TW201503184A - Method for manufacturing stacked power inductor - Google Patents

Abstract

A method for manufacturing a stacked power inductor includes forming a plurality of inner-end conductors which are spaced from each other, two outer-end conductors, and a lead conductor on an upper surface of a substrate; forming stacked electrode blocks above a first end portion and a second end portion of each inner-end conductor and above an end portion of the lead conductor, and forming a stacked outer-end conductor above the outer-end conductor; coating thereon with a first magnetic material layer, but exposing an upper surface of the topmost electrode block and an upper surface of the outer-end conductor; connecting the topmost electrode block of the first end portion of each inner-end conductor with the topmost electrode block of the second end portion of the adjacent inner-end conductor via a plurality of connecting conductors; and coating thereon with a second magnetic material layer. Accordingly, a stacked power conductor is produced.

Description

Method for manufacturing stacked power inductor

The invention relates to a method for manufacturing a stacked power inductor, in particular to a power inductor composed of a plurality of inner end conductors, outer end conductors, laminated electrode blocks, and connecting conductors, and coated with a plurality of magnetic material layers. It is a stacked power inductor with better inductance.

The power inductor is conventionally formed by winding a wire having a right-angled or circular cross section in a spiral shape, and has a plurality of turns extending in a vertical direction, the two ends of which extend out of the wires to be connected to the outer conductor. In the production, the spiral wire of the welded wire is first placed in a mold, and then the magnetic powder material is injected into the mold, and then the magnetic powder material is pressed into a block and finally demolded.

However, the power inductor has the following shortcomings:

1. When the coil component is placed in a mold and the magnetic powder and the adhesive colloidal material injected into the mold are pressurized, there may be a problem that the coil component and the magnetic material are not completely covered due to insufficient pressure, or because the pressure is too large. This leads to cracks in the interface between different materials, resulting in poor product reliability.

2. When these power inductors are applied to high current environments, it is easy It burned because the temperature of the component rose sharply.

In view of the above-mentioned lack of power inductors, the present inventors have made improvements to the research of these defects, and the invention has been produced by long-term research.

Accordingly, the present invention is directed to a method of fabricating a stacked power inductor in which the power inductor is composed of a plurality of inner end conductors, outer end conductors, electrode blocks, and a plurality of connecting conductors.

According to the manufacturing method of the stacked power inductor of the present invention, a plurality of spaced inner end conductors are formed on an upper surface of a substrate; each inner end conductor has a first end portion and a second end portion, respectively. a plurality of stacked electrode blocks are formed above the first end portion and the second end portion of the inner end conductor; a top electrode block of the first end portion of each inner end conductor and a second end portion of the adjacent inner end conductor Above the top electrode block, a long strip-shaped connecting conductor is connected, thereby making a transversely wound spiral power inductor, which is the second object of the present invention.

According to the manufacturing method of the stacked power inductor of the present invention, in the manufacturing process, after the laminated electrode block is completed at both ends of each inner conductor, the first magnetic material layer is first covered; then the top layer is The upper end surface of the electrode block is exposed, and then connected to the upper surface of the two top electrode blocks by a connecting conductor, so that the inner end conductor, the laminated electrode block, and the connecting conductor form a spiral coil path, and finally covered with a second magnetic material layer. It is a further object of the invention.

According to the manufacturing method of the stacked power inductor of the present invention, The spiral inductor composed of the inner end conductor, the laminated electrode block, and the connecting conductor has a layer number and a height of the laminated electrode block which can be adjusted according to the electronic product to be used, and is another object of the present invention.

According to the manufacturing method of the stacked power inductor of the present invention, the inductance of the power inductor can be easily adjusted, which is another object of the present invention.

As for the detailed construction, application principle, function and effect of the present invention, please refer to the following description according to the drawings to obtain a complete understanding.

1‧‧‧ inner conductor

2‧‧‧Laminated electrode blocks

3‧‧‧Connecting conductor

10‧‧‧Substrate

11, 12, 13, 14, 15‧‧‧ inner conductor

11A, 12A, 13A, 14A, 15A‧‧‧ first end

11B, 12B, 13B, 14B, 15B‧‧‧ second end

41, 42‧‧‧ lead conductor

50‧‧‧First magnetic material coating

51, 52‧‧‧ outer conductor

510, 520‧‧‧ lead conductor

60‧‧‧Bottom electrode block

61, 62‧‧‧ second layer outer conductor

70‧‧‧Top electrode block

71, 72‧‧‧ third layer outer conductor

701, 710, 720‧‧‧ upper surface

80‧‧‧Connecting conductor

81, 82‧‧‧ top outer conductor

90‧‧‧Second magnetic material coating

100‧‧‧ mother substrate

101, 102, 103‧‧‧ substrate unit

100A‧‧‧ inner conductor

111, 112‧‧‧ outer conductor

100B‧‧‧First end

100C‧‧‧second end

110‧‧‧ lead conductor

120‧‧‧Bottom electrode block

121, 122‧‧‧ second layer outer conductor

130‧‧‧Top electrode block

131, 132‧‧‧ third layer outer conductor

200‧‧‧First total magnetic material coating

301‧‧‧Connecting conductor

310, 320‧‧‧ top outer conductor

400‧‧‧Second total magnetic material coating

1000‧‧‧Grained components

Fig. 1 is a perspective view showing a laminated power inductor produced by the method for manufacturing a laminated power inductor of the present invention.

2A-2G are schematic diagrams showing the manufacturing process of the method for manufacturing the laminated power inductor of the present invention.

3A-3H are schematic diagrams showing a matrix manufacturing process of the method for manufacturing a laminated power inductor of the present invention.

The method for manufacturing a stacked power inductor according to the present invention has a power inductor as shown in FIG. 1, and includes: a plurality of inner end conductors 1 arranged side by side, and a plurality of laminated electrodes provided at both end portions of the inner end conductor 1 The block 2, the plurality of connecting conductors 3 of the laminated electrode block 2 connecting the first end and the second end of the adjacent inner end conductors, and the outwardly extending lead conductors 41, 42.

Manufacturing method of laminated power inductor of the present invention, process thereof The steps include: a bottom conductor forming step: as shown in FIG. 2A, a plurality of inner end conductors 11, 12, 13, 14, 15 and two outer end conductors 51, 52 are formed on the upper surface of the substrate 10; wherein each inner end The conductors 11, 12, 13, 14, 15 are disposed at an oblique interval, each having a first end portion 11A, 12A, 13A, 14A, 15A and a second end portion 11B, 12B, 13B, 14B, 15B; The outer end conductors 51 and 52 are formed on both ends of the upper surface of the substrate 10, and the outer side surfaces thereof are aligned with the side edges of the substrate 10, and one end thereof is formed with a long strip-shaped lead conductors 510 and 520 along the longitudinal direction of the substrate. The lead conductors 510, 520 and the outer end conductors 51, 52 may be formed integrally; the length of the lead conductors 510, 520 may be maintained at an appropriate distance from the end of the inner end conductor closest thereto; the inner end conductors 11, 12 , 13, 14, 15 and the outer end conductors 51, 52 are all formed of a conductive metal material having the same height; the bottom electrode block forming step: as shown in FIG. 2B, at each of the inner end conductors 11, 12, 13, 14 , above the first end portions 11A, 12A, 13A, 14A, 15A and above the second end portions 11B, 12B, 13B, 14B, 15B, and Above the ends of the conductors 510, 520, each forming a bottom electrode block 60; above each of the outer end conductors 51, 52 is formed a second outer end conductor 61, 62 overlapping the outer end conductors 51, 52; The bottom electrode block 60 and the second outer end conductors 61, 62 have the same height; the top electrode block forming step: as shown in FIG. 2C, an upper stacked top electrode is formed above each of the bottom electrode blocks 60 Block 70; above the second outer conductors 61, 62, a third outer end conductor 71, 72 overlapping the second outer conductors 61, 62; a top electrode block 70 and a third outer conductor 71, 72 have the same height; a first coating layer forming step: as shown in FIG. 2D, above the substrate 10, an inner end conductor 11, 12, 13, 14, 15 and an outer end conductor 51, 52 are formed. 61, 62, 71, 72, lead conductors 510, 520, bottom electrode block 60 and top electrode block 70 simultaneously coated first magnetic material coating layer 50; layer bare steps: as shown in Figure 2E, using grinding Or a process such as a scraping process, the coating layer covering the upper surface of the top electrode block 70 and the upper surface of the third outer electrode conductors 71, 72 is scraped off, so that the upper surface 701 of the top electrode block 70 and the third outer conductor 71 are provided. The upper surfaces 710 and 720 of the upper portion 710 and 720 are bare; (the pressing, the upper surface 701 of the top electrode block 70 and the upper surfaces 710 and 720 of the third outer conductors 71 and 72 are exposed, or a first magnetic material coating layer 50 is not formed to cover the upper surface thereof; a connecting conductor forming step: as shown in FIG. 2F, at each top layer The exposed upper surface of the pole block 70, and the exposed upper surface of the third outer conductors 71, 72, form a plurality of connecting conductors 80; the first ends of each of the inner end conductors 11, 12, 13, 14, The top electrode block 70 of the portions 11A, 12A, 13A, 14A, 15A and the top electrode block 70 of the second end portions 11B, 12B, 13B, 14B, 15B of the adjacent inner end conductors are each connected by a connecting conductor 80 The top electrode block 70 of the second end portion 11B of the outer inner end conductor 11 and the lead The top electrode block 70 of the conductor 510, and the top electrode block 70 of the first end portion 15A of the outer inner end conductor 15 and the top electrode block 70 of the lead conductor 520 are also connected by a connecting conductor 80 (for example, 11A-12B, 12A). -13B, 13A-14B, 14A-15B, 15A-520, 11B-510), making all inner end conductors 11, 12, 13, 14, 15 and outer end conductors 51, 52, 61, 62, 71, 72 and The electrode blocks 60, 70 constitute a spiral-shaped conductor that communicates in a horizontal direction; a top-side outer-end conductor 81, 82 is formed over the third outer-end conductors 71, 72, and the thickness of the top-side outer-end conductors 81, 82 and the connection conductor 80 The second coating layer forming step: as shown in FIG. 2G, a second coating of each of the connecting conductors 80 and the top outer end conductors 81, 82 is formed over the first magnetic material covering layer 50. The magnetic material is coated 90.

As described above, it is known that the coating of the plurality of magnetic material coating layers is formed by segmentation, so that the formation of each of the magnetic material coating layers is more reliable, and not only the protection of the conductor but also the destruction of the inductance can be avoided, thereby improving the overall The inductance of the inductor.

The manufacturing method of the stacked power inductor of the present invention is also mass-produced in a matrix, and the manufacturing steps are as follows: First step: as shown in FIG. 3A, firstly, a matrix is divided on a mother substrate 100. Arranging a plurality of substrate units 101, 102, 103 ̇ ̇; a plurality of obliquely spaced inner end conductors 100A and two outer end conductors 111, 112 are formed on the upper surface of each of the substrate units 101, 102, 103 ̇ ̇; Each inner end conductor 100A has a first end portion 100B and a first The two end portions 100C; the outer end conductors 111, 112 on each of the substrate units 101, 102, 103 贴 ̇ are abutting each other, and the lead conductors 110 are disposed along the length direction of the substrate unit; the second step: As shown in FIG. 3B, a bottom electrode block is formed above the first end portion and the second end portion of the inner end conductor 100A of each of the substrate units 101, 102, and 103, and above the end of the lead conductor 110. 120; above each of the substrate units 101, 102, 103 ̇ ̇ ̇ outer end conductors 111, 112, a second outer end conductor 121, 122 overlapping the outer end conductors 111, 112 is formed; As shown in FIG. 3C, a top electrode block 130 is formed over the first end and the second end of each inner conductor 100A, and above the end of the lead conductor 110; the second outer conductor 121 Further, a third layer outer end conductors 131 and 132 are formed on the upper side of the second layer 122. Fourth step: as shown in FIG. 3D, a substrate unit 101, 102, 103 is formed on the mother substrate 100. The inner total conductor, the outer end conductor, and the electrode block are all coated with the first total magnetic material coating layer 200; the fifth step: As shown in Fig. 3E, the first total magnetic properties of the upper surface of each of the substrate units 101, 102, 103 and the top electrode block 130 and the third outer conductors 131, 132 are formed by a grinding or scraping process. The material coating layer 200 is scraped off to expose the upper surfaces of the top electrode block 130 and the third layer outer end conductors 131, 132; The sixth step: as shown in FIG. 3F, a plurality of connection conductors 301 are formed on each of the substrate units 101, 102, and 103, so that the first end portion of each of the inner end conductors and the adjacent inner end conductor are The top electrode blocks of the second end portion are connected by a connecting conductor 301; the top electrode block of the outer inner end conductor is also connected to the top electrode block of the leading end of the lead conductor by a connecting conductor 301; the third outer end conductor 131, Further, a top outer end conductor 310, 320 is formed on the upper side of the first step; a seventh step: as shown in FIG. 3G, a plurality of connecting conductors 301 and top outer end conductors 310, 320 are formed over the mother substrate 100. The second total magnetic material coating layer 400 is coated; the eighth step: Finally, as shown in FIG. 3H, each of the substrate units 101, 102, 103 ̇ ̇ is divided into the granular elements 1000 by a dicing process.

According to the manufacturing method of the stacked power inductor of the present invention, the production efficiency of the stacked power inductor can be improved through the above process, and the adjustment of the number and height of the electrode block can meet the requirements of various electronic products during the production process. Alternatively, when the first magnetic material coating layer is formed, it is not covered to the upper surfaces of the top electrode block and the outer end conductor to reduce the step of scraping off the partial coating layer.

It can be seen from the above that the manufacturing method of the stacked power inductor of the present invention has an innovative process, which can improve the disadvantages of the power inductor, and it has not been disclosed. It is in accordance with the provisions of the patent law. Quasi-patent is really a virtue.

The above is a preferred embodiment of the present invention. If the changes made by the concept of the present invention are not exceeded by the spirit of the specification and the drawings, the present invention should be Within the scope of the agreement, Chen Ming.

10‧‧‧Substrate

50‧‧‧First magnetic material coating

80‧‧‧Connecting conductor

81, 82‧‧‧ top outer conductor

90‧‧‧Second magnetic material coating

Claims (7)

A method of manufacturing a stacked power inductor, comprising: forming a plurality of inner end conductors and two outer end conductors on an upper surface of a substrate; wherein the plurality of inner end conductors and outer end conductors are spaced apart from each other, each of the inner ends The conductors each have a first end and a second end; one end of the outer end conductor is provided with a lead conductor along the length of the substrate, and the end of the lead conductor and the end of the inner end conductor closest thereto Holding a distance; forming an electrode block above the first end portion and the second end portion of each of the inner end conductors and above the end portion of the lead conductor; forming an upper portion of the outer end conductor a second outer end conductor; above the substrate, a first magnetic material coating layer covering the inner end conductor, the lead conductor, the electrode block and the outer end conductor; and the first magnetic material coating layer Above, a plurality of connecting conductors are formed such that the electrode block above the first end of each inner conductor and the electrode block above the second end of the adjacent inner conductor, and the electrode block above the end of the lead conductor Neighbor end conductor The electrode blocks above the end portions are each connected by a connecting conductor so as to form a spiral conductor which is connected in a horizontal direction; a top layer outer end conductor is formed above the second outer end conductor; and the first magnetic material is covered Above the layer, another one will be formed A second magnetic material coating layer covered by the connecting conductor and the top outer end conductor. The method of manufacturing a stacked power inductor according to claim 1, wherein the plurality of inner end guiding systems are arranged at an oblique interval. The method of manufacturing a stacked power inductor according to claim 1, wherein the upper surface of each of the electrode blocks is exposed without being covered by the first magnetic material coating layer before being connected by the connecting conductor. The method of manufacturing a stacked power inductor according to claim 1, wherein the thickness of each of the outer end conductors is the same as the thickness of the inner end conductor, the electrode block or the connecting conductor of the same layer. The method of manufacturing a stacked power inductor according to claim 1, wherein the substrate is a single substrate or a mother substrate composed of a plurality of substrate units. The method of manufacturing a stacked power inductor according to claim 5, wherein a plurality of substrate units on the mother substrate are arranged in a matrix, and a stacked power inductor is fabricated in a matrix arrangement. The manufacturing method of the stacked power inductor according to claim 6, wherein when the stacked power inductor is manufactured in a matrix arrangement, the outer end conductors on the two adjacent substrate units are first formed into one body, and then Separate by cutting.