TW201740401A - Manufacturing method of a SMT inductor - Google Patents

Abstract

A manufacturing method of a SMT inductor includes a powder filling step, a forming step and a curing step. In the powder filling step, a material part is put on a side of a tool, and a magnetic powder is filled into a forming space. In a pre-press step, a pre-press molding compresses the magnetic powder in the forming space. In a pressurizing step, a cutting mold cuts a leadframe, so that the leadframe is cut to form an electrode plate coupled to a coil. In a curing step, the tool is baked, so that the magnetic powder in the forming space is cured to form a main body. The tool is provided for manufacturing and curing the in the inducer in the forming space to provide a good support while curing the inducer and prevent cracking, so as to improve the yield rate of the product.

Description

Surface-adhesive inductor manufacturing method

A manufacturing method of a surface-adhesive inductor, in particular, a manufacturing method in which an inductor is fabricated in a jig, and the jig is baked, and the magnetically conductive powder in the jig is solidified and molded.

According to the general surface-adhesive inductor, please refer to the Republic of China Patent Notice No. I441209, which mainly locates the coil in the cavity, fills the mold with iron powder, and presses the iron with a punching machine. The powder is formed into half of the finished inductor, and the semi-finished inductor is taken out from the cavity and baked to solidify the iron powder, and then the outer layer is plated with a solder layer. However, this method has the following defects. :

(1) When the iron powder is baked and solidified, the inner coil will expand at the same time due to heat, so that when the iron powder is solidified, it is prone to cracking, resulting in a decrease in product yield.

(2) After the soldering layer is baked and solidified by iron powder, it is made in another process, which makes the manufacturing process of the inductor complicated and the cost rises. Furthermore, the inductor must be marked with polarity, because the soldering layer is formed by individual processing, Therefore, it is necessary to measure and mark the polarity of each inductor, which is time-consuming and labor-intensive, and the cost is further improved.

Please refer to the Republic of China Patent Publication No. I486978, which mainly discloses that when the covering body covers the coil, the two extending ends of the coil are extended out of the covering body, and then the two extended ends are sputtered with silver and then bent and fitted. In the coating body, this method is not only time-consuming and labor-intensive, but also when the extending end is bent, the covering body is exposed at the extended end, and may also be broken due to the stress generated when the extending end is bent, resulting in good The rate drops.

Therefore, how to solve the above-mentioned problems and shortcomings is the subject of research and development that the relevant industry is eager to develop.

The main purpose of the present invention is to use the fixture to make and cure the inductor in the molding space of the jig, to provide good support for the inductor during curing, to avoid cracking, and to improve product yield.

The secondary object of the present invention is to use the jig to directly form the electrode piece of the inductor into the molding space of the jig, reduce the manufacturing process of the inductor, and conveniently mark the polarity of the electrode piece.

In order to achieve the above object, the method for manufacturing the surface-adhesive inductor of the present invention comprises the following steps:

(A) Filling the powder: the material is placed on the side of the fixture so that the lead frame of the material member abuts against the side surface of the fixture, and the coil connected to the lead frame is located in the molding space of the fixture and is formed. Filling the space with magnetically permeable powder;

(B) pre-compression: pressing the magnetic conductive powder in the molding space of the jig with a molding die;

(C) Cutting pressurization: cutting the lead frame with a cutting die, so that the lead frame is cut to form an electrode piece connected to the coil, and the cutting die will form an electrode piece after cutting the lead frame, The electrode sheet is pressed into the molding space of the jig, and at the same time, the magnetic conductive powder is pressed again;

(D) Curing and setting: the jig is baked, the magnetic conductive powder is solidified in the molding space to form a body, and the body is taken out from the molding space.

Referring to the first to twelfth drawings, it can be clearly seen from the figure that the present invention is manufactured in accordance with the following steps when manufacturing an inductor:

(100) Filling powder: Please refer to the second and third figures, it can be clearly seen from the figure that the material 1 of the present invention has a lead frame 11 and a coil 12, and the lead frame 11 has a flat shape, which has The connecting piece 111 is provided with a plurality of hollow portions 112 on the connecting piece 111. The lead frame 11 has an electrode piece 113 extending from the side of the connecting piece 111 toward the hollow portion 112, and the coil 12 is provided in plural, and each coil 12 has a winding portion 121. The winding portion 121 has an extending portion 122 extending therefrom, and the welded portion 123 is bent at the end of the extending portion 122. The welded portion 123 of each coil 12 is soldered to the respective hollow portions 112 by the solder 13 being melted in the reflow furnace. The electrode piece 113 is disposed, and the jig 2 is provided with a plurality of molding spaces 21 penetrating the surface and the bottom surface; as shown in the fourth to sixth figures, when the powder filling step is performed, the material 1 is placed On the side of the jig 2, the lead frame 11 of the material member 1 is abutted against the surface of one side of the jig 2, and the coil 12 connected to the lead frame 11 is inserted into the molding space 21 from the side of the molding space 21, and is formed by molding. On the other side of the space 21, the magnetic conductive powder 3 is filled into the molding space 21; further, the jig 2 is provided. The amount of space 21, can be customized with the consumer needs, and not because of the number of the display surface to restrict FIG.

(110) Molding: the material 1 and the jig 2 are moved to the molding die 4, and the molding die 4 is pressed against the magnetic conductive powder 3 in the molding space 21 of the jig 2, and the lead frame 11 is cut. After the lead frame 11 is cut, the electrode sheet 113 connected to the coil 12 is formed, and the electrode sheet 113 is pressed into the molding space 21 of the jig 2; the magnetic flux in the molding space 21 of the jig 2 is formed by the molding die 4; The powder 3 is extruded. Referring to the sixth and seventh figures, the material 1 and the jig 2 are moved between the pre-pressing bottom mold 41 of the forming mold 4 and the pre-pressing upper mold 42, and the pre-compression is performed. The upper mold 42 is convexly provided with the pre-pressing convex portion 421, and when the jig 2 and the material member 1 are moved between the pre-pressing bottom mold 41 and the pre-pressing upper mold 42, the lead frame 11 of the material member 1 is abutted against the pre-pressing The surface of the bottom mold 41 is pressed, and the pre-pressing convex portion 421 is continuously introduced into the molding space 21 to press the magnetic conductive powder 3; when the forming mold 4 cuts the lead frame 11, refer to the eighth to the tenth drawings. It is shown that the jig 2 is first moved between the cutting bottom mold 43 of the forming mold 4 and the cutting upper mold 44, and the cutting bottom mold 43 is convexly provided with the abutting convex portion 431, and the cutting upper mold 44 is convexly disposed. Cutting convex portion 441 When the material 1 and the jig 2 are moved between the cutting bottom mold 43 of the forming mold 4 and the cutting upper mold 44, the other side of the jig 2 away from the material member 1 is abutted against the surface of the cutting bottom mold 43, The magnetic conductive powder 3 is abutted against the convex portion 431 for entering the molding space 21 of the jig 2, and the cutting convex portion 441 continues to cut the lead frame 11 to form the electrode sheet 113, and the electrode sheet 113 is pressed into the jig. In the molding space 21 of 2, the magnetic conductive powder 3 is again pressed at the same time.

(120) Curing setting: Referring to the tenth to twelfth drawings, the jig 2 is removed from the molding die 4, and the jig 2 is separately baked to solidify the magnetic conductive powder 3 in the molding space 21. The body 3' is formed, and the body 3' is taken out from the molding space 21, that is, the fabrication of the inductor is completed.

Furthermore, the step of curing and setting may be performed after the jig 2 is removed from the molding die 4, and then the jig 2 is moved to the polarity indicating device, and the polarity indicating device is marked on the electrode sheet 113 for polarity, and then treated. After the baking is carried out with 2, or after the jig 2 is baked, the jig 2 is first moved to the polarity indicating device, and the polarity of the electrode sheet 113 is marked, and then the body 3' is taken out from the molding space 21. .

Referring to the thirteenth to seventeenth drawings, it can be clearly seen from the figure that another embodiment of the molding step of the present invention moves the material member 1 and the jig 2 to the molding die 4, and the molding die 4 is provided with an upper die 45 and a cutting bottom die 46. The upper die 45 has a pressing column 451, and the cutting bottom die 46 has a cutting column 461, and when the molding die 4 faces the molding space 21 of the jig 2 When the inner magnetic conductive powder 3 is pressed and the lead frame 11 is cut, the material 1 and the jig 2 are moved to the upper mold 45 of the molding die 4 and the cutting bottom mold 46 to be placed thereon. The stamper 45 and the cutting bottom mold 46 clamp the solid member 1 and the jig 2, and press the pressing column 451 of the upper stamper 45 to press the magnetic conductive powder 3 in the molding space 21 of the jig 2, and cut it. The cutting column 461 of the bottom mold 46 cuts the lead frame 11 to form the electrode sheet 113, and presses the electrode sheet 113 into the molding space 21 of the jig 2, and simultaneously presses the magnetic conductive powder 3 again.

Therefore, the present invention can solve the deficiencies and shortcomings of the prior art, and can improve the efficiency, and the key technologies are further:

(1) The present invention utilizes the molding space 21 of the jig 2 to allow the magnetic conductive powder 3 to be heated and solidified in the molding space 21. Therefore, the magnetic conductive powder 3 is surrounded by the wall surface of the molding space 21, and has a good supporting effect. When the magnetic conductive powder 3 is used in the curing type cost body 3', cracking is less likely to occur, and the manufacturing yield of the inductor is improved.

(2) The present invention utilizes the molding space 21 of the jig 2 as the lead frame 11 of the material member 1 to cut the slit when the electrode sheet 113 is cut, so that the electrode sheet 113 can be used for the magnetic conductive powder 3 during the manufacture of the inductor. Pre-formed before heat curing, so that the magnetic conductive powder 3 is heated and solidified, the inductor can be formed, thereby simplifying the processing steps of the inductor, increasing productivity, reducing cost, and effectively avoiding products caused by bending in the prior art. Problems with damage and problems with electrode marking.

1‧‧‧Materials
11‧‧‧ lead frame
111‧‧‧Connecting piece
112‧‧‧镂空部
113‧‧‧electrode
12‧‧‧ coil
121‧‧‧Winding Department
122‧‧‧Extension
123‧‧‧Weld Department
13‧‧‧ solder
2‧‧‧ fixture
21‧‧‧Molding space
3‧‧‧Magnetic magnetic powder
3'‧‧‧ Ontology
4‧‧‧Molding mould
41‧‧‧Preloading bottom mold
42‧‧‧Preloading upper die
421‧‧‧Pre-pressed convex
43‧‧‧ Cutting the bottom mold
431‧‧‧Abutment to the convex
44‧‧‧ Cutting the upper mold
441‧‧‧cutting convex parts
45‧‧‧Upper stamper
451‧‧‧Squeeze column
46‧‧‧ Cutting the bottom mold
461‧‧‧Cut columns

The first figure is a flow chart of the present invention. The second figure is a perspective view of the material of the present invention. The third figure is an enlarged view of the portion A of the second figure. The fourth figure is a schematic diagram of the action of the powder filling step of the present invention (1). The fifth figure is a schematic diagram of the action of the powder filling step of the present invention (2). The sixth figure is a schematic diagram of the action of the powder filling step of the present invention (3). The seventh figure is a schematic view (1) of the action of the molding step of the present invention. The eighth figure is a schematic diagram of the action of the forming step of the present invention (2). The ninth drawing is a schematic view (3) of the action of the forming step of the present invention. The tenth figure is a schematic diagram of the action of the forming step of the present invention (4). The eleventh figure is a schematic view of the invention for curing and setting. Figure 12 is a cross-sectional view of an inductor manufactured in accordance with the present invention. The thirteenth drawing is a schematic view (1) of the operation of still another embodiment of the molding step of the present invention. Figure 14 is a schematic view (2) of the operation of still another embodiment of the molding step of the present invention. The fifteenth figure is an enlarged view of part A of the fourteenth figure. Figure 16 is a schematic view (3) of the operation of still another embodiment of the molding step of the present invention. Figure 17 is an enlarged view of part B of Figure 16.

113‧‧‧electrode

12‧‧‧ coil

123‧‧‧Weld Department

2‧‧‧ fixture

21‧‧‧Molding space

3‧‧‧Magnetic magnetic powder

Claims (7)

A method for manufacturing a surface-adhesive inductor includes the following steps: (A) filling the powder: placing the material on one side of the fixture, so that the lead frame of the material member abuts against one side surface of the fixture, and the lead frame The connected coil is located in the molding space of the jig, and is filled with magnetic conductive powder in the molding space; (B) Forming: moving the material and the jig to the molding die, and letting the molding die in the molding space of the jig The magnetic conductive powder is extruded, and the lead frame is cut, the lead frame is cut to form an electrode piece connected to the coil, and the electrode piece is pressed into the molding space of the jig; (C) curing stereotype: The jig is removed from the molding die, and the jig is baked, the magnetic conductive powder is solidified in the molding space to form a body, and the body is taken out from the molding space. The method for manufacturing a surface-adhesive inductor according to claim 1, wherein the lead frame of the material is in the form of a flat plate having a connecting piece, and the connecting piece is provided with a plurality of hollow portions, and the lead frame is connected to the side of the connecting piece The electrode extends toward the hollow portion, and the coils are provided in plural. Each coil has a winding portion, the winding portion has an extending portion, and the end portion of the extending portion is bent with a welded portion, and the welded portions of the respective coils are soldered separately. Electrode sheets at each hollow portion. The manufacturing method of the surface-adhesive inductor according to claim 1, wherein the coils connected to the lead frame of the material member are plurally arranged, and the forming space of the jig is set in plural, and the wire of the material is made When the frame is attached to the side surface of the jig, the coil is inserted through one side of the molding space, and the magnetic conductive powder is filled in by the other side of the molding space. The method for manufacturing a surface-adhesive inductor according to claim 1, wherein the fixture moves the fixture to a polarity marking device before the baking, and the polarity marking device is away from the electrode sheet. The other side surface indicates the polarity. The method for manufacturing a surface-adhesive inductor according to the first aspect of the invention, wherein after the fixture is baked, the fixture is first moved to a polarity marking device, and the polarity marking device is disposed on the body away from the electrode sheet. After the side surface is marked with polarity, the body is removed from the molding space. The method for manufacturing a surface-adhesive inductor according to claim 1, wherein the molding die is provided with a pre-pressing bottom mold, a pre-pressing upper mold, a cutting bottom mold, and a cutting upper mold, and pre-pressing the upper mold. a pre-pressing convex portion is provided, the cutting bottom mold is convexly provided with an abutting convex portion, and the cutting upper mold is convexly provided with a cutting convex portion, and when the forming mold presses the magnetic conductive powder in the molding space of the jig, The workpiece and the fixture are moved between the pre-pressing bottom mold of the forming mold and the pre-pressing upper mold, and the lead frame of the material member is abutted against the surface of the pre-pressing bottom mold, and the pre-pressing convex portion is continuously entered into the molding space. The magnetic conductive powder is extruded. When the molding die cuts the lead frame, the material and the jig are first moved between the cutting bottom mold and the cutting upper mold, so that the jig is away from the other side of the material. By cutting the surface of the bottom mold, the abutting convex portion is provided for the magnetic conductive powder to enter the forming space of the jig, and the cutting convex portion is continuously cut to form the electrode piece, and the electrode piece is pressed into the treatment. The magnetically permeable powder is again extruded in the molding space. The method for manufacturing a surface-adhesive inductor according to claim 1, wherein the molding die is provided with an upper pressing die and a cutting bottom die, and the upper pressing die has a pressing column, and the cutting bottom die has a cutting Cutting the column, when the molding die presses the magnetic conductive powder in the molding space of the jig, and cuts the lead frame, the material and the jig are moved to the molding die and the cutting die is cut. Between the upper mold and the cutting bottom mold, the solid parts and the jig are clamped, and the extrusion column of the upper mold is pressed against the magnetic conductive powder in the molding space of the jig, and the cutting of the bottom mold is cut. The cutting column cuts the lead frame to form an electrode sheet, and presses the electrode sheet into the molding space of the jig, and simultaneously presses the magnetic conductive powder again.