patent No. 3654254 [Summary of Invention] ◎ ◎ [Invention Office] Solution to Problem] An object of the present invention is to provide a method of manufacturing an inductor suitable for realizing a low cost of an inductor by using an inexpensive round wire coil as a coil. [Technical means for solving the problem] In order to attain the object, the method for manufacturing an inductor of the present invention comprises at least the steps of using a material powder containing a magnetic powder and a binder, and having a winding portion and a self-cut winding portion The round wire coil of the two extraction portions of the same height is extracted at the end, and the final compressed body of the winding portion of the round wire coil and the winding portion of each of the extraction portions is embedded; the particle density of the material powder is The uncompressed density D1 is set, and the compression density D2, the high compression density d3, and the final compression density D4 of the target are respectively set so as to satisfy the relationship of the compression density D2 < high compression density D3 < final compression density D4 in the uncompressed density. In the numerical value or numerical range, the above steps include the following steps. (S1) The material powder of the uncompressed density D1 is compression-molded downward, and the primary compression body is formed into a primary compression system, and the primary compression system integrally has a round wire The high compression density D3 portion of the lower surface of the winding portion of the coil is opposite to the lower wall, and the compression density D2 is provided in such a manner as to surround the lower wall. θ 2, and 147456.doc 201106392 has a recess divided by a lower wall and a peripheral wall; (S2) a portion where the winding portion is located between the lower wall and the degree D3 is compressed, and each of the extracting portions is located at a medium compression density D2 The method of inserting the winding portion of the round wire into the concave portion of the primary compression body; (S3) compressing the material powder injected into the primary compression body and the inner side of the winding portion of the round wire coil downward Formed to form, in addition to the lower wall and the peripheral wall, integrally formed with a compression density D2 disposed on the peripheral wall and the coil, and a compression density D2 disposed inside the winding portion of the round wire coil a secondary compression body at the center portion; and (S4) compression molding the secondary compression body upward and downward to form a final dust shrinkage body having a final compression density D 4 . According to the manufacturing method, in the secondary compression process (step s3) of the above step, the material powder is compressed into the upper side of each of the extraction portions of the round wire coil on the peripheral wall of the compression density 〇2 in the primary compression body. The compression density of the primary compression body has a medium compression density, and the material powder compressed here flows in such a manner as to avoid the outer surface of each of the extraction portions having a circular cross section, so that the respective extraction portions are not easily applied. The upper and lower positions and the left and right positions are subject to varying stresses. Further, in the final compression process (step S4) of the above step, the peripheral wall and the upper wall of the compression density D2 of the secondary compression body are compressed to the final compression density D4 on the lower side and the upper side of each of the extraction portions of the round wire coil. 'The circumferential wall and the upper wall are both medium compression density (1), and the particles of the peripheral wall and the upper wall compressed here are flowed so as to avoid the outer curved surface of each of the extracted portions of the circular cross section. It is difficult to apply stress that causes the vertical position and the left and right position to change. That is, in the secondary compression process (step S3), the respective extraction portions of the round wire coil are not 147456.doc 201106392, and the stresses that cause the upper and lower positions and the left and right positions to be changed are easily applied, and the round line in the final compression process (step S4) In the respective extraction portions of the coil, stresses that cause the vertical position and the left and right positions to be changed are not easily applied. Therefore, even if a low-rigidity wire (for example, a wire having a diameter of 0.8 mm or less) is used, the round wire coil is formed. In this case, it is possible to suppress positional displacement, deformation, cracking, and the like in each of the extraction portions of the round wire coil in the above-described steps, and it is also possible to suppress deterioration in quality such as a change in characteristics due to such factors. That is, it is possible to provide an inductor which uses an inexpensive round wire coil as a coil to realize a reduction in the cost of the inductor and which is equal to or higher than the former. [Effect of the Invention] According to the present invention, it is possible to provide a method of manufacturing an inductor which is suitable for realizing a low cost of an inductor by using an inexpensive round wire coil as a coil. The above object and other objects, features, and advantages of the invention will be apparent from the description and appended claims. [Embodiment] 第 [First Embodiment] ▲ Figs. 1 to 6 show an embodiment of the present invention (manufacturing method of an inductor). The first embodiment includes the following steps: al. using a material containing a magnetic powder and a binder a powder and a round wire coil having two winding portions at the same height as the winding portion and the both ends of the winding portion, thereby obtaining a winding portion in which the round wire coil is embedded and a winding portion of each of the drawing portions a side-part of the final compression body step; A step of hardening the final compression body to obtain a heart; a3. step of cleaning the core to remove unnecessary substances; and 147456.doc 201106392 a4_ forming a terminal on the core [Step a1] In the above step a1, as shown in Fig. 1(A), a molding apparatus including a lower mold 1 and an upper mold 20 is used. The lower mold 10 has a lower inner pin 11 and is disposed under The inner sleeve 12 is disposed around the inner pin 11 and the outer sleeve 13 disposed around the lower inner sleeve 12. The top inner pin 11 has a top profile which is higher than the winding portion COa of the round wire coil CO described below. The inner diameter is slightly smaller. In addition, the top inner sleeve 12 has a top profile The rectangular shape of the final compressed body CB3 is substantially uniform in plan view. Further, a fine groove 13 into which a specific depth of each of the drawing portions c〇b of the round wire coil c is inserted is formed on the lower outer sleeve 13 On the other hand, the upper mold 20 has an upper inner pin 21, an inner sleeve 22 disposed around the upper inner pin 21, and an outer sleeve 23 disposed around the upper inner sleeve 21. The bottom view of the pin 21 is slightly larger than the outer diameter of the winding portion COa of the round wire coil c. The upwardly looking contour of the upper inner sleeve 22 is slightly smaller than the plan view of the lower inner sleeve 12. Further, the lower portion of the upper outer sleeve 23 is formed into a shape that can be inserted into the narrow groove 3a of the outer sleeve 13. In the above step a1, first, as shown in Fig. 1(A) The lower inner pin 11 and the lower inner sleeve 12 are lowered, and the material powder MP is introduced into the high cavity formed by the lowering. The material powder MP contains magnetic powder and is applied to at least part of the surface of the magnetic powder. The magnetic powder contains a well-known metal exhibiting strong magnetism, such as a high magnetic alloy (Fe-Ni alloy), superconducting magnetic Gold (Fe_m_M. 147456.doc -10- 201106392 no gold) iron-aluminum-niobium alloy (Fe-Si-Al alloy), ferrite iron, Fe-Co alloy, A1 5 gold, pe_Cr alloy, Fe Si alloy, alloy, ^ ,
Ni或Cr等，其平均粒徑宜為5〜3〇 μ〇ι。黏合劑包含可熱硬 ' 周4标料、例如環氧樹脂、紛酸樹脂、或石夕氧樹脂 等。 繼而，如圖1(B)所示，使下内柱銷u及下内套筒12下降 至圖1 (A)中所投入之材料粉末Mp之上面低於下外套筒η 〇 之、’’田槽13a之底面的位置處為止，並且使下内套筒12進而 下降直至其上面與下内柱銷丨丨之上面之間隔變成高度“為 止。然後，使上内柱銷21下降至其下表面與下内套筒12之 上面之間隔變成南度h3為止，同時使上内套筒a下降至其 下表面與下内套筒12之上面之間隔變成高度h4為止。藉 此，將圖1(A)所投入之材料粉末Mp向下方壓縮而形成一 次壓縮體CB1。 如圖2所示，—次壓縮體CB1—體地具有仰視輪廓為圓 ◎ 形且馬度為h3之下壁CBla、以包圍下壁CBla之方式而設 置之仰視輪廓為矩形且高度為^^之周壁CBlb、及設置於 下壁CB1 a之下表面中央之仰視輪廓為圓形且高度為h2的凸 部CBlc ’並且具有藉由下壁CBla及周壁CBlb而形成之俯 視輪廓為圓形且高度為h4_h3的凹部CBld。凸部CBlc之外 徑較下述圓線線圈C〇之捲繞部c〇a之内徑略小。又，凹部 CBld之直徑Rcbl較下述圓線線圈c〇之捲繞部c〇a之外徑Ni or Cr or the like preferably has an average particle diameter of 5 to 3 Å μ〇. The adhesive contains a heat-hardened 'week 4 standard material such as an epoxy resin, an acid resin, or a stone oxide resin. Then, as shown in FIG. 1(B), the lower inner pin u and the lower inner sleeve 12 are lowered to the upper side of the material powder Mp input in FIG. 1(A) lower than the lower outer sleeve η 、' 'The position of the bottom surface of the field groove 13a, and the lower inner sleeve 12 is further lowered until the interval between the upper surface and the upper inner pin 变成 becomes a height. Then, the upper inner pin 21 is lowered to The distance between the lower surface and the upper surface of the lower inner sleeve 12 becomes the south degree h3, and the upper inner sleeve a is lowered until the interval between the lower surface thereof and the upper surface of the lower inner sleeve 12 becomes the height h4. The material powder Mp to be charged in 1(A) is compressed downward to form a primary compressed body CB1. As shown in Fig. 2, the secondary compressed body CB1 has a bottom view contour and a horse shape is h3 lower wall CBla a peripheral wall CB1b having a bottom view CB1 and a height of the bottom wall CB1, and a convex portion CBlc' having a rounded bottom view and a height h2 disposed at the center of the lower surface of the lower wall CB1 a. And having a circular shape and a height of h4_h3 formed by the lower wall CB1a and the peripheral wall CB1b. The outer diameter of the convex portion CBlc is slightly smaller than the inner diameter of the winding portion c〇a of the round wire coil C〇. Further, the diameter Rcb1 of the concave portion CBld is smaller than the winding portion c of the circular wire coil c〇 described below.外径a outer diameter
Rco略大’深度Dcbl與下述圓線線圈c〇之捲繞部c〇a之高 度Hco大略一致。 147456.doc 11 201106392 又’若將材料粉末MP之粒子密度設為未壓縮密度Dl， 且以滿足未壓縮密度D1 <中壓縮密度D2<高壓縮密度D3<最 終壓縮密度D4之關係之方式而分別設定目標之中壓縮密度 D2、高壓縮密度D3及最終壓縮密度〇4之數值或數值範 圍’則一次壓縮體CB1之下壁CB1 a之不與凸部CB1 c對向之 環狀部分（與下述圓線線圈C〇之捲繞部COa之下表面相向 之部分）之粒子密度為高壓縮密度D3，且周壁CBlb之粒子 密度、凸部CBlc之粒子密度及該凸部cBlc相對向之下壁 CB la之中央部分的粒子密度為中壓縮密度D2(參照陰影之 差異）。換言之，係以一次壓縮體CB 1之下壁CB 1 a之不與 凸部CB 1 c對向之環狀部分成為高壓縮密度，且周壁 CBlb、凸部CBlc及該凸部CBlc相對向之下壁CBl a之中央 部分成為中壓縮密度D2之方式，一邊控制壓縮量及壓力一 邊進行上述一次壓縮成形。 繼而’如圖1(C)所示使上内柱銷21及上内套筒22上升回 復’並且使下内套筒12及下内柱銷11上升直至一次壓縮體 CB1之周壁CBlb之上面達到與下外套筒13之細槽na之底 面大略相同高度之位置處為止。 接著，如圖1(D)所示，將圓線線圈c〇之捲繞部COa插入 至一次壓縮體CB1之凹部CBld内，同時將各抽出部c〇b插 入至下外套筒13之各細槽13a内。 如圖3(A)及圖3(B)所示，圓線線圈c〇係使用剖面圓形之 線材所形成之線圈，具有圓形之捲繞部COa、及自該捲繞 部COa之兩端抽出之直線狀之2個抽出部COb。線材係由含 147456.doc 201106392 有銅等之剖面圓形之金屬線，及含有聚醯胺、聚醯亞胺、 聚醯胺醯亞胺或胺基甲酸酯等之覆蓋該金屬線之外周面的 絕緣材料而構成，其直徑宜為0.1 mm~1.2 mm。 . 又’圓線線圈CO之捲繞部COa之外徑Rco較一次壓縮體 CB1之凹部CBld之直徑Rcbl略小，且該捲繞部COa之高度 Hco與一次壓縮體CB1之凹部CBld之深度Dcbl大略一致。 並且’各抽出部COb位於捲繞部COa之高度方向上端，且 0 以捲繞部COa為基準之各自之高度相同。 圖式中例示了捲繞數約為9、捲繞形態為3重3段之多 層、且捲繞方法為標準捲繞（將線材之一端側固定而將另 一側依序纏至芯上之捲繞方法）者作為圓線線圈C〇，但 亦可根據電感器之尺寸及特性而使用捲繞數及捲繞形態不 同者進行代替。又，亦可使用捲繞方法不同者、例如採用 將線材之一端側及另一端側之兩者依序纏至芯上之捲繞方 法等之捲繞方法者進行代替。 〇 即，圖1(D)中插入至一次壓縮體CB1之凹部CBld内之捲 繞部COa係位於下壁CBla之高壓縮密度D3之環狀部分之 上。又，插入至下外套筒13之各細槽13a内之各抽出部 COb係位於中壓縮密度D2之周壁CBlb之上。 繼而，如圖1 (E)所示，向形成於一次壓縮體CB丨上之高 度h5之模穴及圓線線圈c〇之捲繞部c〇a之内側投入與上述 相同之材料粉末MP。 接著’如® 1(F)所*，使上外套筒23下降而將其下部插 入至下外套筒13之各細槽⑴内，並藉由上外套㈣之下 147456.doc -13· 201106392 部内面而覆蓋該各細槽13a之内側開口之各抽出部Cob的上 側部分。此時，使上外套筒23之下端不接觸於各抽出部 COb。然後，使上内柱銷21與上内套筒22下降至兩者之下 表面與圓線線圈CO之上面之間隔變成高度h6為止。藉 此，將圖1(E)中所投入之材料粉末MP向下方進行壓縮而形 成二次壓縮體CB2。 如圖4(A)所示，二次壓縮體CB2—體地具有仰視輪廓為 圓形且高度為h3之下壁CB2a、以包圍下壁CB2a之方式而 設置之仰視輪廓為矩形且高度為h4之周壁CB2b、設置於 下壁CB2a之下表面中央之仰視輪廓為圓形且高度為h2之凸 部CB2c、設置於周壁CB2b及圓線線圈CO上之俯視輪廓為 矩形且高度為h6之上壁CB2d、及設置於圓線線圈CO之捲 繞部COa之内側之高度為Hco之中心部CB2e。 又，二次壓縮體CB2之下壁CB2a之不與凸部CB2c對向之 環狀部分之粒子密度為高壓縮密度D3，且周壁CB2b之粒 子密度、凸部CB2c之粒子密度、該凸部CB2c相對向之下 壁CB2a之中央部分之粒子密度、上壁CB2d之粒子密度及 中心部CB2e之粒子密度為中壓縮密度D2(參照陰影之差 異）。換言之，係以二次壓縮體CB2之下壁CB2a之不與凸 部CB2c對向之環狀部分成為高壓縮密度D3，且周壁 CB2b、凸部CB2c、該凸部CB2c相對向之下壁CB2a之中央 部分、上壁CB2d及中心部CB2e成為中壓縮密度D2之方 式，一邊控制壓縮量及壓力一邊進行上述二次壓縮成形。 於該二次壓縮過程中，係於圓線線圈CO之捲繞部COa之 147456.doc •14- 201106392 上側及内側將材料粉末MP壓縮成中壓縮密度〇2，但由於 圓線線圈CO之捲繞部COa之下側為高壓縮密度D3且外側 為中壓縮密度D2 ’故不易被施加向下方及外側壓縮該捲繞 部COa之應力。 又，於上述二次壓縮過程中，係於位於一次壓縮體Cb 1 之中壓縮密度D2之周壁CBlb上之圓線線圈c〇之各抽出部 COb之上側將材料粉末MP壓縮成中壓縮密度〇2，但由於 ◎ 一次壓縮體CB1之周壁CBlb為中壓縮密度D2，且此處所壓 縮之材料粉末MP係以沿剖面圓形之各抽出部c〇b之外側曲 面而避開其等之方式流動，故各抽出部C〇b上不易被施加 使其上下位置及左右位置發生變動之應力。 繼而’如圖1 (G)所示’使下内柱銷11上升至其上面與下 内套筒12之上面一致之後，使下内柱銷n及下内套筒12上 升至兩者之上面與圓線線圈C0之下表面之間隔達到高度 h7為止，同時使上内柱銷21及上内套筒22下降至兩者之下 Ο 表面與圓線線圈CO之上面之間隔達到高度h8為止。藉 此’將圖1(F)所示之二次壓縮體CB2向上方及下方壓縮， 並且將凸部CB2c相對向之下壁CB2a之中央部分藉由該凸 部CB2c而壓入至捲繞部c〇a之内側，從而形成最終壓縮體 CB3。 如圖4(B)所示，最終壓縮體CB3形成為高度約h7 + h8i 長方體形狀，圓線線圈(：〇之捲繞部c〇a及各抽出部C〇b之 捲繞部COa側之一部分係埋設於該最終壓縮體CB3内，且 各抽出部C〇b之剩餘部分係自該最終壓縮體cb3突出至外 147456.doc 15 201106392 部。 又，最終壓縮體CB3整體之粒子密度為最終壓縮密度 D4(參照陰影之差異）。換言之，以使最終壓縮體CB3整體 成為最終壓縮密度D4之方式，一邊控制壓縮量及壓力一邊 進行上述最終壓縮成形。 於該最終壓縮過程中，由於圓線線圈CO之捲繞部COa之 下側為高壓縮密度D3且上側為中壓縮密度D2，故該捲繞 部Coa藉由高壓縮密度D3之部位向上方被壓縮，其高度較 初始高度Hco略低，但由於此處之捲繞部COa之壓縮方向 為上方，故各抽出部COb上不易因該壓縮而被施加使其上 下位置及左右位置發生變動的應力。 又，於上述最終壓縮過程中，係於圓線線圈CO之各抽 出部COb之下側及上側將二次壓縮體CB2之中壓縮密度D2 之周壁CB2b及上壁CB2d壓縮成最終壓縮密度D3，但由於 該周壁CB2b及上壁CB2d同為中壓縮密度D2，且此處所壓 縮之周壁CB2b及上壁CB2d之粒子係以沿剖面圓形之各抽 出部COb之外側曲面而避開其等之方式流動，故各抽出部 COb上不易被施加使其上下位置及左右位置發生變動之應 力。 繼而，如圖1(H)所示，使上内柱銷21及上内套筒22上升 回復，並且使下内柱銷11及下内套筒12上升至可將最終壓 縮體CB3取出至外部之位置為止。然後，將最終壓縮體 CB3自成形裝置中取出。 此處，就上述中壓縮密度D2、高壓縮密度D3及最終壓 147456.doc -16- 201106392 縮密度D4進行說明。而且，中壓縮密度D2、高壓縮密度 D3及最終壓縮密度D4之測定例如係以如下方式進行：將 一次壓縮體CB1、二次壓縮體CB2及最終壓縮體CB3之相 符部位切出特定體積，測量其重量並算出重量/體積。 上述中壓縮密度D2與上述最終壓縮密度D4之關係宜為 0.70<(D2/D4)<0.85。若（D2/D4)為 0.70以下，貝丨J 將圓線線 圈CO之捲繞部COa插入至一次壓縮體CB1之凹部CB1 d内時 (參照圖1(D))，該一次壓縮體CB1之周壁CBlb容易崩塌。 另一方面，若（D2/D4)為0.85以上，則形成二次壓縮體CB2 時（參照圖1(F))，圓線線圈CO之抽出部COb容易變形。 又，上述高壓縮密度D3與上述最終壓縮密度D4之關係 宜為 0.90<(D3/D4)<0.97。若（D3/D4)為 0.90 以下，貝，J 形成 二次壓縮體CB2時（參照圖1(F))，易於圓線線圈CO之捲繞 部COa產生潛沒（subduction)而導致抽出部COb變形。另一 方面，若（D3/D4)為0.97以上，則形成最終壓縮體CB3時 (參照圖1(G))，二次壓縮體CB2之高壓縮密度D3部分難以 達到最終壓縮密度D4。 <步驟a2> 於上述步驟a2中，實施將自成形裝置取出之最終壓縮體 CB3加熱至特定溫度、即加熱至材料粉末MP所含之黏合劑 硬化之溫度的處理，而獲得如圖5(A)及圖5(B)所示之磁心 PC。 如圖5(A)所示，於磁心PC之上面，與上内柱鎖21之仰視 輪廓相當之圓形之痕跡PCa作為成形痕跡而殘留。又，如 147456.doc -17- 201106392 圖5(B)所示，於磁心PC之下表面，與下内柱銷丨丨之俯視輪 廓相當之圓形之痕跡PCb作為成形痕跡而殘留。 <步驟a3> 於上述步驟a3中，對上述步驟a2所獲得之磁心pc實施超 音波清洗等之清洗，而自磁心PC之表面去除無需物、例如 附著於表面之多餘之材料粉末MP等。 〈步驟a4> 於上述步驟a4中，將各抽出部c〇b之突出部分以其前端 迴繞至磁心PC之下表面之方式彎折，去除迴繞部分之絕緣 材料而使金屬線露出。然後，如圖6所示’將仰視輪廓成 矩形之2個端子TE以與露出之金屬線電性導通之方式而形 成於磁心PC之下表面。端子TE之形成可採用使用熱固性 树脂貼附金屬製之端子板之方法、或將電極漿料塗佈成矩 形後焙燒之方法等。 根據上述第1實施形態，於上述步驟&1之二次壓縮過程 中圓線線圈CO之各抽出部COb上不易被施加使其上下位置 及左右位置發生變動之應力，且於最終壓縮過程中圓線線 圈CO之各抽出部COb上亦不易被施加使其上下位置及左右 位置發生憂動的應力，故即便於使用利用低剛性之線材 (例如直徑為0.8 mm以下之線材）所形成之圓線線圈c〇之情 形時，亦可抑制於上述步驟al中圓線線圈c〇之各抽出部 產生位置偏移、變形或龜裂等，並且亦可抑制由於該等原 因而導致之特性變化等之品質降低。即，可提供一種使用 廉價之圓線線圈作為線圈而實現電感器之低價化，並且品 147456.doc •18· 201106392 質為先前者同等以上之電感器。 又’根據上述第1實施形態’於上述步驟al之最終壓縮 過程中可將圓線線圈C0之捲繞部c〇a向上方壓縮，而使其 • 冑度較初始高度Hco略低，故即便於構成捲繞部⑽之線 ㈣存在上下方向之間隙之情形時，亦可消除該間隙而有 助於特性提高。 [第2實施形態] 〇 &圖7〜圖9係顯示本發明（電感器之製造方法）之第2實施形 態。该第2實施形態包含如下步驟： bi·使用含有磁性粉末及黏合劑之材料粉末、與具有捲繞 部及自該捲繞部之兩端抽出之同一高度之2個抽出部之 圓線線圈，而獲得埋設有該圓線線圈之捲繞部及各抽 出部之捲繞部側一部分之最終壓縮體的步驟； M·對最終壓縮體實施硬化處理而獲得磁心之步驟’· b3.對磁心進行清洗而去除無需物之步驟；及 〇 b4·於磁心上形成端子之步驟。 步驟b2〜b4係與第1實施形態之步驟a2〜a4相同，故此處 僅對步驟b 1進行說明。 <步驟bl> 如圖7(A)所示，於上述步驟bl中係使用具備下模％及上 模40之成型裝置。 下模30具有下内柱鎖31、及配置於其周圍之下套筒 下内柱銷3 1之俯視輪廓係與下述最終壓縮體丨3之俯視 輪廓大略一致之矩形。又，於下套筒32之上面形成有可插 147456.doc -19- 201106392 入如圖3所不之圓線線圈co之各抽出部COb之特定深度之 細槽3 2 a。 另方面，上模40具有上内柱銷41、配置於上内柱銷41 周圍之上内套筒42、及配置於上内套筒42周圍之上外套筒 43。上模40之構成及形狀等與第1實施形態之上模20相 同。 於上述步驟bi中，首先如圖7(A)所示，使下内柱銷31下 降，並於藉由該下降所形成之高度hl (相當於圖丨（&)之高度 h 1)之模八中技入與苐1實施形態相同之材料粉末Mp。 繼而，如圖7(B)所示，使下内柱銷3丨下降至圖7(A)中投 入之材料粉末MP之上面較下套筒32之細槽32a之底面低之 位置為止。然後，使上内柱銷41下降至其下表面與下内柱 銷3 1之上面之間隔達到高度h3 (相當於圖1 (b)之高度h3)為 止’同時使上内套筒42下降至其下表面與下内柱銷31之上 面之間隔達到高度h4(相當於圖1(B)之高度h4)為止。藉 此，將圖7(A)中投入之材料粉末mp向下方壓縮而形成一 次壓縮體CB11。 如圖8所示，一次壓縮體CB11—體地具有仰視輪廓為圓 形且高度為h3之下壁CB 11a、及以包圍下壁CB 11a之方式 而設置之仰視輪廓為矩形且高度為h4的周壁CBllb，同時 具有由下壁CB 11 a與周壁CB lib所形成之俯視輪廓為圓形 且高度為h4-h3之凹部CBllc。該凹部CB1 lc之直徑Rcbl 1 較圖3所示之圓線線圈CO之捲繞部COa的外徑Rco略大， 又，深度Dcbll與圖3所示圓線線圈CO之捲繞部COa之高度 147456.doc •20- 201106392Rco is slightly larger, and the depth Dcbl substantially coincides with the height Hco of the winding portion c〇a of the round wire coil c〇 described below. 147456.doc 11 201106392 Further, if the particle density of the material powder MP is set to the uncompressed density D1, and the relationship between the uncompressed density D1 <the medium compression density D2<the high compression density D3<the final compression density D4 is satisfied, The numerical value or the numerical range of the compression density D2, the high compression density D3, and the final compression density 〇4 among the targets is respectively set, and the annular portion of the lower wall CB1 a of the primary compression body CB1 is not opposed to the convex portion CB1 c (and The particle density of the surface of the round wire coil C〇 below the winding portion COa is a high compression density D3, and the particle density of the peripheral wall CBlb, the particle density of the convex portion CBlc, and the convex portion cBlc are relatively downward. The particle density at the central portion of the wall CB la is the medium compression density D2 (refer to the difference in shadow). In other words, the annular portion of the lower wall CB 1 a of the primary compressed body CB 1 that does not face the convex portion CB 1 c has a high compression density, and the peripheral wall CB1b, the convex portion CBlc, and the convex portion CBlc are relatively downward. The central portion of the wall CB11 has a medium compression density D2, and the above-described primary compression molding is performed while controlling the amount of compression and pressure. Then, as shown in FIG. 1(C), the upper inner pin 21 and the upper inner sleeve 22 are raised back and the lower inner sleeve 12 and the lower inner pin 11 are raised up to the upper surface of the peripheral wall CB1 of the primary compressed body CB1. The position is substantially the same height as the bottom surface of the narrow groove na of the lower outer sleeve 13. Next, as shown in Fig. 1(D), the winding portion COa of the round wire coil c is inserted into the concave portion CB1 of the primary compression body CB1, and each of the extraction portions c〇b is inserted into each of the lower outer sleeves 13. Inside the narrow groove 13a. As shown in FIG. 3(A) and FIG. 3(B), the round wire coil c is a coil formed by a wire having a circular cross section, and has a circular winding portion COa and two winding portions COa. The two extracted portions COb are drawn in a straight line at the end. The wire is made of a wire having a circular cross section of copper, etc., containing 147456.doc 201106392, and covering the outer circumference of the metal wire containing polyamine, polyimine, polyamidimide or urethane. It is made of insulating material and has a diameter of 0.1 mm to 1.2 mm. Further, the outer diameter Rco of the winding portion COa of the round wire coil CO is slightly smaller than the diameter Rcbl of the concave portion CBld of the primary compression body CB1, and the height Hco of the winding portion COa and the depth Ccld of the concave portion CB1 of the primary compressed body CB1 are Dcbl Slightly consistent. Further, each of the extraction portions COb is located at the upper end in the height direction of the winding portion COa, and 0 has the same height based on the winding portion COa. The figure exemplifies a multilayer having a number of windings of about 9, a winding form of three by three, and a winding method of standard winding (fixing one end side of the wire and winding the other side onto the core in order) Although the winding method is used as the round wire coil C〇, it may be replaced by the number of windings and the winding form depending on the size and characteristics of the inductor. Further, a winding method in which the winding method is different, for example, a winding method in which both the end side and the other end side of the wire are sequentially wound around the core may be used instead. That is, the winding portion COa inserted into the concave portion CB1 of the primary compressed body CB1 in Fig. 1(D) is located on the annular portion of the high compression density D3 of the lower wall CBla. Further, the respective extraction portions COb inserted into the respective narrow grooves 13a of the lower outer sleeve 13 are located above the peripheral wall CB1b of the medium compression density D2. Then, as shown in Fig. 1(E), the same material powder MP as described above is introduced to the inside of the winding portion c〇a of the cavity h5 and the round wire coil c〇 formed on the primary compressed body CB. Then, as in the case of ® 1 (F), the upper outer sleeve 23 is lowered and the lower portion thereof is inserted into each of the narrow grooves (1) of the lower outer sleeve 13, and by the upper outer casing (four) 147456.doc -13· The inner surface of the inner surface of each of the thin grooves 13a covers the upper portion of the inner peripheral opening of the thin groove 13a. At this time, the lower end of the upper outer sleeve 23 is not in contact with the respective extraction portions COb. Then, the upper inner pin 21 and the upper inner sleeve 22 are lowered until the interval between the lower surface and the upper surface of the round wire coil CO becomes the height h6. Thereby, the material powder MP charged in Fig. 1(E) is compressed downward to form a secondary compressed body CB2. As shown in FIG. 4(A), the secondary compression body CB2 has a bottom view CB2a having a bottom view and a lower wall CB2a, and a bottom view having a height of h4. The peripheral wall CB2b, the convex portion CB2c having a circular shape and having a height h2 disposed at the center of the lower surface of the lower wall CB2a, and the top surface of the peripheral wall CB2b and the circular coil CO are rectangular in shape and have a height of h6. The height of CB2d and the inner side of the winding portion COa of the round wire coil CO is the center portion CB2e of Hco. Further, the particle density of the annular portion of the lower wall CB2a of the secondary compressed body CB2 which is not opposed to the convex portion CB2c is a high compression density D3, and the particle density of the peripheral wall CB2b, the particle density of the convex portion CB2c, and the convex portion CB2c The particle density of the central portion of the lower wall CB2a, the particle density of the upper wall CB2d, and the particle density of the central portion CB2e are the medium compression density D2 (refer to the difference in shadow). In other words, the annular portion of the lower wall CB2a of the secondary compressed body CB2 that does not face the convex portion CB2c has a high compression density D3, and the peripheral wall CB2b, the convex portion CB2c, and the convex portion CB2c are opposed to the lower wall CB2a. The central portion, the upper wall CB2d, and the central portion CB2e have a medium compression density D2, and the secondary compression molding is performed while controlling the amount of compression and pressure. In the secondary compression process, the material powder MP is compressed into a medium compression density 〇2 on the upper side and the inner side of the winding portion COa of the round wire coil CO 147456.doc •14-201106392, but due to the volume of the round wire coil CO The lower side of the winding portion COa has a high compression density D3 and the outer side has a medium compression density D2', so that the stress of compressing the winding portion COa downward and outward is not easily applied. Further, in the above secondary compression process, the material powder MP is compressed to a medium compression density on the upper side of each of the extraction portions COb of the round wire coil c of the peripheral wall CB1b of the compression density D2 in the primary compression body Cb1. 2. However, since the peripheral wall CBlb of the primary compressed body CB1 has a medium compression density D2, and the material powder MP compressed here is flowed away from the outer curved surface of each of the extracted portions c〇b of the circular cross section. Therefore, the stress on the upper and lower positions and the left and right positions is not easily applied to each of the extraction portions C〇b. Then, as shown in FIG. 1(G), after the lower inner pin 11 is raised to the upper surface thereof and the upper inner sleeve 12 is aligned, the lower inner pin n and the lower inner sleeve 12 are raised to the upper side. The distance from the lower surface of the round wire coil C0 reaches the height h7, and the upper inner pin 21 and the upper inner sleeve 22 are lowered to the lower side, and the distance between the upper surface and the upper surface of the round wire coil CO reaches the height h8. Thereby, the secondary compression body CB2 shown in FIG. 1(F) is compressed upward and downward, and the central portion of the convex portion CB2c facing the lower wall CB2a is pressed into the winding portion by the convex portion CB2c. The inside of c〇a forms the final compressed body CB3. As shown in Fig. 4(B), the final compressed body CB3 is formed into a rectangular parallelepiped shape having a height of about h7 + h8i, and the round wire coil (the winding portion c〇a of the crucible and the winding portion COa side of each of the extraction portions C〇b) A portion is embedded in the final compressed body CB3, and the remaining portion of each of the extracted portions C〇b protrudes from the final compressed body cb3 to the outer portion 147456.doc 15 201106392. Further, the final particle density of the entire compressed body CB3 is final. The compression density D4 (refer to the difference in the shadow). In other words, the final compression molding is performed while controlling the amount of compression and pressure so that the entire final compression body CB3 becomes the final compression density D4. In the final compression process, the round line The lower side of the winding portion COa of the coil CO has a high compression density D3 and the upper side has a medium compression density D2. Therefore, the winding portion Coa is compressed upward by a portion having a high compression density D3, and its height is slightly lower than the initial height Hco. However, since the compression direction of the winding portion COa is upward, the stress is not easily applied to the upper and lower positions and the left and right positions due to the compression in each of the extraction portions COb. In the lower side and the upper side of each of the extraction portions COb of the round wire coil CO, the peripheral wall CB2b and the upper wall CB2d of the compression density D2 of the secondary compression body CB2 are compressed into a final compression density D3, but due to the peripheral wall CB2b and the upper portion The wall CB2d has the medium compression density D2, and the particles of the peripheral wall CB2b and the upper wall CB2d compressed here are flowed so as to avoid the outer curved surface of each of the extracted portions COb having a circular cross section, so that the respective extracting portions COb It is difficult to apply a stress that causes the upper and lower positions and the left and right positions to change. Then, as shown in Fig. 1(H), the upper inner pin 21 and the upper inner sleeve 22 are raised and returned, and the lower inner pin 11 and the lower inner pin 11 are The lower inner sleeve 12 is raised to a position where the final compressed body CB3 can be taken out to the outside. Then, the final compressed body CB3 is taken out from the forming device. Here, the above-mentioned medium compression density D2, high compression density D3, and final pressure are obtained. 147456.doc -16- 201106392 The density D4 is described. Further, the measurement of the medium compression density D2, the high compression density D3, and the final compression density D4 is performed, for example, by performing the primary compression body CB1, the secondary compression body CB2, and Final compression The specific portion of CB3 is cut out to a specific volume, and the weight is measured to calculate the weight/volume. The relationship between the above-mentioned compression density D2 and the above final compression density D4 is preferably 0.70 lt; (D2/D4) < 0.85. If (D2/D4 When it is 0.70 or less, when the winding portion COa of the round wire coil CO is inserted into the concave portion CB1d of the primary compressed body CB1 (see FIG. 1(D)), the peripheral wall CB1b of the primary compressed body CB1 is liable to collapse. On the other hand, when (D2/D4) is 0.85 or more, when the secondary compressed body CB2 is formed (see FIG. 1(F)), the extraction portion COb of the round wire coil CO is easily deformed. Further, the relationship between the high compression density D3 and the final compression density D4 is preferably 0.90 lt; (D3/D4) < 0.97. When (D3/D4) is 0.90 or less, when J and J form the secondary compact CB2 (see Fig. 1(F)), the winding portion COa of the round wire coil CO is liable to be subduction, resulting in the extraction portion COb. Deformation. On the other hand, when (D3/D4) is 0.97 or more, when the final compressed body CB3 is formed (see Fig. 1(G)), it is difficult for the high compression density D3 portion of the secondary compressed body CB2 to reach the final compression density D4. <Step a2> In the above step a2, a process of heating the final compressed body CB3 taken out from the forming apparatus to a specific temperature, that is, heating to a temperature at which the binder contained in the material powder MP is hardened is performed, and as shown in Fig. 5 ( A) and the core PC shown in Fig. 5(B). As shown in Fig. 5(A), on the upper surface of the core PC, a circular mark PCa corresponding to the bottom view of the upper inner column lock 21 remains as a forming mark. Further, as shown in Fig. 5(B) of 147456.doc -17-201106392, on the lower surface of the core PC, a circular mark PCb corresponding to the plan view of the lower inner pin is retained as a forming mark. <Step a3> In the above-described step a3, the magnetic core pc obtained in the above step a2 is subjected to cleaning by ultrasonic cleaning or the like, and unnecessary substances such as the material powder MP attached to the surface, and the like are removed from the surface of the core PC. <Step a4> In the above step a4, the protruding portion of each of the extraction portions c〇b is bent so that the front end thereof is wound around the lower surface of the core PC, and the insulating material of the rewinding portion is removed to expose the metal wire. Then, as shown in Fig. 6, the two terminals TE having a rectangular shape in a bottom view are electrically connected to the exposed metal wires to form a lower surface of the core PC. The terminal TE may be formed by attaching a metal terminal plate using a thermosetting resin or a method of applying an electrode paste to a rectangular shape and then baking. According to the first embodiment, in the secondary compression process of the above step & 1, the stresses of the upper and lower positions and the left and right positions of the round wire coil CO are hardly applied, and the final compression process is performed. In each of the extraction portions COb of the round wire coil CO, it is difficult to apply a stress that causes the upper and lower positions and the left and right positions to wobble. Therefore, even a wire formed of a low rigidity wire (for example, a wire having a diameter of 0.8 mm or less) is used. In the case of the wire coil c〇, it is possible to suppress positional displacement, deformation, cracking, and the like of each of the extraction portions of the round wire coil c in the above-described step a1, and also to suppress variations in characteristics due to such factors, and the like. The quality is reduced. That is, it is possible to provide a low-cost inductor using a cheap round wire coil as a coil, and an inductor of the same or higher as the former. Further, in the final compression process of the above-described step a1, the winding portion c〇a of the round wire coil C0 can be compressed upward, and the twist is slightly lower than the initial height Hco, so that even When the line (four) constituting the winding portion (10) has a gap in the vertical direction, the gap can be eliminated to contribute to the improvement in characteristics. [Second Embodiment] Fig. 7 to Fig. 9 show a second embodiment of the present invention (manufacturing method of an inductor). The second embodiment includes the following steps: bi. using a material powder containing a magnetic powder and a binder, and a round wire coil having two winding portions at the same height as the winding portion and the both ends of the winding portion. And a step of obtaining a final compressed body in which the winding portion of the round wire coil and a portion of the winding portion of each of the drawing portions are embedded; M. a step of obtaining a core by hardening the final compressed body'. b3. a step of cleaning to remove unnecessary materials; and 〇b4· forming a terminal on the core. Since steps b2 to b4 are the same as steps a2 to a4 of the first embodiment, only step b 1 will be described here. <Step bl> As shown in Fig. 7(A), a molding apparatus having the lower mold % and the upper mold 40 is used in the above step bl. The lower mold 30 has a lower inner column lock 31 and a rectangular shape in which the outer contour of the lower inner pin 3 1 disposed under the sleeve is substantially identical to the plan view of the final compression body 下述 3 described below. Further, on the lower sleeve 32, a fine groove 3 2 a into which a specific depth of each of the extraction portions COb of the round wire coil co as shown in Fig. 3 can be inserted is formed by inserting 147456.doc -19 - 201106392. On the other hand, the upper mold 40 has an upper inner pin 41, an inner sleeve 42 disposed around the upper inner pin 41, and an outer sleeve 43 disposed around the upper inner sleeve 42. The configuration, shape, and the like of the upper mold 40 are the same as those of the upper mold 20 of the first embodiment. In the above step bi, first, as shown in FIG. 7(A), the lower inner pin 31 is lowered, and the height hl formed by the lowering (corresponding to the height h 1 of the image) In the eighth embodiment, the material powder Mp is the same as that of the first embodiment. Then, as shown in Fig. 7(B), the lower inner pin 3 is lowered until the upper surface of the material powder MP to be fed in Fig. 7(A) is lower than the bottom surface of the narrow groove 32a of the lower sleeve 32. Then, the upper inner pin 41 is lowered until the interval between the lower surface thereof and the upper surface of the lower inner pin 3 1 reaches the height h3 (corresponding to the height h3 of FIG. 1(b)) while the upper inner sleeve 42 is lowered to The distance between the lower surface and the upper surface of the lower inner pin 31 reaches a height h4 (corresponding to the height h4 of Fig. 1(B)). As a result, the material powder mp to be charged in Fig. 7(A) is compressed downward to form a primary compressed body CB11. As shown in FIG. 8, the primary compression body CB11 has a bottom view CB 11a having a bottom view and a height h3, and a bottom view having a bottom view CB 11a and a height of h4. The peripheral wall CB11b has a concave portion CBllc formed by the lower wall CB 11 a and the peripheral wall CB lib and having a circular shape and a height of h4 - h3. The diameter Rcbl 1 of the concave portion CB1 lc is slightly larger than the outer diameter Rco of the winding portion COa of the round wire coil CO shown in Fig. 3, and the depth Dcb11 is the height of the winding portion COa of the round wire coil CO shown in Fig. 3. 147456.doc •20- 201106392
Hco大略一致。 又’與第1實施形態同樣地’若將所投入之材料粉末MP 之粒子密度設為未壓縮密度D1，且以滿足未壓縮密度di< 中壓縮密度D2<高壓縮密度D3<最終壓縮密度D4之關係之 方式而分別設定目標之中壓縮密度D2、高壓縮密度D3及 最終壓縮密度D4之數值或數值範圍，則一次壓縮體cb 11 之下壁CB11 a之粒子密度為高壓縮密度D3，且周壁CB lib 0 之粒子密度為中壓縮密度D2(參照陰影之差異）。換言之， 以使一次壓縮體CB11之下壁CBlla成為高壓縮密度D3，且 周壁CBllb成為中壓縮密度D2之方式，一邊控制壓縮量及 壓力一邊進行上述一次壓縮成形。 繼而’如圖7(C)所示，將上内柱銷41及上内套筒42上升 回復’並且使下内柱銷3 1上升至一次壓縮體CB 11之周壁 CBllb之上面達到與下套筒32之細槽32a之底面大略相同高 度的位置為止。 〇 接著’如圖7(D)所示，將圖3所示之圓線線圈CO之捲繞 部C〇a插入至一次壓縮體CB11之凹部CBllc内，同時將各 抽出部COb插入至下套筒32之各細槽32a内。 即’圖7(D)中插入至一次壓縮體CB!丨之凹部cb 11 c内之 捲繞部COa係位於高壓縮密度之下壁CBlla上。又，插 入至下套筒32之各細槽32a内之各抽出部c〇b係位於中壓 縮密度D2之周壁CBllb上。 繼而’如圖7(E)所示’向一次壓縮體CB11上所形成之高 度h5(相當於圖ι(Ε)之高度h5)之模穴及圓線線圈c〇之捲繞 147456.doc -21 - 201106392 部COa之内側投入與上述相同之材料粉末河卩。 然後’如圖7(F)所示，使上外套筒43下降而將其下部插 入至下套筒32之各細槽32a内，並藉由上外套筒43之下部 内面來覆蓋該細槽32a之内側開口之各抽出部c〇b的上側部 分。此時，使上外套筒43之下端不接觸於各抽出部c〇b。 然後，使上内柱銷41及上内套筒42下降至兩者之下表面與 圓線線圈CO之上面之間隔達到高度h6(相當於圖1(F)之高 度h6)為止。藉此，將圖7(E)中投入之材料粉末Mp向下方 壓縮而形成二次壓縮體CB 12。 如圖9(A)所示，二次壓縮體CB12__體地具有仰視輪廓為 圓形且高度為h3之下壁CB12a、以包圍下壁CB12a之方式 而δ免置之仰視輪廓為矩形且高度為h4之周壁cB12b、設置 於周壁CB 12b及圓線線圈CO上之俯視輪廓為矩形且高度為 匕6之上壁CB 12c、及設置於圓線線圈c〇之捲繞部c〇a之内 側之高度為Hco的中心部CB 12d。 又’二次壓縮體CB 12之下壁CB 12a之粒子密度為高壓縮 密度D3 ’且周壁CB 12b之粒子密度、上壁CB 12c之粒子密 度及中心部CB12d之粒子密度為中壓縮密度d2(參照陰影 之差異）。換言之’以使二次壓縮體CB12之下壁CB12a成 為咼壓縮密度D3，且周壁CB 12b、上壁CB 12c及中心部 CB12d成為中壓縮密度D2之方式，一邊控制壓縮量及壓力 一邊進行上述二次壓縮成形。 於該二次壓縮過程中，係於圓線線圈C〇之捲繞部COa之 上側及内侧將材料粉末MP壓縮成中壓縮密度D2，但由於 I47456.doc -22- 201106392 圓線線圈CO之捲繞部COa之下側為高壓縮密度D3且外側 為中壓縮密度D2，故不易被施加向下方及外側壓縮該捲繞 部COa之應力。 又，於上述二次壓縮過程中，係於位於一次壓縮體 CB11之中壓縮密度D2之周壁CB1 lb上之圓線線圈c〇之各 抽出部COb的上側將材料粉末mp壓縮成中壓縮密度D2， 但由於一次壓縮體CB11之周壁CBllb為中壓縮密度D2，並 Q 且此處所壓縮之材料粉末MP係以沿剖面圓形之各抽出部 COb之外側曲面而避開其等之方式流動，故各抽出部c〇b 上不易被施加使其上下位置及左右位置發生變動之應力。 繼而，如圖7(G)所示，使下内柱銷31上升至其上面與圓 線線圈CO之下表面之間隔達到高度h7(相當於圖RG)之高 度h7)為止，同時使上内柱銷41與上内套筒42下降至兩者 之下表面與圓線線圈co之上面之間隔達到高度h8(相當於 圖1(G)之高度h8)為止。藉此，將圖7(F)所示之二次壓縮體 〇 CB12向上方及下方壓縮而形成最終壓縮體CBi3〇 如圖9(B)所示，最終壓縮體cm3係形成為高度約…+以 之長方體形狀，圓線線圈CO之捲繞部c〇a及各抽出部c〇b 之捲繞部COa側之一部分係埋設於該最終壓縮體CBn内， 且各抽出部cob之剩餘部分自該最終壓縮體CB13突出至外 部。 又，最終壓縮體CB13整體之粒子密度為最終壓縮密度 D4(參照陰影之差異）。換言之，以使最終壓縮體an之整 體成為最終壓縮密度D4之方式…邊控制壓縮量及壓力一 147456.doc •23· 201106392 邊進行上述最終壓縮成形。 於該最終壓縮過程中，由於圓線線圈CO之捲繞部COa之 下側為高壓縮密度D3且上側為中壓縮密度D2，故該捲繞 部Coa藉由高壓縮密度D3之部位向上方被壓縮，其高度較 初始高度Hco略低，但此處之捲繞部COa之壓縮方向為上 方，故各抽出部COb上不易因該壓縮而被施加使其上下位 置及左右位置發生變動之應力。 又，於上述壓縮過程中，係於圓線線圈CO之各抽出部 COb之下側及上側將二次壓縮體CB12之中壓縮密度02之 周壁CB 12b及上壁CB 12c壓縮成最終壓縮密度D3，但由於 該周壁CB 12b及上壁CB 12c同為中壓縮密度D2，並且此處 所壓縮之周壁CB 12b及上壁CB 12c之粒子係以沿剖面圓形 之各抽出部COb之外側曲面而避開其等之方式流動，故各 抽出部COb上不易被施加使其上下位置及左右位置發生變 動之應力。 繼而，如圖7(H)所示，使上内柱銷41及上内套筒42上升 回復，並且使下内柱銷31上升至將最終壓縮體CB13取出 至外部之位置為止。然後，將最終壓縮體CB 13自成形裝 置中取出。 而且，由於上述步驟bl中所使用之下模3〇中並無如第i 實施形態之下模10之下内柱銷u，故上述步驟b3f所形成 之磁心之下表面並未殘留如圖5(B)所示之圓形之痕跡 PCb。 此處’就上述中壓縮密度D2、高壓縮密度出及最終壓 147456.doc -24- 201106392 縮密度D4加以說明《而且，中壓縮密度〇2、高壓縮密度 D3及最終壓縮密度〇4之測定例如係以如下方式進行·將 一次壓縮體CB1、二次壓縮體CB2及最終壓縮體cB3之相 - 符部位切出特定之體積，測量其重量並算出重量/體積。 上述中壓縮密度D2與上述最終壓縮密度D4之關係宜為 〇.70<(D2/D4)<0.85。若（D2/D4)為 〇.70以下，則將圓線線 圈CO之捲繞部c〇a插入至一次壓縮體CB11之凹部CBl lc内 0 時（參照圖7(D))，該一次壓縮體CB11之周壁CBllb容易崩 塌。另一方面，若（D2/D4)為0.85以上，則形成二次壓縮體 CB12時（參照圖7(F)) ’圓線線圈CO之抽出部COb容易變 形。 又’上述高壓縮密度D3與上述最終壓縮密度D4之關係 宜為0.90<(〇3/04)<0.97。若（03/04)為0.90以下，則形成 二次壓縮體CB 12時（參照圖7(F))，易於圓線線圈CO之捲繞 部COa上產生潛沒而導致抽出部c〇b變形。另一方面，若 〇 (D3/D4)為0.97以上，則形成最終壓縮體CB13時（參照圖 7(G)) ’二次壓縮體CB12之高壓縮密度D3部分難以達到最 終壓縮密度D4。 根據上述第2實施形態，於上述步驟b 1之二次壓縮過程 中圓線線圈C0之各抽出部COb上不易被施加使其上下位置 及左右位置發生變動之應力，且於最終壓縮過程中圓線線 圈C0之各抽出部c〇b上亦不易被施加使其上下位置及左右 位置發生變動的應力，故即便於使用利用低剛性之線材 (例如直徑為0.8 mm以下之線材）所形成之圓線線圈C0之情 147456.doc -25- 201106392 形時，亦可抑制上述步驟bl中在圓線線圈CO之各抽出部 上產生位置偏移、變形或龜裂等，並且亦可抑制由於該等 原因而導致之特性變化等之品質降低。即，可提供一種使 用廉價之圓線線圈作為線圈而實現電感器之低價化、並且 品質為先前者同等以上之電感器。 又根據上述第2實施形態，於上述步驟b丨之最終壓縮 過程中可將圓線線圈c〇之捲繞部c〇a向上方壓縮，使其高 度較初始高度Hco略低，故即便於構成捲繞部c〇a之線材 間存在上下方向之間隙之情形時，亦可消除該間隙而有助 於特性提高。 [實驗例] 以下，對上述第1實施形態及第2實施形態之具體之實驗 例進行說明。 该實驗所使用之材料粉末係於含有Fe Cr_si合金之平均 粒徑為1〇 _之磁性粉末上藉由喷霧使之附著含有環氧樹 月旨之黏:劑而成者，磁性粉末與黏合劑之體積比為9:卜 只驗中所使用之圓線線圈係由利用含有聚醢亞胺之 厚度為G.G2麵之絕緣材料來覆蓋含有銅之直徑為Μ麵 之金屬線而成之線材所構成者。圓線線圈之捲繞數、搂繞 形態及捲繞方法係與圖3所示者相同，捲繞部之外徑_ 之以。）為5.0 mm，捲繞部之高度（圖3之Hc〇)為〗*麵。 此處’將上述步驟幻與上述步驟匕”之高度…設為之別 mm ^ μ巧/又nj扠局υ·92 mm、 南度114設為2·45 mm、蔣古痒从 將阿度h5設為〗·8〇 mm、將高度h6: 147456.doc -26- 201106392 為1.10 nun、將高度h7設為0 88 mm、將高度⑽設為〇 88 mm ’並且將未壓縮密度D1設為2.85 g/cm 3、將中壓縮密 度D2設為4.60 g/cm3、將高壓縮密度D3設為5.48 g/cm3、 將最終壓縮密度D4設為5.80 g/cm 3(參照圖10)。上述中壓 縮密度D2、高壓縮密度〇3及最終壓縮密度〇4之測定係以 如下方式進行：將一次壓縮體、二次壓縮體及最終壓縮體 之相符部位切出長度3.00 mm、寬度3.00 mm及高度1.00 Q mm之稜柱狀，測量其重量並算出重量/體積。 於此種條件下，按照上述步驟&1與上述步驟bl*將最終 壓縮體各形成50個之後，自侧面起至中心部為止研磨該最 終壓縮體，並藉由光學顯微鏡確認圓線線圈之狀態後，其 結果為所有圓線線圈之各抽出部的上下位置及左右位置大 體上均未發現變動，且該各抽出部亦未發現成問題之位置 偏移或變形。又，圓線線圈之捲繞部係自其高度為14 mm 而壓縮成平均1.1 mm，但該捲繞部之捲繞形態上並未發現 Ο 成問題之混亂。進而，使用之前所形成之各50個最終壓縮 體，且按照上述步驟a2〜a4及上述步驟b2〜b4來製造電感器 後’其結果為並未產生不合格品。 作為比較例，於與上述相同之材料粉末（相當於高度μ 之高度為2.95 mm)内直接壓入與上述相同之圓線線圈之捲 繞部，然後於其上投入與上述相同之材料粉末（相當於高 度h5之高度為1.80 mm)，之後將整體向上方及下方壓縮 (相當於高度h7及高度h8之高度分別為〇88 mm)，而形成 50個最終壓縮體。接著，自側面起至令心部為止研磨所形 147456.doc -27- 201106392 成之最終壓縮體’利用光學顯微鏡確認圓線線圈之狀態 後’其結果為所有圓線線圈之各抽出部的上下位置及左右 位置皆發生變動，且該各抽出部上顯著產生位置偏移或變 形。又，使用之前所形成之5 0個最終壓縮體，且按照上述 步驟a2~a4及上述步驟b2〜b4而製造電感器後，其結果為產 生23個圓線線圈之抽出部被切斷而成為不合格品者。 【圖式簡單說明】 圖1 (A)~圖1 (H)係本發明之第1實施形態之壓縮成形裝置 及壓縮成形步驟之說明圖； 圖2係圖1 (B)所示之一次壓縮體之放大剖面圖； 圖3(A)係圖1(D)所示之圓線線圈之放大俯視圖，圖3(B) 係沿圖3(A)之S 1-S 1線之剖面圖； 圖4(A)係圖1(F)所示之二次壓縮體之放大剖面圖，圖 4(B)係圖1 (G)所示之最終壓縮體之放大剖面圖； 圖5(A)係對最終壓縮體進行硬化處理所獲得之磁心之俯 視圖’圖5(B)係圖5(A)所示之磁心之仰視圖； 圖6係於圖5(A)及圖5(B)所示之磁心上設置端子而獲得 之電感器之仰視圖； 圖7(A)〜圖7(H)係本發明之第2實施形態之壓縮成形裝置 及壓縮成形步驟之說明圖； 圖8係圖7(B)所示之一次壓縮體之放大剖面圖； 圖9(A)係圖7(F)所示之二次壓縮體之放大剖面圖，圖 9(B)係圖7(G)所示之最終壓縮體之放大剖面圖；及 圖10係用以說明實驗例之圖表。 147456.doc -28- 201106392 【主要元件符號說明】 10 下模 11 下内柱銷 12 下内套筒 13 下外套筒 13a 細槽 20 上模 21 ❹ 上内柱鎖 22 上内套筒 23 上外套筒 30 下模 31 下内柱銷 32 下套筒 32a 細槽 40 上模 〇 41 上内柱鎖 42 上内套筒 43 上外套筒 CB1 一次壓縮體 CBla 下壁 CBlb 周壁 CBlc 凸部 CBld 凹部 CB2 二次壓縮體 147456.doc -29- 201106392 CB2a 下壁 CB2b 周壁 CB2c 凸部 CB2d 上壁 CB2e 中心部 CB3 最終壓縮體 CB11 一次壓縮體 CB1 la 下壁 CB1 lb 周壁 CB1 lc 凹部 CB12 二次壓縮體 CB12a 下壁 CB12b 周壁 CB12c 上壁 CB12d 中心部 CB13 最終壓縮體 CO 圓線線圈 COa 捲繞部 COb 抽出部 MP 材料粉末 PC 磁心 147456.doc -30-Hco is roughly the same. In the same manner as in the first embodiment, the particle density of the input material powder MP is set to the uncompressed density D1, and the uncompressed density di<medium density D2<high compression density D3<final compression density D4 is satisfied. In the relationship between the values of the compression density D2, the high compression density D3, and the final compression density D4, the particle density of the lower wall CB11a of the primary compression body cb11 is a high compression density D3, and The particle density of the peripheral wall CB lib 0 is the medium compression density D2 (refer to the difference in shadow). In other words, the primary compression molding is performed while controlling the amount of compression and the pressure so that the lower wall CB11a of the primary compressed body CB11 has a high compression density D3 and the peripheral wall CB11b has a medium compression density D2. Then, as shown in FIG. 7(C), the upper inner pin 41 and the upper inner sleeve 42 are raised back to 'and the lower inner pin 3 1 is raised to the upper side of the peripheral wall CB11b of the primary compressed body CB 11 to reach the lower sleeve. The bottom surface of the narrow groove 32a of the cylinder 32 is substantially at the same height position. Next, as shown in Fig. 7(D), the winding portion C〇a of the round wire coil CO shown in Fig. 3 is inserted into the concave portion CBllc of the primary compression body CB11, and the respective extraction portions COb are inserted into the lower sleeve. Inside each of the narrow grooves 32a of the cylinder 32. Namely, the winding portion COa inserted into the concave portion cb 11 c of the primary compressed body CB! 图 in Fig. 7(D) is located on the wall CB11a below the high compression density. Further, the respective extraction portions c 〇 b inserted into the respective narrow grooves 32a of the lower sleeve 32 are located on the peripheral wall CB11b of the intermediate compression density D2. Then, as shown in Fig. 7(E), the height h5 (corresponding to the height h5 of Fig. 1) formed by the primary compression body CB11 and the winding of the round wire coil c〇 147456.doc - 21 - 201106392 The inside of the COa is put into the same material as the above. Then, as shown in Fig. 7(F), the upper outer sleeve 43 is lowered to insert the lower portion thereof into each of the narrow grooves 32a of the lower sleeve 32, and the fine is covered by the inner surface of the lower outer sleeve 43 The upper portion of each of the extraction portions c〇b of the inside of the groove 32a is opened. At this time, the lower end of the upper outer sleeve 43 is not in contact with the respective extraction portions c〇b. Then, the upper inner pin 41 and the upper inner sleeve 42 are lowered until the interval between the lower surface and the upper surface of the round wire coil CO reaches the height h6 (corresponding to the height h6 of Fig. 1(F)). Thereby, the material powder Mp introduced in Fig. 7(E) is compressed downward to form the secondary compressed body CB12. As shown in FIG. 9(A), the secondary compression body CB12__ has a bottom view contour which is circular and has a height h3 lower wall CB12a, and surrounds the lower wall CB12a. The peripheral wall cB12b of h4, the peripheral wall CB 12b, and the round wire coil CO have a rectangular shape in plan view, a height 匕6 upper wall CB 12c, and a winding portion c〇a disposed on the round wire coil c〇. The height is the center portion CB 12d of Hco. Further, the particle density of the lower wall CB 12a of the secondary compressed body CB 12 is a high compression density D3 ' and the particle density of the peripheral wall CB 12b, the particle density of the upper wall CB 12c, and the particle density of the central portion CB12d are the medium compression density d2 ( Refer to the difference in shadows). In other words, in order to make the lower wall CB12a of the secondary compressed body CB12 a compression density D3, and the peripheral wall CB 12b, the upper wall CB 12c, and the center portion CB12d have a medium compression density D2, the above two are performed while controlling the amount of compression and pressure. Secondary compression forming. In the secondary compression process, the material powder MP is compressed to a medium compression density D2 on the upper side and the inner side of the winding portion COa of the round wire coil C, but due to the winding of the coil of the coil of I47456.doc -22- 201106392 The lower side of the winding portion COa has a high compression density D3 and the outer side has a medium compression density D2, so that it is difficult to apply a stress that compresses the winding portion COa downward and outward. Further, in the secondary compression process, the material powder mp is compressed to a medium compression density D2 on the upper side of each of the extraction portions COb of the round wire coil c of the peripheral wall CB1 lb of the compression density D2 in the primary compression body CB11. However, since the peripheral wall CB11b of the primary compressed body CB11 has a medium compression density D2, and the material powder MP compressed here is flowed away from the outer curved surface of each of the extracted portions COb having a circular cross section, the flow is avoided. The stress on the upper and lower positions and the left and right positions is not easily applied to each of the extraction portions c〇b. Then, as shown in Fig. 7(G), the lower inner pin 31 is raised to the upper surface thereof and the lower surface of the round wire coil CO reaches the height h7 (corresponding to the height h7 of the figure RG). The pin 41 and the upper inner sleeve 42 are lowered until the lower surface of the both sides and the upper surface of the round wire coil co reach a height h8 (corresponding to the height h8 of Fig. 1(G)). Thereby, the secondary compression body 〇CB12 shown in FIG. 7(F) is compressed upward and downward to form the final compressed body CBi3. As shown in FIG. 9(B), the final compressed body cm3 is formed to have a height of about... In the rectangular parallelepiped shape, a portion of the winding portion c〇a of the round wire coil CO and a portion of the winding portion COa of each of the extraction portions c〇b are embedded in the final compressed body CBn, and the remaining portions of the respective extraction portions cob are self-contained. This final compressed body CB13 protrudes to the outside. Further, the particle density of the entire compressed body CB13 as a whole is the final compression density D4 (refer to the difference in shadow). In other words, the final compression molding is performed while controlling the amount of compression and the pressure of the final compression body an as the final compression density D4. In the final compression process, since the lower side of the winding portion COa of the round wire coil CO has a high compression density D3 and the upper side has a medium compression density D2, the winding portion Coa is upwardly moved by the portion of the high compression density D3. In the compression, the height is slightly lower than the initial height Hco. However, since the compression direction of the winding portion COa is upward, the pressure of the upper and lower positions and the left and right positions of the respective extraction portions COb are not easily applied by the compression. Further, in the above-described compression process, the peripheral wall CB 12b and the upper wall CB 12c of the compression density 02 of the secondary compression body CB12 are compressed to the final compression density D3 on the lower side and the upper side of each of the extraction portions COb of the round wire coil CO. However, since the peripheral wall CB 12b and the upper wall CB 12c are both of the medium compression density D2, and the particles of the peripheral wall CB 12b and the upper wall CB 12c compressed here are circumscribed by the curved surface of each of the extracted portions COb along the circular cross section. Since the flow is performed in the same manner, the stress on the COb is not easily applied to the upper and lower positions and the left and right positions. Then, as shown in Fig. 7(H), the upper inner pin 41 and the upper inner sleeve 42 are raised and returned, and the lower inner pin 31 is raised to a position where the final compressed body CB13 is taken out to the outside. Then, the final compressed body CB 13 is taken out from the forming apparatus. Moreover, since the inner pin 5 of the die 10 under the first embodiment is not in the lower die 3 used in the above step bl, the lower surface of the core formed by the above step b3f does not remain as shown in FIG. 5. (B) The circular trace PCb shown. Here, 'the above-mentioned compression density D2, high compression density and final pressure 147456.doc -24-201106392 shrinkage density D4 are described." Moreover, the medium compression density 〇2, the high compression density D3 and the final compression density 〇4 are determined. For example, the phase of the primary compressed body CB1, the secondary compressed body CB2, and the final compressed body cB3 is cut out to a specific volume, and the weight is measured to calculate the weight/volume. The relationship between the above-mentioned medium compression density D2 and the above final compression density D4 is preferably 〇.70 < (D2/D4) < 0.85. When (D2/D4) is 〇.70 or less, the winding portion c〇a of the round wire coil CO is inserted into the concave portion CB1 lc of the primary compressed body CB11 (refer to FIG. 7(D)), and the primary compression is performed. The peripheral wall CB11b of the body CB11 is liable to collapse. On the other hand, when (D2/D4) is 0.85 or more, when the secondary compressed body CB12 is formed (see Fig. 7(F)), the extraction portion COb of the round wire coil CO is easily deformed. Further, the relationship between the above-mentioned high compression density D3 and the above final compression density D4 is preferably 0.90 lt; (〇3/04) < 0.97. When (03/04) is 0.90 or less, when the secondary compression body CB 12 is formed (see FIG. 7(F)), it is easy to cause a potential in the winding portion COa of the round wire coil CO, and the extraction portion c〇b is deformed. . On the other hand, when 〇 (D3/D4) is 0.97 or more, when the final compressed body CB13 is formed (see Fig. 7(G)), it is difficult for the high compression density D3 portion of the secondary compressed body CB12 to reach the final compression density D4. According to the second embodiment, in the secondary compression process of the step b1, the stresses of the upper and lower positions and the left and right positions of the round wire coil C0 are less likely to be applied, and the final compression process is performed. It is also difficult to apply a stress that causes the vertical position and the left and right position to vary in each of the extraction portions c〇b of the coil C0. Therefore, even a wire formed of a low-rigidity wire (for example, a wire having a diameter of 0.8 mm or less) is used. In the case of the wire coil C0, 147456.doc -25- 201106392, it is possible to suppress positional displacement, deformation, cracking, and the like in each of the extraction portions of the round wire coil CO in the above step bl, and it is also possible to suppress the The quality of the characteristics such as changes in characteristics is reduced. In other words, it is possible to provide an inductor which uses a low-cost round wire coil as a coil to reduce the cost of the inductor and has a quality equal to or higher than the former. According to the second embodiment, in the final compression process of the step b, the winding portion c〇a of the round wire coil c can be compressed upward, and the height thereof is slightly lower than the initial height Hco. When there is a gap between the wires of the winding portion c〇a in the vertical direction, the gap can be eliminated to contribute to the improvement in characteristics. [Experimental Example] Hereinafter, specific experimental examples of the first embodiment and the second embodiment will be described. The material powder used in the experiment is based on a magnetic powder having an average particle diameter of 1 〇 _ containing Fe Cr-si alloy, and is adhered to a viscous agent containing an epoxy resin, and the magnetic powder is bonded thereto. The volume ratio of the agent is 9: The round wire coil used in the test is made by covering the metal wire having the diameter of the copper surface with the thickness of the G.G2 surface containing the polyimine. The wire is composed of. The number of windings of the round wire coil, the winding form, and the winding method are the same as those shown in Fig. 3, and the outer diameter of the winding portion is _. ) is 5.0 mm, and the height of the winding portion (Hc〇 in Fig. 3) is a * face. Here's the height of the above steps and the above steps ...... set to mm ^ μ Qiao / nj fork υ · 92 mm, south 114 set to 2. 45 mm, Jiang Gu itching from the A H5 is set to 〖·8〇mm, height h6: 147456.doc -26- 201106392 is 1.10 nun, height h7 is set to 0 88 mm, height (10) is set to 〇88 mm ' and uncompressed density D1 is set to 2.85 g/cm 3 , the medium compression density D2 was 4.60 g/cm 3 , the high compression density D3 was 5.48 g/cm 3 , and the final compression density D4 was 5.80 g/cm 3 (refer to FIG. 10 ). The measurement of the compression density D2, the high compression density 〇3, and the final compression density 〇4 is performed by cutting the matching portions of the primary compressed body, the secondary compressed body, and the final compressed body by a length of 3.00 mm, a width of 3.00 mm, and a height. Having a prismatic shape of 1.00 Q mm, measuring the weight and calculating the weight/volume. Under these conditions, 50 pieces of the final compressed body are formed according to the above steps & 1 and the above step bl*, from the side to the center. Grinding the final compressed body and confirming the state of the round wire coil by an optical microscope, the result is all In the upper and lower positions and the left and right positions of the respective extraction portions of the wire coil, substantially no change was observed, and the positional deviation or deformation of the problem was not found in the respective extraction portions. Moreover, the winding portion of the round wire coil was from its height. 14 mm and compressed to an average of 1.1 mm, but the winding form of the winding portion was not found to be a problematic problem. Further, each of the 50 final compressed bodies formed before use was used, and according to the above steps a2 to a4 and After the inductors were manufactured in the above steps b2 to b4, the result was that no defective product was produced. As a comparative example, the same material powder (corresponding to the height μ of the height of 2.95 mm) was directly pressed into the same manner as described above. The winding portion of the round wire coil is then placed with the same material powder as above (corresponding to a height h5 of 1.80 mm), and then the whole is compressed upwards and downwards (corresponding to the height h7 and height h8) 〇88 mm), respectively, and 50 final compression bodies are formed. Then, from the side to the heart, the shape is 147456.doc -27- 201106392. The final compression body is confirmed by optical microscopy. After the state, the result is that the upper and lower positions and the left and right positions of the respective extraction portions of all the round wire coils are changed, and the positional deviation or deformation is remarkably generated on the respective extraction portions. Further, the 50 finals formed before use are used. After the inductor is manufactured and the inductors are manufactured in accordance with the above steps a2 to a4 and the above steps b2 to b4, the result is that the extraction portion of the 23 round coils is cut and becomes a defective product. 1(A) to 1(H) are explanatory views of a compression molding apparatus and a compression molding step according to a first embodiment of the present invention; and Fig. 2 is an enlarged cross-sectional view showing a primary compression body shown in Fig. 1(B); Fig. 3(A) is an enlarged plan view of the round wire coil shown in Fig. 1(D), and Fig. 3(B) is a cross-sectional view taken along line S1-S1 of Fig. 3(A); Fig. 4(A) Fig. 1(F) is an enlarged cross-sectional view of the secondary compression body, Fig. 4(B) is an enlarged sectional view of the final compression body shown in Fig. 1(G); Fig. 5(A) is for the final compression body. FIG. 5(B) is a bottom view of the magnetic core shown in FIG. 5(A); FIG. 6 is a terminal provided on the magnetic core shown in FIG. 5(A) and FIG. 5(B); FIG. And won FIG. 7(A) to FIG. 7(H) are explanatory views of a compression molding apparatus and a compression molding step according to a second embodiment of the present invention; FIG. 8 is a diagram showing FIG. 7(B). An enlarged cross-sectional view of the primary compression body; Fig. 9(A) is an enlarged cross-sectional view of the secondary compression body shown in Fig. 7(F), and Fig. 9(B) is an enlarged view of the final compression body shown in Fig. 7(G) The cross-sectional view; and Fig. 10 are diagrams for explaining experimental examples. 147456.doc -28- 201106392 [Description of main components] 10 Lower die 11 Lower inner pin 12 Lower inner sleeve 13 Lower outer sleeve 13a Thin groove 20 Upper die 21 上 Upper inner column lock 22 Upper inner sleeve 23 Outer sleeve 30 Lower die 31 Lower inner pin 32 Lower sleeve 32a Fine groove 40 Upper die 41 Upper inner cylinder lock 42 Upper inner sleeve 43 Upper outer sleeve CB1 Primary compression body CBla Lower wall CBlb Peripheral wall CBlc Convex CBld Concave CB2 secondary compression body 147456.doc -29- 201106392 CB2a lower wall CB2b peripheral wall CB2c convex part CB2d upper wall CB2e central part CB3 final compression body CB11 primary compression body CB1 la lower wall CB1 lb peripheral wall CB1 lc concave part CB12 secondary compression body CB12a Lower wall CB12b Peripheral wall CB12c Upper wall CB12d Center part CB13 Final compression body CO Round wire coil COa Coiled part COb Extraction part MP Material powder PC Magnetic core 147456.doc -30-