TW201535439A - The manufacturing method and the structure of the low profile inductor coil - Google Patents

Abstract

The present invention is related to a manufacturing method of the low profile inductor coil and the structure thereof. By using a board, a mold, a supporting board, and a pressing device, a coil is wrapped in a iron powdered clad body doped with plastic. Then, forming two electrodes by the electrode-forming process for being respectively connected with the two electrical terminals, which is exposed to the clad body. Moreover, the present invention further provides a structure of the low profile inductor coil for the manufacturing method.

Description

Manufacturing method and structure of thin inductor coil

The invention relates to the technical field of an inductor coil, in particular to a method for manufacturing a thin inductor coil and a structure thereof.

With the development of industry and technology, electronic products are widely used in the lives of modern people; among them, inductive coils play an indispensable role in electronic products.

Please refer to the first A figure to the first E picture, which is a schematic diagram of the manufacturing process of a thin induction coil; and please refer to the second figure at the same time, which is a flow chart of the manufacturing method of the thin induction coil. As shown in the figure, a conventional method for manufacturing a thin inductor coil includes the following steps: First, a step (S01') is performed to separately stamp a first conductive plate 110a' and a second conductive plate 110b'. a first coil layer 120a' of the first guiding member 125a' and a second coil layer 120b' including a second guiding member 125b'; then, performing a step (S02') to solder the same The first coil layer 120a' and the second coil layer 120b' simultaneously join the two guiding wires 130' such that the first coil layer 120a' and the second coil layer 120b' constitute an inductive coil 120' .

After the foregoing steps are completed, the method further performs the step (S03'), and the inductor 120' is covered by a cover 140', wherein the cover 140' is formed of a magnetic powder material; finally, steps are performed. (S04'), the first guiding member 125a' and the second guiding member 125b' are cut and welded and fixed into two electrodes.

However, the conventional method of manufacturing the thin inductor coil is mass-produced by means of the strip 200', and the plurality of inductor coils 120' are removed from the 200' strip by cutting, and then the remaining strips are taken. 200' is directly discarded; thus, not only does the manufacturing cost of the inductor coil 120' increase, but also the waste of the strip 200'. In addition, in this step (S02'), the first coil layer 120a' and the second coil layer 120b' are laminated by welding to form an inductor coil 120', which further increases the inductance. The manufacturing difficulty of the coil 120'.

Through the above, it can be known that the manufacturing method of the conventional thin inductor coil has disadvantages and disadvantages; in view of this, the inventors of the present invention have vigorously studied and invented, and finally developed a construction and manufacturing method of a thin inductor coil of the present invention.

The main object of the present invention is to provide a method for manufacturing a thin inductor coil by coating a coil with a plastic powder doped with plastic through a substrate, a mold, a support plate, and a pressing device. Wrap Finally, an electrode is formed by forming an electrode to respectively connect the two electrical terminals of the coil exposed outside the covering body; in addition, the present invention also provides a configuration of a thin inductor coil to respond The manufacturing method of the above thin inductor coil.

Therefore, in order to achieve the above-mentioned main object of the present invention, the inventors of the present invention have proposed a method for manufacturing a thin inductor coil, comprising the steps of: (1) placing a plurality of coils on a substrate on a surface of a substrate, and forming One of the plurality of second receiving holes is disposed under the substrate, wherein the coil comprises two electrical terminals; (21) a mold having a plurality of first receiving holes is covered in the plurality of The plurality of first accommodating holes respectively correspond to the plurality of second accommodating holes and respectively accommodate the plurality of coils; (22) a plastic powder doped with plastic through a filling process Filling into the plurality of first accommodating holes; (23) inserting into the plurality of first accommodating holes by a plurality of pressing columns of a pressing device, so that the plastic doped iron Forming a plurality of first covering bodies to respectively cover the plurality of coils; (3) removing the substrate and the base layer; (41) inverting and placing the mold on the support plate, and by using the plurality Pressing the plurality of first covering bodies to generate a filling space; (42) removing the pressing device; (43) refilling the plastic-doped iron powder into the plural through a molding process (44) by inserting the plurality of top pressing columns into the plurality of first receiving holes and the second receiving holes respectively, so that the plastic powder doped with plastic Forming a plurality of second covering bodies corresponding to the plurality of first covering bodies to respectively cover the plurality of coils, and causing the plurality of first covering bodies and the plurality of second covering bodies to The plurality of coils form a plurality of thin inductor coils; wherein the two electrical terminals of the coil are exposed outside the first covering body and the second covering body; (5) removing the supporting plate; 6) respectively pressing the plurality of thin inductor coils in the plurality of first receiving holes by the plurality of top pressing columns to extract the plurality of thin inductor coils; and (7) the plurality of thin inductor coils An electrode forming process is performed to form two electrodes to respectively connect the two electrical terminals exposed by the coil to the outside of the first covering body and the second covering body.

Moreover, the inventor of the present invention further has a structure of a thin inductor coil, comprising: a coil having two electrical terminals; a first covering body having a resin and an iron powder, the coil is made a molding coating; a second coating body having a resin and an iron powder, wherein the bottom edge of the coil is formed by being coated and combined with the first covering body; The two electrodes are disposed outside the first covering body and the second covering body, and are electrically connected to the two electrical terminals.

<present invention> <知知>

110a’‧‧‧First conductive plate

110b’‧‧‧Second conductive plate

120'‧‧‧Inductance coil

120a’‧‧‧First coil layer

120b’‧‧‧second coil layer

125a’‧‧‧First Guide

125b’‧‧‧Second guide

130’‧‧‧Guide wiring

140’‧‧‧ Cover

200’‧‧‧

S01’~S04’‧‧‧ method steps

<present invention>

1‧‧‧Thin Inductor Coil

2‧‧‧Substrate

3‧‧‧Mold

4‧‧‧Support board

5‧‧‧Pushing device

11‧‧‧ coil

13‧‧‧First wrap

14‧‧‧Second cladding

15‧‧‧Electrode

21‧‧‧ grassroots

31‧‧‧First accommodating hole

41‧‧‧Second accommodating hole

51‧‧‧Top column

112‧‧‧Electrical terminals

S01‧‧‧ method steps

S021~S023‧‧‧ method steps

S03‧‧‧ method steps

S041~S044‧‧‧ method steps

S05~S07‧‧‧ method steps

The first AE diagram is a schematic diagram of a manufacturing method of a thin inductor coil; the second diagram is a flowchart of a conventional manufacturing method; the third AB diagram is a flowchart of a method for manufacturing the thin inductor coil of the present invention; BRIEF DESCRIPTION OF THE DRAWINGS FIG. 5 is a side cross-sectional view showing a manufacturing method of a thin inductor coil of the present invention; FIG. 7 is a perspective view of a semi-finished product of a thin inductor coil; A perspective view of another embodiment of a thin inductor coil; a ninth diagram is a cross-sectional view of still another embodiment of the thin inductor coil of the present invention; and a tenth diagram is a perspective view of the ninth diagram.

In order to more clearly describe the manufacturing method and structure of a thin inductor coil proposed by the present invention, the following will be described in detail with reference to the drawings. A preferred embodiment of the invention.

Please refer to FIG. 3A and FIG. 3B, which are flowcharts of a method for manufacturing a thin inductor coil of the present invention. As shown in the figure, the manufacturing method of the thin inductor coil of the present invention comprises the following steps: as shown in the process diagram of FIG. 4A, the method first performs a step (S01) to position a plurality of coils 11 on the surface of a substrate 2. A base layer 21 is disposed on the substrate 2, and the support plate 4 is formed under the substrate 2. The coil 11 includes two electrical terminals 112.

As shown in the process diagram of FIG. 4B and the process cross-sectional view of FIG. 5A, the method is followed by step (S021), and a mold 3 having a plurality of first receiving holes 31 is covered in the plurality of coils. The plurality of first accommodating holes 31 respectively correspond to the plurality of second accommodating holes 41, and respectively accommodate the plurality of coils 11; and then perform steps (S022) and (S023), A plastic-doped iron powder is poured into the plurality of first receiving holes 31 through a filling process, and a plurality of pressing columns 51 of a pressing device 5 respectively enter the plurality of In a receiving hole 31, the plastic doped iron powder forms a plurality of first covering bodies 13 to respectively cover the plurality of coils 11.

As shown in the process schematic diagrams of the fourth C to fourth D and the process cross-sectional views of the fifth B to fifth D, the manufacturing method of the present invention performs the step (S03) after completing the step (S023), Step (S041), removing the substrate 2 and the base layer 21, and placing the mold 3 in an inverted manner and on the support On the board 4, the plurality of first covering bodies 13 are pressed down by the plurality of pressing columns 51 to generate a filling space.

Then, the step (S042) and the step (S043) are performed, the pressing device 5 is removed, and the plastic-doped iron powder is refilled into the plurality of first receiving holes 31 through a filling process. And after the step (S043) is performed, the step (S044) is performed, and the plurality of pressing columns 51 are respectively squeezed into the plurality of first receiving holes 31 and the second receiving holes 41. So that the plastic-doped iron powder forms a plurality of second covering bodies 14 corresponding to the plurality of first covering bodies 13 to respectively cover the plurality of coils 11 and make the plurality of first ones The covering body 13 and the plurality of second covering bodies 14 and the plurality of coils 11 form a plurality of thin inductor coils 1; wherein the two electrical terminals 112 of the coil 11 are exposed to the first covering body 13 It is outside the second covering body 14.

As shown in the process diagram of FIG. E and the process profile of the fifth E diagram, after the step (S044) is completed, the steps (S05) and (S06) are subsequently performed to remove the support plate 4, and by The plurality of pressing columns 51 of the pressing device 5 respectively press the plurality of thin inductor coils 1 in the plurality of first receiving holes 31, and then take out the plurality of thin inductor coils 1.

Please refer to the third figure, and please refer to the sixth and seventh figures at the same time, which are a semi-finished perspective view and a finished perspective view of the thin inductor coil of the present invention; the manufacturing method of the present invention can be obtained after the step (S06) is performed. The semi-finished product of the thin inductor coil 1 shown in the sixth figure; as shown in the seventh figure, the most After performing the step (S07), an electrode forming process is performed on the semi-finished products of the plurality of thin inductor coils 1 to form two electrodes 15 for respectively connecting the coils 11 to be exposed to the first covering body 13 and the second cladding. Two electrical terminals 112 outside the body 14.

The step of forming the electrode (S08) may be a vacuum sputtering process on a predetermined block around the electrical terminals 112 on both sides of the thin inductor coil 1, and then performing nickel plating on the vacuum sputtering region ( Ni), finally performing tin plating (Sn) on the nickel layer to form the two electrodes 15; or directly dipping (or plating) silver (Ag) on the vacuum sputtering region, thereby forming the Two electrodes 15.

In view of the above, please refer to the eighth figure, which is a perspective view of another embodiment of the thin inductor coil of the present invention. As shown in the eighth figure, the electrode is formed in the vacuum sputtering region, and the two metal electrode plates are respectively separated. Soldering is fixed to the two electrical terminals 112 to form two electrodes 15.

Through the above, the manufacturing method of the thin inductor coil 1 of the present invention has been completely explained. Next, the configuration of a thin inductor coil 1 of the present invention will be described by way of illustration; please refer to the sixth and seventh figures, for example, As shown in the sixth and seventh figures, a thin inductor 1 of the present invention includes a coil 11, a first covering body 13, a second covering body 14, and two electrodes 15.

The coil 11 has two electrical terminals 112 exposed on the outside of the first covering body 13 and the second covering body 14 to be respectively electrically connected. And connecting the two electrodes 15; and the first covering body 13 has a resin and iron powder, and the coil 11 is formed into a molding coating. On the other hand, the second covering body 14 has a resin and iron. Powder, and the bottom edge of the coil 11 is formed into a coating, and is combined with the first covering body 13 to form.

Further, the coil 11 is composed of a metal wire and an insulating layer coated on the outside of the metal wire. Further, the coil 11 may be formed by a copper wire and an insulating layer coated on the outside of the copper wire. .

Please refer to the ninth and tenth drawings, which are a cross-sectional view and a perspective view of still another embodiment of the thin inductor coil 1 of the present invention. As shown in the ninth and tenth views, another thin inductor coil 1 of the present invention is shown. The embodiment includes two coils 11, a first covering body 13, a second covering body 14, and two electrodes 15.

The two coils 11 are respectively disposed in the first covering body 13 and the second covering body 14 in a mirrored manner, and the two electrical terminals 112 of one coil 11 are electrically connected to each other. Two electrical terminals 112 of one coil 11 are electrically connected to the two electrodes 15, respectively.

Thus, the above system has completely and clearly explained the construction and manufacturing method of the thin inductor coil of the present invention; and, we can know that the present invention has the following advantages:

1. Through the manufacturing method of the present invention, a thin inductor coil can be manufactured by means of a tape, so that the production cost can be reduced and waste can be avoided.

2. The electrode forming process of the present invention can avoid the combination of the inductor coil and the external electrode by means of soldering, further reducing the difficulty of manufacturing.

It is to be understood that the foregoing detailed description of the embodiments of the present invention is not intended to Both should be included in the scope of the patent in this case.

S01‧‧‧ method steps

S021~S023‧‧‧ method steps

S03‧‧‧ method steps

S041~S042‧‧‧ method steps

Claims (10)

A manufacturing method of a thin inductor coil includes the following steps: (1) positioning a plurality of coils on a base layer of a substrate surface, and positioning a support plate formed with a plurality of second receiving holes on the substrate In the lower part, the coil system includes two electrical terminals; (21) a mold having a plurality of first receiving holes is overlaid on the plurality of coils, so that the plurality of first receiving holes respectively correspond to The plurality of second receiving holes are respectively received by the plurality of coils; (22) pouring a plastic-doped iron powder into the plurality of first receiving holes through a filling process; (23) Inserting a plurality of top pressing columns of a pressing device into the plurality of first receiving holes respectively, so that the plastic doped iron powder forms a plurality of first covering bodies to respectively cover the plurality of pressing bodies (3) removing the substrate and the base layer; (41) disposing the mold on the support plate in an inverted manner, and pressing the plurality of first claddings by the plurality of pressing columns respectively Forming a filling space; (42) removing the pressing device; (43) applying the doping through a filling process Iron again poured into the plastic of the plurality of first receiving hole being; (44) by the plurality of columns are pressed against the top of the plurality of first receiving hole And the second accommodating hole, the plastic-doped iron powder is formed into a plurality of second covering bodies corresponding to the plurality of first covering bodies to respectively cover the plurality of coils, and The plurality of first cladding bodies, the plurality of second cladding bodies and the plurality of coils form a plurality of thin inductor coils; wherein the two electrical terminals of the coil are exposed to the first cladding body and (5) removing the support plate; (6) respectively pressing the plurality of thin inductor coils in the plurality of first receiving holes by the plurality of pressing columns, and further And extracting the plurality of thin inductor coils; and (7) performing an electrode forming process on the plurality of thin inductor coils, thereby forming two electrodes to respectively connect the coils to be exposed outside the first covering body and the second covering body Two electrical terminals. The method for manufacturing a thin inductor coil according to the first aspect of the invention, wherein the electrode is formed by performing a vacuum sputtering process on a predetermined block around the electrical terminals on both sides of the thin inductor coil, and then Nickel plating (Ni) is performed on the vacuum sputtering region, and finally tin plating (Sn) is performed on the nickel layer to form the two electrodes; or directly on the vacuum sputtering region ( Or silver (Ag) is plated to form the two electrodes. The method for manufacturing a thin inductor coil according to the second aspect of the invention, wherein the electrode is formed by soldering and fixing two metal electrode plates to the two electrical terminals in the vacuum sputtering region. Thereby forming the two electrodes. A structure of a thin inductor coil includes: at least one coil, and each coil has two electrical terminals; a first covering body having a resin and an iron powder, the coil is formed by a molding a second covering body having a resin and an iron powder, the bottom edge of the coil is formed by being integrally coated and combined with the first covering body; and two electrodes are disposed in the first package The covering body and the outer side of the second covering body are electrically connected to the two electrical terminals. The structure of the thin inductor coil of the fourth aspect of the invention, wherein the two electrical terminals are exposed outside the first covering body and the second covering body to electrically connect the two Electrodes. The structure of a thin inductor coil according to claim 4, wherein the coil is composed of a metal wire and an insulating layer coated on the outside of the metal wire. The construction of the thin inductor coil according to claim 4 of the patent application, The coil is composed of a copper wire and an insulating layer coated on the outside of the copper wire. The configuration of the thin inductor coil of the fourth aspect of the invention, wherein the number of the coils is two, and the two coils are mirrored respectively disposed on the first covering body and the second covering body. And the two electrical terminals of one of the coils are electrically connected to the two electrical terminals of the other coil, and the two electrical terminals are also electrically connected, and the two are respectively disposed. electrode. The structure of a thin inductor coil according to claim 4, wherein the electrode is formed by performing a vacuum sputtering process on a predetermined block around the electrical terminals on both sides of the thin inductor coil, and then Nickel plating (Ni) is performed on the vacuum sputtering region, and tin plating (Sn) is performed on the nickel layer to form the two electrodes; or directly on the vacuum sputtering region (or plating) Silver (Ag) by which the two electrodes are formed. The structure of a thin inductor coil according to claim 9, wherein the electrode is formed in the vacuum sputtering region, and the two metal electrode plates are respectively soldered and fixed to the two electrical terminals, thereby The two electrodes are formed.